Page 1
Plasma Cutting
Power Supply
Firepower FP-55
A-02766
Operating Manual
April 4, 2003 Manual No. 0-2846
Page 2
Page 3
WARNINGS
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
Firepower 55 (FP-55)
Operating Manual Number 0-2846
www.firepoweronline.com
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 2001 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: April 4, 2003
Record the following information for Warranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
Page 4
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
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes........................................................... 1-3
1.06 Documents De Reference............................................................................ 1-5
1.07 Declaration of Conformity............................................................................. 1-7
1.08 Statement of W arranty.................................................................................. 1-8
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications/Design Features.................................................................... 2-1
2.04 P ow er Supply Options.................................................................................. 2-2
SECTION 3:
INST ALLATION PROCEDURES ....................................................................................... 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Lifting Options .............................................................................................. 3-1
3.05 Primary Input Power Connections ................................................................ 3-2
3.06 Gas Connections ......................................................................................... 3-2
3.07 Torch Connections ....................................................................................... 3-3
3.08 Ground Connections For Mechaniz ed Applications...................................... 3-4
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction ................................................................................................. 4-1
4.02 Functional Overview.................................................................................... 4-1
4.03 Operating Controls ...................................................................................... 4-1
4.04 Preparations For Operating ......................................................................... 4-2
4.05 Sequence of Operation................................................................................ 4-3
Page 5
TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE................................................................................. 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Maintenance ................................................................................... 5-1
5.03 Common Faults............................................................................................ 5-2
5.04 Basic T roubleshooting Guide........................................................................ 5-3
5.05 P ow er Supply Basic P arts Replacement ...................................................... 5-5
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 P ower Supply Replacement ......................................................................... 6-2
6.04 Replacement Parts....................................................................................... 6-2
6.05 Optional Equipment ...................................................................................... 6-2
APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIA GRAM) .........................................A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................ A-3
APPENDIX 4: SYSTEM SCHEMATIC.......................................................................................A-4
Page 6
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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) 1-1 GENERAL INFORMA TION
Page 8
• 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 where
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 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.
• To protect your hearing from loud noise, wear pr otective 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,
Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING, obtainable from the American
W elding Society , 550 N.W. LeJeune Rd, Miami, FL
33126
3. NIOSH, SAFETY AND HEAL TH IN ARC WELD-
ING 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 ATION AND EDUCA TIONAL EYE AND
F ACE PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway,
New York, NY 10018
GENERAL INFORMATION 1-2 Date 5/1/00 (Special)
Page 9
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY
10018
7. A WS Standard A6.0, WELDING AND CUTTING
CONT AINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
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. NFP A 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, V A
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 Ar ch Street, Philadelphia, P A
19103
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREP ARA TION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable
from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable fr om American
National Standards Institute, 1430 Broadway, New
York, NY 10018
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
Date: 5/1/00 (Special) 1-3 GENERAL INFORMA TION
Page 10
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.
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.
• 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
• 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
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.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
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.
GENERAL INFORMATION 1-4 Date 5/1/00 (Special)
Page 11
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• 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
• 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 TRA V AIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, W ashington, 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 auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR
LA PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales
(American National Standards Institute), 1430
Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprès de l’American National Standards Institute,
1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
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
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
permanente de l’ouïe.
8. Norme 51 de l’Association Américaine pour la Pro-
• 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
tection contre les Incendies (NFPA), 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
niveaux sûrs.
Date: 5/1/00 (Special) 1-5 GENERAL INFORMA TION
Page 12
9. Norme 70 de la NFPA, CODE ELECTRIQUE
NATIONAL, disponible auprès de la National
Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès
de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA 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. Livret 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 PRÉPARA TION 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 1-6 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 repr esentative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: 5/1/00 (Special) 1-7 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 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-55, POWER SUPPLIES PA RTS 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
GENERAL INFORMATION 1-8 Date 5/1/00 (Special)
Page 15
SECTION 2:
p
2.03 Specifications/Design Features
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the Firepower
FP-55 Plasma Cutting Power Supply only. Servicing 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 Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
NOTE
Refer to the T orch Manual pr ovided with this Power
Supply for torch and cutting information.
2.02 General Description
The power supply provides 40 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, primary input power cable with
molded plug, and work cable & clamp.
Refer to Section 2.04 for power supply options and accessories.
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Features
• Main power ON/OFF switch
• RUN/SET switch
• output current control
• torch leads access
• work lead
2. Rear Panel Features
• Primary input power cable with molded plug
• gas pressure gauge regulator/filter assembly
• gas supply connection
3. Front Panel Indicators
AC, TEMP, GAS, DC
4. Input Power (See Note)
208/230V AC (±10%), 60 Hz, Single Phase, 39/37 amps
NOTE
Refer to Appendix 1 for input wiring requirements.
5. Output Power
Continuously variable from 20 to 40 amps maximum
A-02766
Figure 2-1 Firepower FP-55 Power Supply
6. Duty Cycle (see NOTE)
NOTE
The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher
than shown in the chart.
Power Supply Duty Cycle
Ambient
Tem
erature
Duty Cy cle
Current
DC Voltage
7. Pilot Circuitry
Capacitive Discharge (CD), Ignition DC Pilot
104° F
(40° C)
40% 60% 100%
40 Amps n/ a 25 Amps
96 vdc n/ a 96 vdc
104° F
(40° C)
104° F
(40° C)
Manual 0-2846 2-1 INTRODUCTION
Page 16
8. Weight
52 lbs (23.6 kg)
Weight includes Power Supply w/Input Cable and
plug, Work Lead, and Torch & Leads.
9. Overall Dimensions (incl. handles)
Length: 22-1/2 inches (572 mm)
Width: 10-3/4 inches (273 mm)
Height: 16-3/8 inches (416 mm)
B. Gas Regulator/Filter Assembly Specifications
The following specifications apply to the standard Gas
Regulator/Filter Assembly only:
1. Operating Pressure (Output)
70 psi (4.8 bar)
2. Maximum input gas pressure
125 psi (8.6 bar)
3. Filter
Particulate Type Filter (to 20 microns)
2.04 Power Supply Options
The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for item number
and ordering information.
A. Single-Stage In-Line Air Filter Kit
A Single Stage In-Line Air Filter for use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns.
INTRODUCTION 2-2 Manual 0-2846
Page 17
SECTION 3:
CAUTION
INSTALLATION
3.01 Introduction
NOTES
Depending on how the system was ordered, some
Power Supply Options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all sub-sections be read for general information.
This Section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site selection
2. Unpacking
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
The product is packaged and protected to prevent damage during shipping.
1. Unpack each item and remove any packing material.
2. Locate the packing list(s) and use the list(s) 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 the installation.
3.04 Lifting Options
This unit is equipped with a handle for hand carrying
purposes.
WARNINGS
3. Connections to Power Supply
a. Input power
b. Gas Connections
c. T o r ch Leads
d. Work cable
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 (Section 1)
to be sure that the selected location meets all safety
requirements.
The power supply is fan cooled by air flow through the
side panel to the front and rear panels. Air flow must not
be obstructed. Provide at least 2 feet (0.6 m) in the rear
and at least 6 inches (150 mm) on each side for clearance.
Provide sufficient clearance in front of the unit to allow
access to the front panel controls (min. 6 inches or 150
mm).
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
F ALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handle, using two hands.
• Handle is designed for hand lifting only. Be sure
unit is lifted and transported safely and securely.
WARNING
HANDLE is not for mechanical lifting.
• Use hand cart or similar device of adequate capacity to move unit.
• Place and secure unit on a proper skid before transporting with a fork lift or other vehicle.
Manual 0-2846 3-1 INST ALLATION
Page 18
3.05 Primary Input Power
H
1
Regulator/Filter
Connections
This power supply comes with a factory-installed input
power cable and plug designed to accept input power of
208/230VAC (±10%), 60 Hz, single phase, 39/37 amps.
1. Check your 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.
3.06 Gas Connections
A. Gas Requirements
WARNING
Connect the gas supply as follows:
1. If an optional air line filter is to be installed, refer to procedures in subsection 3.06-D.
2. Connect the gas line to the inlet port. The illustration shows
typical fittings as an example. Other fittings may be used.
Install the fittings and tighten.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
Regulator/Filter
Assembly
Inlet Port
This unit is not to be used with oxygen (O2).
Gases: Single Gas - Plasma/Secondary
Compressed Air Only
Pressure: 70 psi (4.8 bar)
CAUTION
Maximum pressure at inlet must not exceed 125
psi (8.6 bar)
Flow: Cutting - 200 standard cubic feet/hr (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
B. Checking Air Quality
To test the quality of air, place the RUN/SET switch to
SET position, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moistur e in the air
will be visible on the lens. Do not initiate an arc!
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
1/4 NPT to 1/4"
(6mm) Fitting
ose Clamp
Gas Supply
Hose
Plastic
A-02783
Bowl
Figure 3-1a Gas Connection to Regulator/Filter
Assembly (units with type A Regulator/Filter)
Assembly
Inlet Port
Bowl
/4 NPT to 1/4"
(6mm) Fitting
C. Connecting Gas Supply to Unit
The gas supply is connected to the Pressure Regulator/
Filter Assembly located on the rear of the unit. The connection is the same for compressed air or high pressure
gas cylinders.
Hose Clamp
Gas Supply
Art # A-02999
Hose
Figure 3-1b Gas Connection to Regulator/Filter
Assembly (units with type B Regulator/Filter)
INST ALLATION 3-2 Manual 0-2846
Page 19
D. Installing Optional Single-Stage Air Filter
Additional filtering is recommended when using air from
a compressor to insure that moisture and debris fr om the
supply hose does not enter the torch. Although the Pr essure Regulator does have its own filter, the optional
Single-Stage Air Filter is recommended for impr oved filtering. The optional in-line filter is highly effective at
removing moisture and particulate matter from the air
stream to at least 0.85 microns.
Connect the gas supply as follows:
1. Attach the Single-Stage Air Filter Kit to the Regulator/Filter Assembly inlet port as shown. The illustration shows typical fittings as an example.
Other fittings may be used. Install the fittings and
tighten.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
Regulator/Filter
Assembly
Bowl
1/4 NPT Hose Fitting
Hose Clamp
1/4" (6 mm) Gas Supply Hose
Inlet Port
A-03000
Figure 3-2b Optional Single-Stage Air Filter
Installation (units with type B Regulator/Filter)
E. Using High Pressure Gas Cylinders
Regulator/Filter
Assembly & Bracket
Inlet Port
Filter
Hose
Filter
Assembly
1/4 NPT Hose Fitting
Hose Clamp
1/4" (6 mm) Gas Supply Hose
A-02784
Figure 3-2a Optional Single-Stage Air Filter
Installation (units with type A Regulator/Filter)
Refer to the following when using high pressure gas cylinders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high
pressure gas regulators.
2. 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.
3. 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 200 scfh (94.3 lpm).
4. Slide the gas supply hose over the barbed fitting.
5. Secure the gas supply hose in place with the adjustable hose clamp.
NOTE
Supply hose must be at least 1/4 inch hose (6 mm)
I.D.
Manual 0-2846 3-3 INST ALLATION
Page 20
3.07 Torch Connections
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
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.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
1. Remove the Cover of the Power Supply to gain
access to the Torch Bulkhead Panel. See Section
5.05.
2. Remove the retaining nut from the Strain Relief.
Torch Leads
Assembly
Strain Relief
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Control Circuit
Connectors
Torch Lead
Assembly
A-03527
Adapter
Connector
Plug
Negative/Plasma
Pilot Lead Stud
Negative/Plasma Lead
Connection
Pilot Lead
Lead
Figure 3-4 Torch Lead Connections To Bulkhead
6. Connect the Control (PIP) Circuit Connectors to
the mating connectors on the Power Supply
Adapter.
7. Remove the top nut and washer from the Pilot
Stud.
Negative /
Plasma Lead
A-03529
Pilot Lead
Strain Relief
Nut
Figure 3-3 Retaining Nut Removal
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.
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in Step 7.
9. Tighten the Strain Relief onto the Torch Leads.
10. Check the torch for proper parts assembly per the
torch manual.
CAUTION
The torch parts must correspond with the type of
operation. Refer to the appropriate torch manual
for proper parts selection.
11. Re-install the Power Supply Cover on the Power
Supply.
INST ALLATION 3-4 Manual 0-2846
Page 21
Adapter Connector
Control Circuit
Connectors
Not
Used
Adapter
Negative/Plasma
Lead Connection
Not
Used
Pilot Lead
2. Components that are mounted on the cutting machine;
CNC controller, plasma remote controls, height controllers, remote arc starters, etc., should be gr ounded
to the cutting machine frame (chassis) with at least a
2
12 AWG (4 mm
) wire. Flat copper braid works even
better.
3. The cutting machine frame is then connected to the
“Star” point using AWG 6 (13,3 mm
2
) or larger wire.
4. The plasma power supply work cable (see NOTE) is
connected to the cutting table at the single point “Star”
ground.
Negative/Plasma
Lead
A-03528
Torch Lead
Assembly
Remote
Cable
Connector
Figure 3-5 Torch Lead Connections To Bulkhead
3.08 Ground Connections For
Mechanized Applications
A. Electromagnetic Interference (EMI)
Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.
This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height
controllers, etc. T o minimize RF interference, follow these
grounding procedures when installing mechanized systems:
B. Grounding
1. The preferred grounding arrangement is a single point
or “Star” ground. The single point, usually on the
cutting table, is connected with 1/0 (42 mm2) or larger
wire to a good earth ground (refer to paragraph ‘C’,
Creating An Earth Gr ound). The ground rod must be
placed as close as possible to the cutting table. Ideally less than 10 ft (3,0 m), but no more than 20 ft
(6,1 m).
NOTE
All ground wires should be as short as possible.
Wires of long length will have increased r esistance
to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a
larger diameter wire is better.
NOTE
Do Not connect the work cable directly to the
ground rod.
5. Make sure work cable and ground cables are properly connected. The work cable must have a solid
connection to the cutting table. The work and ground
connections must be free from rust, dirt, grease, oil
and paint. If necessary grind or sand down to bare
metal. Use lock washers to keep the connections tight.
Using electrical joint compound to prevent corrosion
is also recommended.
6. The plasma power supply chassis is connected to the
power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can
set up ground loop currents that cause interference.
When the plasma power supply is far away from the
ground rod and interference is experienced, it may
help to install a second earth ground rod next to the
plasma power supply. The plasma power supply
chassis would then be connected to this ground rod.
NOTE
It is recommend that the Plasma Power Supply be
within 20 - 30 ft (6,1 – 9,1 mm) of the cutting
table, if possible.
7. The plasma control cable should be shielded with the
shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground
loop currents which may cause more interfer ence than
with no shield at all.
C. Creating An Earth Ground
1. To cr eate a solid, low resistance, earth ground, drive a
1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1,8 - 2,4 m) into the earth so that
the rod contacts moist soil over most of its length.
Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE).
Ground rods, typically 10 ft (3,0 m) long, may be
Manual 0-2846 3-5 INST ALLATION
Page 22
welded end to end for greater lengths. Locate the rod
as close as possible to the work table. Install a ground
wire, 1/0 (53,5 mm2) or greater, between the ground
rod and the star ground point on the cutting table.
NOTE
Ideally, a properly installed ground r od will have a
resistance of three ohms or less.
T o test for a proper earth ground using 1 15 VAC, refer
to the following diagram. Ideally, the reading on the
multimeter should be 3.0 VAC or less.
115VAC: 3.0 VAC
230VAC: 1.5 VAC
~
V
Meter set to
VAC setting
~
V
D. Routing Of Torch Leads
1. To minimize RF interference, position torch leads as
far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables
have to pass over torch leads, do so at an angle. Do
not run the plasma control or other control cables in
parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and increased chance of RF interference.
WARNING
Use extreme caution. This
test uses live voltage.
Neutral
115 or 230VAC
Line (Hot)
A-02971
Light Bulb
100W
VR COM A
_
+
Machine
Earth Ground
Figure 3-6 Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft
(6,1 – 9,1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which
has more surface area may help. Sometimes keeping
the soil around the ground rod moist by continuously
running a small amount of water into it will work.
Adding salt to the soil by soaking it in salt water may
also reduce its resistance. When these methods are
used, periodic checking of the ground resistance is required to make sure the ground is still good.
INST ALLATION 3-6 Manual 0-2846
Page 23
SECTION 4:
OPERATION
3. Work Cable and Clamp
20 ft. (6.1 m) work cable with clamp, factory installed.
4. Roll Handle/Torch Leads Wrap
4.01 Introduction
This section identifies the front and rear components, and
describes the power supply operating controls and procedures.
4.02 Functional Overview
The Firepower FP-55 Power Supply provides operating
flexibility through the use of simple controls.
4.03 Operating Controls
This subsection provides specfic functional descriptions
of the power supply operating controls and indicators.
A. Front and Side Panels
1. Control Panel
All operator controls, except gas pressure adjustment,
are located on this panel: power ON/OFF switch,
RUN/SET switch; CURRENT control; LED indicators
for AC Power, TEMP, GAS, and DC.
The torch leads wrap around the handle for easy storage. Factory installed torch & leads.
B. Control Panel
A
30
25
3
20
1
Figure 4-2 Operating Controls
35
40
A-03641
4
5
6
7
2
2
4
A-02772
3
Figure 4-1 Front and Side Panel Connections
2. Torch Leads Input
1. ON / OFF Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control
circuits.
2. RUN / SET
Switch
1
RUN position is used for general torch operation.
T orch switch must be held. SET position used for setting gas pressure and pur ging lines.
3. Current Control (A)
Adjustment to set the output current between 20-40
amps.
4. AC Power Indicator
Green indicator will blink ON-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.
Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.
Manual 0-2846 4-1 OPERATION
Page 24
TEMP Indicator
1
3
5.
Normally OFF . Y ellow 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 indicator will come ON when the input gas pressure
is set to
35 psi (2.4 bar) or higher . Indicator will be OFF
when the pressure falls below 35 psi (2.4 bar).
7.
DC Indicator
Green indicator will come ON while the torch switch is
pressed. Indicates DC output circuit is active.
C. Rear Panel
1. Gas Input Port
Input connection for compressed air input.
1
2
A-03042
Figure 4-3b Rear Panel (units with type B Regulator/
Filter)
W ARNING
2. Primary Input Power Cable/Strain Relief
Factory installed primary input power cable strain relief for
This unit is not to be used with oxygen (O2).
the primary power cable, capable of handling the input voltage designed for this unit.
3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pressure to the
Power Supply . The pressure r egulator has its own built-in
air line filter .
Factory installed. For improved filtering, other
filtering packages are available as options.
4.04 Preparations For Operating
This procedure should be followed at the beginning of each
shift:
W ARNING
3
2
A-02790
Disconnect primary power at the source before
assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. T orch Part s Selection
Figure 4-3a Rear Panel (units with type A
Regulator/Filter)
Check the torch for proper assembly and appropriate
front end torch parts. Refer to the torch manual for
proper parts selection.
OPERATION 4-2 Manual 0-2846
Page 25
B. Check Primary Input Power Source
1. Check the power source for proper input voltage.
Make sure the input power source meets the power
requirements for the unit per subsection 2.03-A,
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 single gas supply . Make sur e gas source
meets requirements (refer to subsection 3.06, Gas Con-
nections). Check connections and turn gas supply on.
D. Work Cable Connection
Check for a solid work cable connection to the
workpiece.
E. Torch Connection
Check that the torch is properly connected.
F. Power On
On the Power Supply place the ON/OFF switch to
the ON position.
G. Select Current Output Level
a. AC Power Indicator blinks ON and OFF for
eight seconds then stays ON. Fan turns on.
NOTE
Gas comes on if T or ch Trigger is pressed (although
unit will not pilot until switch is released and reclosed after the light stops blinking).
4. Place RUN/SET switch to SET mode.
a. Gas solenoid opens and gas flows to set pres-
sure. Gas Pressure Regulator/Filter Assembly
should be set to 70 psi (4.8 bar). GAS indicator
turns ON.
NOTE
GAS Indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Gas Pressure Regulator/Filter Assembly.
5. Place RUN/SET switch to RUN mode.
a. Gas flow stops. GAS Indicator turns OFF.
6. Protect eyes and press or activate torch switch.
a. Gas pre-flow starts (approximately 2 seconds).
GAS Indicator turns ON.
7. After gas pre-flow:
On the Control Panel, set the desired current output
level between 20-40 amps for cutting or gouging.
H. Set Operating Pressure
Place the RUN/SET switch to the SET position. Gas
will flow. Adjust gas pressure control to 70 psi (4.8
bar).
I. Prepare to Cut
Return the RUN/SET switch to RUN position. Gas
will not flow until the Torch Trigger is pressed.
The system is now ready for operation. Push the T or ch
Trigger to start the pilot arc. There is a 2 second preflow before the arc starts.
4.05 Sequence of Operation
The following is a typical sequence of operation for this
power supply. Refer to Appendix for block diagram.
1. Close main power source disconnect switch.
a. AC power is available at the Power Supply.
2. Place RUN/SET switch to RUN mode.
a. Power Supply enabled. DC indicator turns ON.
Pilot Relay closes.
8. Pilot arc is established
9. Move T orch within transfer distance of workpiece.
a. Main arc transfer. Pilot arc OFF.
10. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece while the
torch switch is activated, the main arc will stop
and the pilot arc will automatically restart.
11. Release or deactivate the torch switch.
a. Main arc stops. Pilot arc stops (power supply
enable signal removed).
NOTES
If torch is activated during post-flow , the pilot ar c
will immediately restart.
If torch is within 1/4 inch (6.4mm) transfer distance to workpiece, the main arc will transfer.
3. Place the ON/OFF power switch on the front panel
of the Power Supply to ON position.
Manual 0-2846 4-3 OPERATION
Page 26
12. Gas will flow for 10 seconds (post-flow).
a. Gas solenoid closes. Gas flow stops. GAS indi-
cator turns OFF.
13. Place the ON/OFF power switch on the front panel
of the unit to OFF.
a. AC Power indicator turns OFF. Fan turns OFF .
14. Place the main power disconnect to open.
a. Main AC power is removed fr om the system.
NOTE
For information on cutting techniques, cutting
problems, cutting speeds, cut quality, etc., r efer to
the torch manual supplied with the torch.
This completes the Operation Section.
OPERA TION 4-4 Man ual 0-2846
Page 27
SECTION 5:
SERVICE
5.01 Introduction
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted other than by properly trained
personnel.
NOTE
Trained personnel can receive more advanced
troubleshooting instructions and information on
parts replacement by requesting Service Manual
0-2847.
B. Filter Regulator Element Replacement
The Filter /Regulator Assembly is located on the rear panel.
For better system performance, the Filter/Regulator Assembly filter element should be checked per Appendix 3,
Maintenance Schedule, and either cleaned or replaced.
1. Remove power from the power supply; turn off the
gas supply.
Regulator
Assembly
5.02 General Maintenance
A. Maintenance Schedule
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
To clean the unit, open the enclosure per procedures in
section 5.05-A, Cover Removal, and use a vacuum cleaner
to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents for cleaning
electrical apparatus may be used.
Perform routine maintenance according to the schedule in
Appendix 3. The actual frequency of maintenance may
need to be adjusted according to the operating environment.
Baffle
Ring
Filter
Element
Spring
Spool
Bowl
A-02954
Figure 5-1a Filter/Regulator - Removing the Filter
Element (units with type A Regulator/Filter)
Regulator/Filter
Assembly
Baffle
Ring
Filter
Element
Spring
Spool
Bowl
A-02995
Figure 5-1b Filter/Regulator - Removing the Filter
Element (units with type B Regulator/Filter)
Manual 0-2846 5- 1 SERVICE
Page 28
2. Unscrew the bowl on the bottom of the Filter/Regulator Assembly. The filter element will be visible
and still attached to the main body of the Filter/
Regulator .
3. Grasp the filter element and unscrew it from the
Filter/Regulator body . The filter element will come
off with a spool and some additional pieces.
4. Note the correct assembly of the filter/spool then
remove the filter from the spool and either clean it
or replace it.
5. The filter element and spool, with the baffle ring in
place (teeth facing downward) can be screwed back
into the Filter/Regulator body by compressing the
spring on the spool. Tighten firmly by hand.
6. Reinstall the bowl.
7. T urn on the air supply.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cover
Barbed
Fitting
Assembled Filter
A-02476
C. Optional Single-Stage Filter Element
Replacement
NOTES
These instructions apply to power supplies where
the optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when
the Filter Element becomes completely saturated.
The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element
to dry.
1. Remove power from power supply .
2. Shut off air supply and bleed down system before
disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Cover counter-clockwise and remove it
from the Filter Housing. The Filter Element is located inside the Housing.
Figure 5-2 Optional Single-Stage Filter Element
Replacement
5. Remove the Filter Element from the Housing and
set Element aside to dry .
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first, as shown
in Figure 5-2.
7. Replace Housing on Cover .
8. Reattach gas supply hose.
NOTE
If unit leaks between housing and cover , inspect the
"O" Ring for cuts or other damage.
5.03 Common Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. T or ch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Firepower Parts used
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
SERVICE 5-2 Manual 0-2846
Page 29
d. Work cable disconnected
B. How to Use This Guide
e. Worn torch parts
f. Non-Genuine Firepower Parts used
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Firepower Parts used
4. Short T orch 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
f. Non-Genuine Firepower parts used
5.04 Basic Troubleshooting Guide
W ARNING
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.
A. Basic T r oubleshooting: Overview
The following information is a guide to help the Customer/
Operator determine the most likely causes for various
symptoms. Follow all instructions as listed and complete
each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (T ext T ype)
1. Cause (Italic Type)
a. Check/Remedy (Text T ype)
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.
Common Symptoms
A. AC Power indicator OFF
1. Switch at customer's main power panel in OFF position.
a. Close main power panel switch.
2. Customer's main power line fuse(s) blown
a. Check main power panel fuse(s) and replace as
required.
3. Actual input voltage does not correspond to voltage of
unit
a. V erify that the input line voltage is 208/230 V AC
(±10%), single phase.
4. Unit internal fuse blown or loose
a. If blown, double check input voltage and replace
fuse per subsection 5.05-B. If fuse blows again,
return unit to an authorized service center .
This guide covers a basic level of troubleshooting that re-
quires limited disassembly 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-55 Power Supply Service
Manual 0-2847.
Manual 0-2846 5- 3 SERVICE
5. 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 around the unit
and correct condition.
2. Fan blocked
a. Check and correct condition.
Page 30
3. Unit is overheated
F . Limited output with no control
a. Allow unit to cool down for at least 5 minutes.
Make sure the unit has not been operated beyond Duty Cycle limit. See Section 2 for duty
cycle specifications.
4. Input line voltage is below 75% of rated level
a. Check and connect to proper input power line.
5. 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. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
3. Gas pressure too high or too low
a. Set pressure to 70 psi (4.8 bar).
4. Faulty components in unit
1. Poor input or output connections
a. Check all input and output connections.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
G. Erratic or improper cutting output
1. Poor input or output connections
a. Check all input and output connections.
2. Poor ground or work connection is poor .
a. Check connection.
H. Arc shuts off during operation; Arc will not re-start
when torch switch is activated.
1. Unit is overheated (TEMP indicator ON)
a. Allow unit to cool down for at least 5 minutes.
Make sure the unit has not been operated beyond Duty Cycle limit. See Section 2 for duty
cycle specifications.
2. Fan blades blocked (TEMP indicator ON)
a. Return for repair or have qualified technician
repair per Service Manual.
D. No cutting output; T orch switch activated; AC
Power indicator ON; Gas flowing; Fan operating
1. T orch not pr operly 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. Refer to the torch manual for details.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
4. Faulty T orc h
a. Return for repair or have qualified technician
repair per T or ch Manual.
E. Low cutting output
1. Incorrect setting of CURRENT control
a. Check and adjust to proper setting.
2. Faulty components in unit
a. Check and clear blades.
3. Airflow obstructed (TEMP indicator ON)
a. Check for obstructed air flow around the unit
and correct condition.
4. Gas pressure too low (GAS indicator OFF when torch
switch is activated)
a. Check source for at 70 psi (4.8 bar); adjust as
needed.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. No gas flow; AC POWER indicator ON; Fan
operating
1. Gas not connected or pressure too low
a. Check source for at least 70 psi (4.8 bar).
2. Gas supply pressure too high
a. Adjust to maximum 125 psi inlet pressure.
3. Shield Cup not properly installed.
a. Check to see that Control Circuit (PIP) pins are
installed. Refer to the torch manual for details.
a. Return for repair or have qualified technician
repair per Service Manual.
SERVICE 5-4 Manual 0-2846
Page 31
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. T orch cuts but not adequately
1. Current set too low
a. Increase current setting.
2. T orch is being moved too fast acr oss 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).
5.05 Power Supply Basic Parts Replacement
W ARNING
Upper screws
Lower screws
Ground wire
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
This section describes procedures for basic parts replacement. For more detailed parts replacement procedures,
refer to the Firepower 55 Power Supply Service Manual.
A. Cover Removal
1. Remove the upper screws which fasten the cover to
the main assembly .
A-02776
Figure 5-3 Cover Removal
2. Loosen, but do not remove, the lower screws, then
carefully pull the Cover up and away from the unit
to gain access to the inside of the unit.
NOTE
There is a ground wire connection to the inside of
the unit. There is no need to disconnect the ground
wire, unless there is a need for more room to work.
3. T o reinstall the cover , complete the following:
a. Reconnect the ground wire, if necessary .
b. Place the cover onto the frame so that it rests on
the lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the upper screws.
Manual 0-2846 5- 5 SERVICE
Page 32
B. Fuse Replacement
1. Remove the unit cover per paragraph "A" above.
2. Locate the internal fuse on the left side of the center
chassis.
3. Replace the fuse. Refer to Section 6 for replacement
fuse catalog number .
4. Reinstall the cover per paragraph "A" above.
Fuse Location
Figure 5-4 Internal Fuse Location
This completes the service procedures.
A-02957
SERVICE 5-6 Manual 0-2846
Page 33
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 Replacement Parts
Section 6.05 Optional Equipment
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
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 0-2846 6-1 P ARTS LISTS
Page 34
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, gas pressur e regulator/
air filter , input power cable & plug, and operating manual.
Qty Description Catalog #
1 Firepower FP-55 Power Supply, 208/230VAC, Single-Phase, 60Hz 3-5230-FP
6.04 Replacement Parts
Qty Description Catalog #
1 Fuse (1/2A, 250V) 9-6395
1 Regulator/Filter Assembly Element Replacement 9-8534
(for Type A Regulator/Filter)
1 Regulator/Filter Assembly Element Replacement 9-4414
(for Type B Regulator/Filter)
6.05 Optional Equipment
Qty Description Catalog #
1 Single-Stage Filter Kit (includes Filter & Hose) 1445-0080
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
Regulator / Filter Assembly
Type A
A-03326
Type A-1
Regulator/Filter Assembly Types
Type B
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cover
Barbed
Fitting
Assembled Filter
A-02476
Optional Single-Stage In-Line Air Filter Kit
PARTS LISTS 6-2 Manual 0-2846
Page 35
APPENDIX 1: INPUT WIRING REQUIREMENTS
Pow er Input Current Input
Voltage Frequency 1-Ph 1-Ph Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts) (Hz) (kVA) (Amps) 1-Ph 1-Ph 1-Ph
208 60 8.2 39 45 8 8
230 60 8.2 37 45 8 8
Line Vol t ages with Suggested Circ uit Protec t i on and Wire Sizes
Bas ed on Nat i onal E l ec tric Code and Canadian El ec t ri c Code
NOTES
The table above is based on the following output current and voltage: 125 vdc @ 40A
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.
Sugge sted Siz es (Se e Notes)Input
Manual 0-2846 A-1 APPENDIX
Page 36
APPENDIX 2: 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 arc established
ACTION
ON/OFF switch
to ON.
RESULT
AC indicator blinks for 8
seconds then steady on.
Fans on.
Pilot relay closes.
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 moved within
transfer distance of workpiece.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
(Power supply enable signal removed)
post-flow, pilot arc will immediately restart.
(1/4 in/6.4mm) of workpiece, main arc
Gas solenoid closes, gas flow stops.
Main arc stops.
Gas flows (10 seconds)
NOTE - If torch is activated during
If torch is within transfer distance
will transfer.
After post-flow:
GAS indicator off.
ACTION
ON/OFF switch
to OFF
RESULT
All indicators off.
Power supply fans off.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Open external
disconnect.
RESULT
No power to system
A-03568
APPENDIX A-2 Manual 0-2846
Page 37
APPENDIX 3: MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts
listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air flow .
2. Blow or vacuum dust and dirt out of the entire machine.
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.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, r eplace if necessary.
Manual 0-2846 A-3 APPENDIX
Page 38
APPENDIX 4: SYSTEM SCHEMATIC
A-03269
APPENDIX A-4 Manual 0-2846
Page 39
A-03269
Manual 0-2846 A-5 APPENDIX
Page 40
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