Tweco FP-38 User Manual

Plasma Cutting
Power Supply
Firepower
TM
FP-38 P ower Supply
A-03286
Operating Manual
May 5, 2003 Manual No. 0-2967
Read and understand this entire Manual and your employer’s safety practices before installing, oper­ating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
FirepowerTM FP-38 Power Supply
Operating Manual Number 0-2967
Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711
www.firepoweronline.com
Copyright 2002 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
Publication Date: May 5, 2003
Record the following information for W arranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and Warnings..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications.................................................................................................. 1-2
1.07 Declaration of Conformity............................................................................. 1-4
1.08 Statement of W arranty.................................................................................. 1-5
SECTION 2: SPECIFICATIONS............................................................................................... 2-1
Options and Accessories ..................................................................................... 2-2
Torch Specifications ............................................................................................. 2-2
SECTION 3: INSTALLATION .................................................................................................... 3-1
3.1 Unpacking .................................................................................................... 3-1
3.2 Lifting Options .............................................................................................. 3-1
3.3 Primary Input Power Connections................................................................ 3-2
3.4 Gas Connections ......................................................................................... 3-3
3.5 Torch Connections ....................................................................................... 3-6
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Product Features.......................................................................................... 4-1
4.02 Preparations For Operating.......................................................................... 4-3
4.03 Sequence of Operation ................................................................................ 4-7
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance ................................................................................... 5-1
5.02 Common Faults............................................................................................ 5-4
5.03 Basic T roubleshooting Guide ........................................................................ 5-5
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 Replacement Assemblies............................................................................ 6-1
6.04 Power Supply Replacement P arts ................................................................ 6-1
6.05 Options and Accessories ............................................................................. 6-2
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIA GRAM) .........................................A-1
APPENDIX 2: DATA TA G INFORMATION .................................................................................A-2
APPENDIX 3: SYSTEM SCHEMATIC.......................................................................................A-4
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 background 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

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 1-603-298­5711 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.”
May 14, 2002 1-1 GENERAL INFORMATION
• Wear 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 alu- minum alloys underwater or on a water table un­less the hydrogen gas can be eliminated or dissipated. Trapped hydrogen 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 protect 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 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 protected.
• 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, Washington, 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, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU­P A TION AND EDUCATIONAL EYE AND FACE 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 1-2 May 14, 2002
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 Standar d 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 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 W1 17.2, 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 PREPARA­TION FOR WELDING AND CUTTING OF CONT AIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
May 14, 2002 1-3 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street
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 r equirements. 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 manufac-
turing process. This is to ensure the product is safe, when used according 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 product 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: Giorgio Bassi
Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy
GENERAL INFORMATION 1-4 May 14, 2002

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 PARTICULAR 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 four (4) years fr om date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such three (3) year period.
FP-38 POWER SUPPLIES PARTS LABOR
MAIN POWER MAGNETICS ...................................................................................................... 3 YEARS ................... 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ..................................................................................... 3 YEARS ................... 1 YEAR
CONTROL PC BOARD .................................................................................................................. 3 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 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 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
May 14, 2002 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 May 14, 2002

SECTION 2: SPECIFICATIONS

)
Firepower FP -38 Power Supply Specifications
Input Power (See Note 1)
Power Sensing Input Power Cab l e Output Current
Power Supply Gas Fi l tering Abili t y
Firepower FP -38 Power Supply Duty Cycle (Not e 3
Am bient Temperature Duty Cy cle 35% 60% DC Volt age 78 vdc 89 vdc Current 30 Am ps 22 Am ps
. P ower s upply acc ept s 120-230 VAC input power. No manual switc hi ng i s required.
1
Plug m ust be replac ed for 208/230V i nput power.
2.
. Duty Cycle is the percentage of time the system can be operated without overheating. Dut y cy cle is
3
reduced if primary i nput voltage (AC) is l ow or the DC voltage is higher than s hown in this chart.
. A i r s uppl y m ust be free of oil, moi s ture, and other c ont am i nant s . Ex cess i ve oil and mois t ure may caus e
4
double-arcing, rapi d t ip wear, or even com plet e torch failure. Cont am i nant s m ay caus e poor c utting performance and rapid electrode wear. Optional fil t ers provide increased fil t ering capabilit i es .
120 VA C (± 10%), Single-Phas e, 50/60 Hz 208 - 230 VAC (± 10%), S i ngle-P has e, 50/60 Hz Automatic Voltage Selection. See Note 1. Cable with pl ug, for 120VAC, 20-A m p S i ngle-P hase input power. (Note 2) 20-30 Amps, continuousl y variable
Part iculates to 20 Mic rons (Not e 4)
104° F (40° C)
n/a %
n/a vdc
n/a A m ps
Notes
A-03378
15.75"
400 mm
21"
0.53 m
43 lb / 19.5 kg
10"
254 mm
Weight includes torch & leads, input power cord, and work cable with clamp.
150 mm
6"
150 mm
6"
150 mm
A-03379
6"
150 mm
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit proper cooling and reduce duty cycle.
6"
Manual 0-2967 2-1 SPECIFICA TIONS
Electrical Requirements
(Amps) F u se (Amps ) Wire (AWG) W ire (Canada)
F irepower FP -38 Input Power Requi rements
Suggest ed S izes (See Notes )
Input
Voltage Freq. (kVA)
(Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph
120 50 / 60 208 50 / 60 230 50 / 60
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. 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.
Power Input Current Input
3.629351212
3.516201212
3.414201212
Line Voltages with Suggested Circuit Protecti on and Wire Sizes
Based on National Electri c Code and Canadian Electric Code
NOTES
Extension Cords
Extension cords must meet National Electric Code Guidelines (and OSHA Guidelines, where applicable). Extension cords must have the same rating as the service and must have a three-pronged plug.

Options and Accessories

The following options is available for this Power Supply . Section 6 pr ovides catalog numbers and ordering informa­tion.
A. Single-Stage Air Filter Kit
A single-stage air filter for use on compressed air shop systems. Highly effective at removing moisture and particulate matter from the air stream to at least 0.85 microns.
SPECIFICA TIONS 2-2 Manual 0-2967

SECTION 3: INSTALLATION

3.1 Unpacking

1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.

3.2 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.
WARNINGS
Do not touch live electrical parts. Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment. HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handles, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-2967 3-1 INST ALLATION

3.3 Primary Input Power Connections

CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power sour ce, fuse, and any extension cords used must conform to local electrical code and the recommended circuit pr otection and wiring requirements as specified in Section 2.
Power Cord and Plug
This power supply includes an input power cord and plug suitable for 120 VAC, 20 Amp, Single - Phase input power .
A-03382
For 208 / 230 VAC input power, replace the supplied power plug. Use only an appr oved r eplacement input power plug with ground.
Replace the plug as follows:
1. Cut the original cord close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according to the plug manufacturer's instr uctions. All three conductors must be connected to the plug.
Connect the input power cord as follows:
1. Check the power source for correct voltage before plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
120 V, 20A, 1Ø
INST ALLATION 3-2 Manual 0-2967
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