Firepower FP-38 Operating Manual Download Page 36 | Manualshive

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SERVICE

5-10

Manual 0-2967

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Summary of Contents for FP-38

Page 1: ...Plasma Cutting Power Supply Firepower TM FP 38 Power Supply Operating Manual May 5 2003 Manual No 0 2967 A 03286...

Page 2: ......

Page 3: ...2002 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 hereb...

Page 4: ...nections 3 2 3 4 Gas Connections 3 3 3 5 Torch Connections 3 6 SECTION 4 OPERATION 4 1 4 01 Product Features 4 1 4 02 Preparations For Operating 4 3 4 03 Sequence of Operation 4 7 SECTION 5 SERVICE 5...

Page 5: ...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 me...

Page 6: ...this manual 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 These arc rays will damage your eyes an...

Page 7: ...e Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highw...

Page 8: ...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 EN5007...

Page 9: ...epower 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 i...

Page 10: ...GENERAL INFORMATION 1 6 May 14 2002...

Page 11: ...60 Hz Automatic Voltage Selection See Note 1 Cable with plug for 120VAC 20 Amp Single Phase input power Note 2 20 30 Amps continuously variable Particulates to 20 Microns Note 4 Firepower FP 38 Power...

Page 12: ...r plug installations 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...

Page 13: ...ng Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNINGS Do not touch live electrical parts Disconnect input power cord b...

Page 14: ...ower A 03382 120 V 20A 1 For 208 230 VAC input power replace the supplied power plug Use only an approved replacement input power plug with ground Replace the plug as follows 1 Cut the original cord c...

Page 15: ...eal 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...

Page 16: ...er hose 3 Connect the gas line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instructi...

Page 17: ...h may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm 4 Connect...

Page 18: ...sconnect primary power at the source before connecting the torch 1 Align the male connector on the torch lead with the female receptacle on the power supply Press the connector into the receptacle ful...

Page 19: ...Manual 0 2967 4 1 OPERATION SECTION 4 OPERATION 4 01 Product Features A General Features A 03287 Handle and Leads Wrap Gas Pressure Knob Torch Leads Connector Work Cable and Clamp Control Panel...

Page 20: ...te input power Refer to Section 2 for input power requirements 4 AC Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is in protective interlock mode S...

Page 21: ...ts with this torch B Torch Connection Check that the torch is properly connected C Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source m...

Page 22: ...ufficient gas pressure for power supply operation Minimum pressure for power supply operation is below the minimum for torch operation A 03384 A 30 20 26 28 24 22 G Set Operating Pressure Place the Po...

Page 23: ...Protect eyes with appropriate shielding Refer to the torch manual for torch operation details J Cutting Technique Hold the torch with one or two hands with the torch tip close to the workpiece Do not...

Page 24: ...1 400 10 1 Typical Cutting Speeds Air Plasma on Mild Steel 24 10 0 25 0 5 12 7 0 4 A 03381 Output current setting or cutting speeds may be reduced to allow slower cutting when following a line using a...

Page 25: ...switch OFF then ON 3 Put RUN SET switch to SET down position a Gas flows to set pressure Turn gas pressure adjustment knob to set pressure to 65 psi 4 5 bar 4 Put RUN SET switch to RUN up position Ga...

Page 26: ...OPERATION 4 8 Manual 0 2967...

Page 27: ...emovingtorchparts B Every three months A Check internal air filter replace if necessary 1 Shut off input power turn off the gas supply Bleed down the gas supply 2 Remove the upper cover screws 3 Loose...

Page 28: ...t 8 Screw the filter element and spool with the baffle ring in place teeth facing downward back into the Regulator body by compressing the spring on the spool Tighten firmly by hand A 03377 Replacemen...

Page 29: ...unter clockwise 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 7 Replace Housing on...

Page 30: ...cable disconnected 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 cut...

Page 31: ...l 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 follow...

Page 32: ...on to power supply is loose a Release torch trigger and set ON OFF switch to OFF down Tighten torch connector to receptacle on power supply securely Do not use tools Set ON OFF switch to ON up 4 Syste...

Page 33: ...tch is activated AC indicator ON TEMP indicator OFF DC indicator OFF 1 System is in SET mode a Release torch trigger Change power supply RUN SET switch to RUN up position 2 Torch Head upper O ring in...

Page 34: ...a Check all input and output connections 2 Work cable connection to work piece is poor a Make sure that work cable has a proper connection to a clean dry area of the workpiece 3 Faulty components in u...

Page 35: ...es worn a Check torch shield cup tip starter element and electrode replace as needed 6 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual N No gas flo...

Page 36: ...SERVICE 5 10 Manual 0 2967...

Page 37: ...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 Address all inquiries to your autho rized distributor 6 03 Rep...

Page 38: ...Shown 1445 0913 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 A 02476 Filter...

Page 39: ...cator on when input pressure is adequate ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts ACTION ON OFF switch to ON RESULT AC indicator O...

Page 40: ...voltage values I A 03288 Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltage Plasma Cutting Symbol Manufacturer s Name and or Logo Location Model and R...

Page 41: ...Manual 0 2967 A 3 APPENDIX This page left blank...

Page 42: ...VDC NORMALLY CLOSED TEST POINTS TP1 LOGIC COMMON TP2 SHORT TO TP23 TO DISABLE BIAS SUPPLY TP6 SHORT TO TP24 TO DISABLE POWER FACTOR CORRECTION TP8 SHORT TO TP26 TO DISABLE SHORTED TORCH PROTECTION E14...

Page 43: ...5 E4 REL ECO 100213 GCW 7 29 02 AA 42X1089 Thursday March 20 2003 1 1 INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 CM38 120 208 230V SINGLE PHASE 50 60 Hz Tuesday May 15 2001 15 05 29 THER...

Page 44: ...APPENDIX A 6 Manual 0 2967...

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