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Summary of Contents for Firepower FirePower FP-82
- Page 1 Plasma Cutting Power Supply FirePower FP-82 A-02990 Operating Manual January 28, 2003 Manual No. 0-2870...
- Page 3 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 FP-82 Operating Manual Number 0-2870 www.firepoweronline.com Published by: Thermal Dynamics Corporation...
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Page 4: Table Of Contents
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 ................ - 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 Troubleshooting Guide ................ 5-3 5.05 Power Supply Basic Parts Replacement ............5-5 SECTION 6: PARTS LISTS ........................
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Page 7: General Information
SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume. -
Page 8: Publications
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •... -
Page 9: Note, Attention Et Avertissement
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question. - Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.
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Page 11: Documents De Reference
ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •... - Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection 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.
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Page 13: Declaration Of Conformity
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 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. -
Page 14: 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 four (4) years from 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. -
Page 15: Introduction
(AC) is low or the DC voltage is higher 2.01 Scope of Manual than shown in the chart. This manual contains descriptions, operating instructions FirePower FP-82 Power Supply Duty Cycle and basic maintenance procedures for the FirePower 82 104° F 104° F 104° F Ambient Plasma Cutting Power Supply only. -
Page 16: Options And Accessories
2.04 Options and Accessories The following options and accessories are available for this power supply. Refer to Section 6, Parts Lists, for cata- log numbers and ordering information. A. Single Stage Air Line Filter Kit For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns. -
Page 17: Introduction
SECTION 3: 3.03 Unpacking INSTALLATION The product is packaged and protected to prevent dam- age during shipping. 1. Unpack each item and remove any packing material. 3.01 Introduction 2. Locate the packing list(s) and use the list(s) to iden- This Section describes installation of the Power Supply tify and account for each item. -
Page 18: Primary Input Power Connections
B. Checking Air Quality 3.05 Primary Input Power Connections To test the quality of air, place the RUN/SET switch to SET (down) position, place a welding filter lens in front of the torch Check your power source for correct voltage before con- and turn on the gas. - Page 19 D. Installing Optional Air Filter Kits 2. Optional Two-Stage Air Filter Kit This optional two-stage air line filter is also for use Additional filtering is recommended when using air from on compressed air shop systems. Filter removes mois- a compressor to insure that moisture and debris from the ture and contaminants to at least 5 microns.
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Page 20: Torch Connections
E. Using High Pressure Gas Cylinders Strain Relief Refer to the following when using high pressure gas cyl- Torch Leads inders as the gas supply: Assembly CAUTION Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator. 1. - Page 21 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. CAUTION The torch parts must correspond with the type of operation.
- Page 22 INSTALLATION Manual 0-2870...
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Page 23: Operation
5. Torch Bulkhead Panel SECTION 4: The torch bulkhead panel is under the power supply OPERATION cover. • Pilot Lead Stud 4.01 Introduction Connects the pilot control wire on the torch to the unit. This section describes the power supply operating con- trols and procedures, identifies the front and rear com- •... -
Page 24: Preparations For Operating
AC Power Indicator Primary input power cable with plug. Green indicator will blink ON-OFF for approximately eight 3. Gas Pressure Regulator/Filter Assembly seconds and then stay ON after the ON/OFF power switch Pressure regulator to adjust the input gas pressure to the is set to ON. - Page 25 D. Work Cable Connection 4.04 Sequence of Operation Check for a solid work cable connection to the work- The following is a typical sequence of operation for this piece. power supply. Refer to Appendix 2 for block diagram. 1. Close main power source disconnect switch. Make a solid work cable a.
- Page 26 10. Complete cutting operation. NOTES If the torch is lifted from the workpiece while the torch is activated, the main arc will stop and the pilot arc will automatically restart. At output settings over 40 amps, control circuitry in the power supply automatically reduces output current to 40 amps if the torch tip contacts the workpiece.
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Page 27: Customer/Operator Service
The filter element and spool, with the baffle ring in SECTION 5: place (teeth facing downward) can be screwed back CUSTOMER/OPERATOR into the Regulator body by compressing the spring on the spool. Tighten firmly by hand. SERVICE 5.01 Introduction This section describes basic maintenance procedures per- formable by operating personnel. -
Page 28: Common Faults
Worn torch parts Shut off air supply and bleed down system before e. Cutting current too low changing Filter Elements. Non-Genuine FirePower parts used WARNING Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result. -
Page 29: Basic Troubleshooting Guide
Improper cutting current C. Common Symptoms e. Non-Genuine FirePower parts used A. AC Power indicator 4. Short Torch Parts Life 1. Switch at customer's main power panel in OFF posi- tion. - Page 30 3. Unit is overheated E. Low cutting output a. Allow unit to cool down for at least 5 minutes. 1. Incorrect setting of CURRENT (A) control Make sure the unit has not been operated be- a. Check and adjust to proper setting. yond Duty Cycle limit.
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Page 31: Power Supply Basic Parts Replacement
I. No gas flow; AC POWER indicator ON; Fan 5.05 Power Supply Basic Parts operates Replacement 1. Gas not connected or pressure too low a. Check source for at least 70 psi (4.8 bar). WARNING 2. Gas supply pressure too high a. - Page 32 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. To reinstall the cover, complete the following: a. Reconnect the ground wire, if necessary. b.
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Page 33: Parts Lists
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable com- ponents. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 Replacement Parts Section 6.05 Options and Accessories NOTE Parts listed without item numbers are not shown, but may be ordered by the catalog number shown. -
Page 34: Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, gas pressure regulator/ filter, and operating manual. Description Catalog # Firepower FP-82 Power Supply, 208/230VAC, Single-Phase, 1445-0002 with input power cable and plug 6.04 Replacement Parts... -
Page 35: Appendix 1: Input Wiring Requirements
APPENDIX 1: INPUT WIRING REQUIREMENTS FirePower FP-82 Input Wiring Requirements Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph... -
Page 36: Sequence Of Operation
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET RUN/SET switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops. Gas solenoid open, seconds then steady on. -
Page 37: Appendix 3: Maintenance Schedule
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. -
Page 38: Appendix 4: System Schematic
APPENDIX 4: SYSTEM SCHEMATIC INPUT DIODE IGBT PCB ASSEMBLY 19X1756 ASSEMBLY 19X1755 E12A E17A GATE 208/230V DRIVE COPPER SINGLE PHASE STRAP INPUT (78) GATE DRIVE (33) E19A E21A INRUSH +12VDC CHASSIS IGBT PCB ASSEMBLY 19X1756 E12B FILTERING +18V E17B GATE DRIVE 230V GATE... - Page 39 OUTPUT DIODE OUTPUT INDUCTOR ASSEMBLY E34B 19X1757 E39B MAIN E50B E(62) E48B E11A PILOT E(35) E53B E54B E56B J30 P30 E60B J31 P31 THRU SCREW TERMINAL OUTPUT DIODE ASSEMBLY E34A CHASSIS GND 19X1757 E39A E50A E11B E48A CD ASSEMBLY E53A 19X1751 E54A E56A...
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