Related Manuals for Firepower FP-78
Summary of Contents for Firepower FP-78
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Page 1: Operating Manual
7/8"- 200 VOLT AIR PLASMA CUTTING POWER SUPPLY A-01678 Operating Manual December 16, 1998 Manual No. 0-2700... - Page 3 The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in the FP-78 Air Plasma Cutting Power Supply Operat- ing Manual, whether such error results from negligence, accident, or any other cause.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1 1.01 Notes, Cautions and Warnings ............... 1 1.02 Important Safety Precautions ................. 1 1.03 Publications ....................2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes ............. 3 1.06 Documents De Reference ................ - Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................29 6.01 Introduction ....................29 6.02 Ordering Information ..................29 6.03 Complete System Replacement ..............30 6.04 Options and Accessories ................30 APPENDIX I: INPUT WIRING REQUIREMENTS ................ 31 APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ..........32 APPENDIX III: SYSTEM SCHEMATIC ..................
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Page 7: General Information
• Use an air-supplied respirator if ventilation is not SECTION 1: adequate to remove all fumes and gases. GENERAL INFORMATION • 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. -
Page 8: Publications
• Protect others in the work area from the arc rays. Use protective booths, screens or shields. FIRE AND EXPLOSION • Use the shade of lens as recommended in Subsec- tion 1.03, item 4. Fire and explosion can be caused by hot slag, sparks, or the plasma arc. -
Page 9: Note, Attention Et Avertissement
12. CSA Standard W117.2, CODE FOR SAFETY IN 1.05 Precautions De Securite WELDING AND CUTTING, obtainable from the Ca- Importantes nadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 13. NWSA booklet, WELDING SAFETY BIBLIOGRA- AVERTISSEMENT PHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 L’OPÉRATION ET LA MAINTENANCE DU 14. - Page 10 • Utilisez un équipement spécial tel que des tables de • Prévoyez une veille d’incendie lors de tout travail coupe à débit d’eau ou à courant descendant pour dans une zone présentant des dangers d’incendie. capter la fumée et les gaz. •...
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Page 11: Documents De Reference
• Pour des renseignements sur la manière de tester le 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- bruit, consultez l’article 1, page 5. TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 1.06 Documents De Reference 02269 10. -
Page 12: Declaration Of Conformity
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc- tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National leg- islation for the enforcement of this Directive. -
Page 13: Statement Of Warranty
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The limited warranty periods for Firepower products shall be as follows: A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such two (2) year period. - Page 14 GENERAL INFORMATION...
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Page 15: Introduction
This manual contains descriptions, operating instructions 2.03 Specifications/Design Features and basic maintenance procedures for the FP-78 Air Plasma Cutting Power Supply. Service of this equip- A. Power Supply Technical Specifications ment is restricted to Firepower® trained personnel; un-... -
Page 16: Power Supply Options And Accessories
B. Gas Regulator Assembly Specifications The following specifications apply to the Gas Regu- lator Assembly only: 1. Gas regulator maximum gauge pressure 160 psi (11 bar or 11.03 kPa) 2. Maximum input gas pressure 125 psi (8.6 bar or 861 kPa) 2.04 Power Supply Options and Accessories NOTE... -
Page 17: Installation Procedures
Provide sufficient clearance in front of the unit to allow SECTION 3: access to the front panel controls (minimum 6 inches or 0.15 m). INSTALLATION PROCEDURES CAUTION Operation without proper air flow will inhibit 3.01 Introduction proper cooling and reduce duty cycle. NOTE 3.03 Unpacking Depending on how the system was ordered, some... -
Page 18: Lifting Options
3.04 Lifting Options WARNING WARNINGS Disconnect primary power at the source before as- sembling or disassembling the Power Supply, torch parts, or torch and leads assemblies. Do not touch live electrical parts. Disconnect input power conductors from de-en- 1. Remove the four screws securing the Handle and the ergized supply line before moving unit. -
Page 19: Input Power Cable Connections
3.07 Gas Connections Cover A. Gas Requirements WARNING This unit not to be used with oxygen (O Cover Screws Gases: Compressed Air or Nitrogen (N ) Only (5 Places On Each Side) Pressure: 60 psi (4.1 bar or 410 kPa) CAUTION Maximum input gas pressure must not exceed 125 psi (8.6 bar or 861 kPa) - Page 20 NOTE A barb fitting is provided for connection of the gas supply hose to the rear of the Power Supply. The fitting is placed in the Spare Parts Kit for shipment. Filter IN Port 2. Depending on the options installed at the factory, in- Gas Connector stall the supplied barb fitting into the gas connector Fitting...
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Page 21: Connecting Torch Leads
7. Secure the gas supply hose inplace with the adjust- CAUTION able hose clamp. NOTE This system is designed for use with the FP78- 1torch only. Do not connect any other torch to Supply hose must be at least #4 hose (1/4 in or 6 this power supply. -
Page 22: Work Cable And Ground Connections
4. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and in- creased chance of RF interference. Pilot/Output 5. Make sure work cable and ground cables are prop- PC Board erly connected. Control Cable Black Wire From A-01685 Pilot Cable... -
Page 23: Operation
5. Leads Wrap 4.02 Functional Overview Bracket connected to the Cover of the unit for use in The Firepower FP-78 provides a degree of operating flex- storing the torch, torch leads and work cable when ibility and the use of simple controls. - Page 24 4. TEMP Indicator Normally OFF. Yellow LED indicator will come ON when the internal temperature senors detect tempera- tures above normal limits. The unit should be al- lowed to cool before continuing operation. C. Torch Panel Bulkhead The torch panel bulkhead area is located behind the Front Panel and requires removal of the Power Supply Cover for access.
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Page 25: Sequence Of Operation
NOTE Power Supply will not come ON if the gas pres- sure is set below 45 psi (3.1 bar or 310 kPa) at the Regulator Assembly. 3. Protect eyes and press or activate torch switch a. Gas pre-flows starts. b. GAS indicator turns ON. 4. -
Page 26: Preparations For Operating
D. Work Cable Connection 4.05 Preparations for Operating Check for a solid and clean work cable connection to Follow this set-up procedure each time the system is op- the workpiece. The area must be free from paint and erated: rust. WARNING Make a solid work cable connection to the work-... - Page 27 Bevel Angle T y p e o f M a t e r ia l The angle between the surface of the cut edge and a plane C a r b o n S t a in le s s G a s A lu m in u m perpendicular to the surface of the plate.
- Page 28 OPERATION Manual 0-2700...
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Page 29: Customer/Operator Service
(page 1). Be sure the operator is equipped formable by operating personnel. No other adjustments with proper gloves, clothing, eye and ear protec- or repairs are to be attempted by other than Firepower tion. Make sure no part of the operator’s body Trained personnel. -
Page 30: Troubleshooting Guide
diameter of a circle, the torch should move counterclock- 3. Excessive Dross Formation wise around the circle. To keep the square edge along an a. Cutting speed too slow outside diameter cut, the torch should travel in a clock- wise direction. b. - Page 31 1. Cause (Italic Type) 5. Input voltage of 460 V AC applied to 208/230/240 V AC or 380/415 V AC Models a. Check/Remedy (Text Type) a. Check input line voltage and correct as re- Locate your symptom, check the causes (easiest listed quired.
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Page 32: Power Supply Parts Replacement
2. Incorrect setting of CURRENT control 5.05 Power Supply Parts Replacement a. Check and adjusted to proper setting. 3. Faulty components in unit a. Return for repair or have qualified technician WARNING repair per Service Manual. G. Erractic or improper cutting output Disconnect primary power to the system before disassembling the torch, leads, or power supply. - Page 33 Cover Cover Screws (5 Places On Each Side) Internal Fuse A-01692 0.8 Amps, 600V Figure 5-3 Internal Fuse Location A-01680 Figure 5-2 Cover Removal 3. Carefully pull the Cover up and away from the unit to gain access to the inside of the unit. 4.
- Page 34 SERVICE Manual 0-2700...
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Page 35: Parts Lists
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown. B. Returns If a Firepower product must be returned for service, con- tact your Firepower distributor. Materials returned to Fire- power without proper authorization will not be accepted. -
Page 36: Complete System Replacement
System includes: Input Power Cable & Plug, Work cable, pressure regulator/air filter, air hose and fittings, torch & leads, torch manual and operating manual. Description Catalog # FP-78 Plasma Cutting System 208/230VAC, Single Phase 1445-0002 6.04 Options and Accessories Description... -
Page 37: Appendix I: Input Wiring Requirements
APPENDIX I: INPUT WIRING REQUIREMENTS Input Power Input Current Suggested Sizes (See Notes) Voltage Freq. 1-Ph 1-Ph (Volts) (Hz) (kVA) (Amps) Fuse (Amps) Wire (AWG) Wire (Canada) 50/60 14.6 41.7 50/60 14.8 38.4 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. -
Page 38: Appendix Ii: Sequence Of Operation (Block Diagram)
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ON/OFF switch to ON. Close external disconnect switch. RESULT RESULT AC indicator blinks for 8 seconds then steady on. Fans on. Power to system. Gas solenoid open, gas flows to set pressure. Gas flow stops after pre-flow (purge). - Page 39 Manual 0-2700 APPENDIX...
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Page 40: Appendix Iii: System Schematic
APPENDIX III: SYSTEM SCHEMATIC A-01707 APPENDIX Manual 0-2700... - Page 41 11/23 EC 8055 A-01707 Manual 0-2700 APPENDIX...