Plasma Cutting Power Supply Firepower FP-55 A-02766 Operating Manual April 4, 2003 Manual No.
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.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ............................................................................................... 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ..................................................................... 1-1 Important Safety Precautions ....................................................................... 1-1 Publications ..................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: CUSTOMER/OPERATOR SERVICE ................................................................................. 5-1 5.01 5.02 5.03 5.04 5.05 Introduction .................................................................................................. 5-1 General Maintenance ................................................................................... 5-1 Common Faults ............................................................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings 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. Throughout this manual, notes, cautions, and warnings are used to highlight important 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. 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.
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. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions. FUMÉE et GAZ CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5. RAYONS D’ARC DE PLASMA 1.06 Documents De Reference 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.
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West 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.
1.08 Statement of Warranty LIMITED WARRANTY: Firepower® (hereinafter “Firepower”) warrants that its products will be free of defects in workmanship or material.
SECTION 2: INTRODUCTION 2.01 Scope of Manual 2.03 Specifications/Design Features A. Power Supply Technical Specifications The following specifications apply to the Power Supply only: 1. Front Panel Features This manual contains descriptions, operating instructions and basic maintenance procedures for the Firepower FP-55 Plasma Cutting Power Supply only.
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.
SECTION 3: 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.
3.05 Primary Input Power Connections Connect the gas supply as follows: 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. 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. 1. Check your power source for correct voltage before plugging in the unit. NOTE 1.
D. Installing Optional Single-Stage Air Filter Additional filtering is recommended when using air from a compressor to insure that moisture and debris from the supply hose does not enter the torch. Although the Pressure Regulator does have its own filter, the optional Single-Stage Air Filter is recommended for improved 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.
3.07 Torch Connections Note: Actual Bulkhead configuration may differ from that shown. NOTE Equipment ordered as a system will have the Torch factory connected to the Power Supply. Adapter Connector Pilot Lead Stud Adapter Plug The Torch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the Torch Bulkhead Panel for the desired application.
Adapter Connector Control Circuit Connectors Negative/Plasma Lead Connection Adapter Not Used 3. The cutting machine frame is then connected to the “Star” point using AWG 6 (13,3 mm2) or larger wire. Not Used Pilot Lead Torch Lead Assembly 2. Components that are mounted on the cutting machine; CNC controller, plasma remote controls, height controllers, remote arc starters, etc., should be grounded to the cutting machine frame (chassis) with at least a 12 AWG (4 mm2) wire.
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. 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.
3. Work Cable and Clamp SECTION 4: OPERATION 20 ft. (6.1 m) work cable with clamp, factory installed. 4. Roll Handle/Torch Leads Wrap The torch leads wrap around the handle for easy storage. Factory installed torch & leads. 4.01 Introduction This section identifies the front and rear components, and describes the power supply operating controls and procedures. B. Control Panel A 4.
5. TEMP Indicator Normally OFF. Yellow indicator will come ON when the internal temperature sensors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation. 1 3 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.
a. AC Power Indicator blinks ON and OFF for eight seconds then stays ON. Fan turns on. B. Check Primary Input Power Source 1. 2. 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. NOTE Gas comes on if Torch Trigger is pressed (although unit will not pilot until switch is released and reclosed after the light stops blinking).
12. Gas will flow for 10 seconds (post-flow). a. Gas solenoid closes. Gas flow stops. GAS indicator 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 from the system. NOTE For information on cutting techniques, cutting problems, cutting speeds, cut quality, etc., refer to the torch manual supplied with the torch. This completes the Operation Section.
SECTION 5: SERVICE 5.01 Introduction 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. 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.
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.
d. Work cable disconnected B. How to Use This Guide e. Worn torch parts 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. f. Non-Genuine Firepower Parts used 3. Excessive Dross Formation a. Cutting speed too slow This guide is set up in the following manner: b. Torch standoff too high from workpiece X. Symptom (Bold Type) c.
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. 1. Poor input or output connections a. Check all input and output connections. 2. Faulty components in unit 4. Input line voltage is below 75% of rated level a. Return for repair or have qualified technician repair per Service Manual. a. Check and connect to proper input power line. 5.
4. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. J. Upper screws Torch cuts but not adequately 1. Current set too low a. Increase current setting. 2. Torch is being moved too fast across workpiece a. Reduce cutting speed (refer to Instruction Manual supplied with torch). Lower screws 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).
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 A-02957 Figure 5-4 Internal Fuse Location This completes the service procedures.
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable 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.
6.03 Power Supply Replacement The following items are included with the replacement power supply: work cable & clamp, gas pressure regulator/ air filter, input power cable & plug, and operating manual. Qty 1 Description Catalog # Firepower FP-55 Power Supply, 208/230VAC, Single-Phase, 60Hz 3-5230-FP 6.
APPENDIX 1: INPUT WIRING REQUIREMENTS Voltage (Volts) 208 230 Input Frequency (Hz) 60 60 Power Input Current Input 1-Ph 1-Ph (kVA) (Amps) 8.2 39 8.
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION Close external disconnect switch. ON/OFF switch to ON. RUN/SET switch to SET. RUN/SET switch to RUN. RESULT RESULT RESULT RESULT Power to system. AC indicator blinks for 8 seconds then steady on. Fans on. Pilot relay closes. Power circuit ready. Gas solenoid open, gas flows to set pressure. GAS indicator on. Gas flow stops. GAS indicator off. ACTION ACTION Protect eyes and activate torch.
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.
APPENDIX 4: SYSTEM SCHEMATIC A-03269 APPENDIX A-4 Manual 0-2846
A-03269 Manual 0-2846 A-5 APPENDIX
