Fire Power Firepower FP-55 User manual

Operating Manual
A-02766
Plasma Cutting
Power Supply
Firepower FP-55
April 4, 2003 Manual No. 0-2846

Plasma Cutting Power Supply
Firepower 55 (FP-55)
Operating Manual Number 0-2846
www.firepoweronline.com
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 2001 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written per-
mission of the publisher is prohibited.
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
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 Warranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, oper-
ating, 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.

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions andWarnings ..................................................................... 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 ............................................................................ 1-5
1.07 Declaration of Conformity............................................................................. 1-7
1.08 Statement ofWarranty.................................................................................. 1-8
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications/DesignFeatures .................................................................... 2-1
2.04 Power Supply Options.................................................................................. 2-2
SECTION 3:
INSTALLATION PROCEDURES ....................................................................................... 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Lifting Options .............................................................................................. 3-1
3.05 Primary Input Power Connections ................................................................ 3-2
3.06 Gas Connections ......................................................................................... 3-2
3.07 Torch Connections ....................................................................................... 3-3
3.08 Ground Connections For Mechanized Applications ...................................... 3-4
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction ................................................................................................. 4-1
4.02 Functional Overview.................................................................................... 4-1
4.03 Operating Controls ...................................................................................... 4-1
4.04 Preparations For Operating ......................................................................... 4-2
4.05 Sequence of Operation................................................................................ 4-3

TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE................................................................................. 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 GeneralMaintenance ................................................................................... 5-1
5.03 Common Faults............................................................................................ 5-2
5.04 BasicTroubleshooting Guide ........................................................................ 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 OptionalEquipment...................................................................................... 6-2
APPENDIX 1: INPUT WIRING REQUIREMENTS ....................................................................A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) .........................................A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................A-3
APPENDIX 4: SYSTEM SCHEMATIC.......................................................................................A-4

Date: 5/1/00(Special) 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structionsbeforeusing theequipment. Call1-603-
298-5711 or your local distributor if you have any
questions.
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.
• 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 metal being used, coatings
on the metal, and the different processes.You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formationregarding the kind andamount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
inyourworkplace,referto item 1 in Subsection 1.03,
Publications in this manual.
• Usespecialequipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de-
fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”

GENERAL INFORMATION 1-2 Date 5/1/00 (Special)
• 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, Publica-
tions.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable ma-
terial in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provideafirewatchwhenworkinginanareawhere
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noisecan cause permanent hearingloss. Plasmaarcpro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noiselevelsshouldbemeasuredto be surethedeci-
bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMAARC RAYS
PlasmaArcRays can injureyoureyesand burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesandburnyour skin if you arenotproperly protected.
• To protect your eyes, always wear a welding hel-
metor shield. Also always wearsafetyglasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is
clearly seen. Experience has shown that lighter
filters may be used when the arc is hidden by the
workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent
of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
3. NIOSH, SAFETYAND HEALTH INARC WELD-
ING AND GAS WELDING AND CUTTING, ob-
tainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATIONAND EDUCATIONALEYEAND
FACE PROTECTION, obtainable fromAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018

Date: 5/1/00(Special) 1-3 GENERAL INFORMATION
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 PRO-
CESSES,obtainable fromAmerican National Stan-
dards Institute, 1430 Broadway, New York, NY
10018
7. AWS StandardA6.0, WELDINGAND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable fromAmerican Welding Soci-
ety, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-
TEMS FOR WELDING, CUTTINGAND ALLIED
PROCESSES, obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL
CODE, obtainable from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269
10. NFPAStandard 51B, CUTTINGAND WELDING
PROCESSES, obtainable from the National Fire
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
JeffersonDavis Highway, Suite 501,Arlington, VA
22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the
CanadianStandardsAssociation, StandardsSales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Sup-
plyAssociation, 1900ArchStreet,Philadelphia, PA
19103
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDINGANDCUTTING
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 RESPIRA-
TORY PROTECTION, obtainable fromAmerican
NationalStandardsInstitute,1430Broadway, New
York, NY 10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupantàl’arcaujetdeplasmaproduitde l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au person-
nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous

GENERAL INFORMATION 1-4 Date 5/1/00 (Special)
lesavertissements,touteslesprécautionsde 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
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtementsse trouvantsurlemétal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables
de coupe à débit d’eau ou à courant descendant
pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Lephosgène,ungaz toxique, est généréparla fumée
provenantdes solvantsetdes produitsde nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de
coupe, produit de la fumée ou des gaz pouvant
contenir des éléments reconnu dans L’ état de la
Californie, qui peuvent causer des défauts de
naissance et le cancer. (La sécurité de santé en
Californie et la code sécurité Sec. 25249.5 et seq.)
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, voiremortels,pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres par-
ties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchezl’alimentation électrique avant touttra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
Lesincendiesetlesexplosionspeuventrésulterdes scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
bustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Necoupezpas et ne soudez pas les conteneursayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
PAS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.

Date: 5/1/00(Special) 1-5 GENERAL INFORMATION
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vosyeuxetbrûler votrepeau.Leprocédé à l’arcdeplasma
produit une lumière infra-rouge et des rayons ultra-vio-
lets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ouunécran de soudeur. Portez toujours deslunettes
de sécurité munies de parois latérales ou des lu-
nettes de protection ou une autre sorte de protec-
tion oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protec-
tion en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégezles autres personnes se trouvantsur lazone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suiventANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
*Cesvaleurss’appliquentoul’arcactuelestobservé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts,
portez des tampons protecteurs et/ou des protec-
tions auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DESÉCURITÉDUTRAVAILET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Docu-
ments,U.S. Government Printing Office,Washing-
ton, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Super-
intendent of Documents, U.S. Government Print-
ing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR
LAPROTECTION DES YEUX ET DUVISAGEAU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales
(American National Standards Institute), 1430
Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprèsde l’American NationalStandardsInstitute,
1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIESLORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage(AWS), LESOUDAGE ETLACOUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès
de laAmerican Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
8. Norme 51 de l’AssociationAméricainepourla Pro-
tection contre les Incendies (NFPA), LES
SYSTEMES À GAZ AVEC ALIMENTATION EN
OXYGENE POUR LE SOUDAGE, LA COUPE ET
LES PROCÉDÉS ASSOCIÉS, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

GENERAL INFORMATION 1-6 Date 5/1/00 (Special)
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. Brochure GCAP-1, LAMANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN
CYLINDRES,disponible auprèsdel’Association
des Gaz Comprimés (Compressed GasAssocia-
tion), 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ
POURLESOUDAGE ET LA COUPE, disponible
auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉDUSOUDAGE,disponibleauprèsde
l’Association Nationale de Fournitures de
Soudage(NationalWelding SupplyAssociation),
1900 Arch Street, Philadelphia, PA 19103
14. NormeAWSF4.1 de l’AssociationAméricainede
Soudage, RECOMMANDATIONS DE PRA-
TIQUESSURESPOUR LAPRÉPARATIONÀLA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès
de la American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-
TION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018

Date: 5/1/00(Special) 1-7 GENERAL INFORMATION
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 Direc-
tive’ (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.
Serialnumbers areunique with eachindividualpiece of equipmentanddetails description, partsusedto manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
* CSA(Canadian StandardsAssociation) 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) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

GENERAL INFORMATION 1-8 Date 5/1/00 (Special)
1.08 Statement of Warranty
LIMITED WARRANTY: Firepower® (hereinafter “Firepower”) warrants that its products will be free of defects in workmanship or
material. Should any failure to conform to this warranty appear within the time period applicable to the Firepower products as stated
below, Firepower shall, upon notification thereof and substantiation that the product has been stored, installed, operated, andmaintained
in accordance with Firepower’s specifications, instructions, recommendations and recognized standard industry practice, and not subject
to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Firepower’s sole option, of
any components or parts of the product determined by Firepower to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Firepower shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Firepower with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by 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 liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY FIREPOWER PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Firepower products shall be as follows: Amaximum 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.
FP-55, POWER SUPPLIES PARTS LABOR
MAIN POWER MAGNETICS ...................................................................................................... 3 YEARS ...................1 YEAR
ORIGINAL MAIN POWER RECTIFIER ..................................................................................... 3 YEARS ...................1 YEAR
CONTROL PC BOARD .................................................................................................................. 3 YEARS ...................1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ......................................................................... 1 YEAR ....................1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT............................................................................. 1 YEAR .................. 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ......................................................................................................................... 1 YEAR .................. 1 YEAR
REPAIR/REPLACEMENTPARTS .................................................................................................... 90 DAYS .................. NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Firepower repair facility
within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to
send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Firepower warranties.
Effective May 5, 2000

Manual 0-2846 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
Thismanual contains descriptions, operatinginstructions
and basic maintenance procedures for the Firepower
FP-55 Plasma Cutting Power Supply only. Servicing of
this equipment is restricted to properly trained person-
nel; unqualified personnel are strictly cautioned against
attempting repairs or adjustments not covered in this
manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip-
ment will assure the dependable operation for which it
was designed.
NOTE
RefertotheTorchManual provided with this Power
Supply for torch and cutting information.
2.02 General Description
Thepowersupplyprovides40 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, primary input power cable with
molded 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 Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Features
• Main power ON/OFF switch
• RUN/SET switch
• output current control
• torch leads access
• work lead
2. Rear Panel Features
• Primary input power cable with molded plug
• gas pressure gauge regulator/filter assembly
• gas supply connection
3. Front Panel Indicators
AC, TEMP, GAS, DC
4. Input Power (See Note)
208/230VAC (±10%), 60 Hz, SinglePhase,39/37 amps
NOTE
Referto Appendix 1 forinputwiring requirements.
5. Output Power
Continuously variable from 20 to 40 amps maximum
6. Duty Cycle (see NOTE)
NOTE
The duty cycle will be reduced if the primary in-
put voltage (AC) is low or the DC voltage is higher
than shown in the chart.
Ambient
Tem
p
erature 104° F
(40° C) 104° F (40° C) 104° F (40° C)
Duty Cycle 40% 60% 100%
Current 40 Amps n/a 25 Amps
DC Voltage 96 vdc n/a 96 vdc
Power Supply Duty Cycle
7. Pilot Circuitry
Capacitive Discharge (CD), Ignition DC Pilot

INTRODUCTION 2-2 Manual 0-2846
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/FilterAssembly 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 Options
The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for item number
and ordering information.
A. Single-Stage In-Line Air Filter Kit
A Single Stage In-Line Air Filter for use with com-
pressed air shop systems. Filters moisture and par-
ticulate matter from the air stream to at least 0.85 mi-
crons.

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-
soriesaregiven 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.

INSTALLATION 3-2 Manual 0-2846
3.05 Primary Input Power
Connections
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.
1. Check your power source for correct voltage before
plugging in the unit.
2. Connect the input power cable (or close the main dis-
connect switch) to supply power to the system.
3.06 Gas Connections
A. Gas Requirements
WARNING
This unit is not to be used with oxygen (O2).
Gases: Single Gas - Plasma/Secondary
CompressedAirOnly
Pressure:70psi(4.8bar)
CAUTION
Maximum pressure at inlet must not exceed 125
psi (8.6 bar)
Flow: Cutting - 200 standard cubic feet/hr (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
B. Checking Air Quality
To test the quality of air, place the RUN/SET switch to
SET position, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moisture in the air
will be visible on the lens. Do not initiate an arc!
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture 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 connected to the Pressure Regulator/
Filter Assembly located on the rear of the unit. The con-
nection is the same for compressed air or high pressure
gas cylinders.
Connectthegassupplyasfollows:
1. Ifanoptionalairlinefilteristobeinstalled,refertoproce-
duresinsubsection3.06-D.
2. Connectthegaslinetotheinletport. Theillustrationshows
typicalfittingsasanexample. Otherfittingsmaybeused.
Installthefittingsandtighten.
NOTE
For a secure seal, apply thread sealant to the fit-
ting threads, according to manufacturer's instruc-
tions. Do Not use teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
A-02783
H
ose Clamp
1/4 NPT to 1/4"
(6mm) Fitting
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
Plastic
Bowl
Figure 3-1a Gas Connection to Regulator/Filter
Assembly (units with type A Regulator/Filter)
Art # A-02999
Hose Clamp
1
/4 NPT to 1/4"
(6mm) Fitting
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
Bowl
Figure 3-1b Gas Connection to Regulator/Filter
Assembly (units with type B Regulator/Filter)

Manual 0-2846 3-3 INSTALLATION
D. Installing Optional Single-Stage Air Filter
Additionalfiltering is recommendedwhenusing air from
a compressor to insure that moisture and debris from the
supply hose does not enter the torch. Although the Pres-
sure Regulator does have its own filter, the optional
Single-StageAir Filter is recommended for improved fil-
tering. The optional in-line filter is highly effective at
removing moisture and particulate matter from the air
stream to at least 0.85 microns.
Connect the gas supply as follows:
1. Attach the Single-Stage Air Filter Kit to the Regu-
lator/FilterAssembly inlet port as shown. The il-
lustration shows typical fittings as an example.
Other fittings may be used. Install the fittings and
tighten.
NOTE
For a secure seal, apply thread sealant to the fit-
ting threads, according to manufacturer's instruc-
tions. Do Not use teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
A-02784
Filter
Assembly
1/4 NPT Hose Fitting
1/4" (6 mm) Gas 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
Assembly Inlet Port
Bowl
1/4 NPT Hose Fitting
1/4" (6 mm) Gas Supply Hose
Hose Clamp
Figure 3-2b Optional Single-Stage Air Filter
Installation (units with type B Regulator/Filter)
E. Using High Pressure Gas Cylinders
Refer to the following when using high pressure gas cyl-
inders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
1. Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-
rial.Momentarilyopeneach cylinder valve to blow
out any dust which may be present.
3. The cylinder must be equipped with an adjustable
high-pressure regulator capableofoutletpressures
up to 100 psi (6.9 bar) maximum and flows of up
to 200 scfh (94.3 lpm).
4. Slide the gas supply hose over the barbed fitting.
5. Secure the gas supply hose in place with the ad-
justable hose clamp.
NOTE
Supply hose must be at least 1/4 inch hose (6 mm)
I.D.

INSTALLATION 3-4 Manual 0-2846
3.07 Torch Connections
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
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.
WARNING
Disconnect primary power at the source before dis-
assembling the torch or torch leads.
1. Remove the Cover of the Power Supply to gain
access to the Torch Bulkhead Panel. See Section
5.05.
2. Remove the retaining nut from the Strain Relief.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-03529
Negative /
Plasma Lead
Pilot Lead
Figure 3-3 Retaining Nut Removal
3. Feed the torch lead ends and the Strain Relief into
the hole in the unit.
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
Assembly
Negative/Plasma
Lead
Adapter
Connector Pilot Lead Stud
Negative/Plasma Lead
Connection
A-03527
Control Circuit
Connectors
Note: Actual Bulkhead
configuration may
differ from that shown.
Figure 3-4 Torch Lead Connections To Bulkhead
6. Connect the Control (PIP) Circuit Connectors to
the mating connectors on the Power Supply
Adapter.
7. Remove the top nut and washer from the Pilot
Stud.
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 per the
torch manual.
CAUTION
The torch parts must correspond with the type of
operation. Refer to the appropriate torch manual
for proper parts selection.
11. Re-install the Power Supply Cover on the Power
Supply.