Firepower Firepower FP-55 Operating Manual Download Page 17

Manual 0-2846

3-1

INSTALLATION

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 informa-
tion.

This Section describes installation of the Power Supply
and connecting the Torch.

These instructions apply to the Power Supply only;  in-
stallation procedures for the Torch, Options, and Acces-
sories are given in Manuals specifically provided for those
units.

The complete installation consists of:

1.

Site selection

2.

Unpacking

3.

Connections to Power Supply

a. Input power

b. Gas Connections

c. Torch Leads

d. Work cable

4.

Grounding

5.

Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and ad-
equate 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).

CAUTION

Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.

3.03 Unpacking

The product is packaged and protected to prevent dam-
age during shipping.

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list(s) to iden-

tify 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 instal-
lation.

3.04 Lifting Options

This unit is equipped with a handle for hand carrying
purposes.

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-ener-
gized supply line before moving unit.

FALLING 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 capac-

ity to move  unit.

• Place and secure unit on a proper skid before trans-

porting with a fork lift or other vehicle.

Summary of Contents for Firepower FP-55

Page 1: ...Operating Manual A 02766 PlasmaCutting PowerSupply Firepower FP 55 April 4 2003 Manual No 0 2846...

Page 2: ......

Page 3: ...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 Warrant...

Page 4: ...Scope of Manual 2 1 2 02 General Description 2 1 2 03 Specifications Design Features 2 1 2 04 Power Supply Options 2 2 SECTION 3 INSTALLATION PROCEDURES 3 1 3 01 Introduction 3 1 3 02 Site Selection 3...

Page 5: ...3 5 05 Power Supply Basic Parts Replacement 5 5 SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Ordering Information 6 1 6 03 Power Supply Replacement 6 2 6 04 Replacement Parts 6 2 6 05 Optiona...

Page 6: ......

Page 7: ...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...

Page 8: ...information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual PLASMAARC RAYS PlasmaArc Rays can injure your eyes and burn your skin The plasma arc process produces ver...

Page 9: ...FOR WELDINGAND 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...

Page 10: ...z pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq CHOC...

Page 11: ...onnes se trouvant sur le lieu de travail Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester...

Page 12: ...URIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S C...

Page 13: ...tion standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 E...

Page 14: ...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 liabilit...

Page 15: ...ed plug and work cable clamp Refer to Section 2 04 for power supply options and ac cessories A 02766 Figure 2 1 Firepower FP 55 Power Supply 2 03 Specifications Design Features A Power Supply Technica...

Page 16: ...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 Opt...

Page 17: ...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 CAUTION Operat...

Page 18: ...may cause double arcing rapid tip wear or even com plete torch failure Contaminants may cause poor cutting performance and rapid electrode wear C Connecting Gas Supply to Unit The gas supply is connec...

Page 19: ...s Supply Hose Regulator Filter Assembly Bracket Inlet Port Hose Clamp Filter Hose Figure 3 2a Optional Single Stage Air Filter Installation units with type A Regulator Filter A 03000 Regulator Filter...

Page 20: ...nit 4 Secure the Strain Relief with the retaining nut re moved earlier 5 Connect the torch Negative Plasma Lead to the bulkhead connection inside the Power Supply Adapter Plug Pilot Lead Torch Lead As...

Page 21: ...4 The plasma power supply work cable see NOTE is connected to the cutting table at the single point Star ground NOTE Do Not connect the work cable directly to the ground rod 5 Make sure work cable an...

Page 22: ...20 30 ft 6 1 9 1 m does not generally increase the effective ness of the ground rod A larger diameter rod which has more surface area may help Sometimes keeping the soil around the ground rod moist b...

Page 23: ...put Hole in the front panel to feed the torch leads through to the internal bulkhead connections 3 Work Cable and Clamp 20 ft 6 1 m work cable with clamp factory installed 4 Roll Handle Torch Leads Wr...

Page 24: ...or Filter A 03042 1 2 3 Figure4 3b RearPanel unitswithtypeBRegulator Filter 2 PrimaryInputPowerCable StrainRelief Factoryinstalledprimaryinputpowercablestrainrelieffor theprimarypowercable capableofha...

Page 25: ...ource disconnect switch a AC power is available at the Power Supply 2 Place RUN SET switch to RUN mode 3 Place the ON OFF power switch on the front panel of the Power Supply to ON position a AC Power...

Page 26: ...r 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 o...

Page 27: ...so 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 t...

Page 28: ...be removed from its hous ing 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 Filte...

Page 29: ...replacement proce dures refer to Firepower FP 55 Power Supply Service Manual 0 2847 B How to Use This Guide ThefollowinginformationisaguidetohelptheCustomer Operator determine the most likely causes f...

Page 30: ...ng of CURRENT control a Check and adjust to proper setting 2 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual F Limited output with no control 1 Poo...

Page 31: ...ction describes procedures for basic parts replace ment For more detailed parts replacement procedures refer to the Firepower 55 Power Supply Service Manual A Cover Removal 1 Remove the upper screws w...

Page 32: ...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 A 02957 F...

Page 33: ...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 p...

Page 34: ...ilter 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...

Page 35: ...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 Cu...

Page 36: ...h is within transfer distance 1 4 in 6 4mm of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Close external disconnect switch RESULT Power...

Page 37: ...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 f...

Page 38: ...APPENDIX A 4 Manual 0 2846 APPENDIX 4 SYSTEM SCHEMATIC A 03269...

Page 39: ...Manual 0 2846 A 5 APPENDIX A 03269...

Page 40: ......

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