Plasma Cutting Power Supply Firepower PC-500 A-03688 Operating Manual June 23, 2004 Manual No.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, 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. Plasma Cutting Power Supply Model PC-500 Operating Manual Number 0-4601 www.firepoweronline.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications ..................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................................................................................................................... 5-1 5.01 5.02 5.03 5.04 General Maintenance .................................................................................... 5-1 Common Faults ............................................................................................ 5-4 Basic Troubleshooting Guide ...................................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings 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. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• 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, Publications. 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.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédure en question. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 AVERTISSEMENT 8.
• Eloignez toute fumée et gaz de votre zone de respiration. 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 revêtements se trouvant sur le métal et des différents procédés.
ultra-violets 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 ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire. • Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.
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.
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA 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.
1.08 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
SECTION 2: INTRODUCTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and basic maintenance procedures for the Firepower Model PC-500 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly trained personnel; 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.
Power Supply Dimensions & Weight Ventilation Clearance Requirements 10.75" 273 mm A-03700 16.375" 416 mm 6" 150 mm 6" 150 mm 6" 150 mm 22.5" 0.57 m 6" 150 mm A-03379 58 lb / 26 kg 2.03 Input Wiring Specifications Input Voltage Freq. (Volts) (Hz.
2.
2.05 Power Supply Options Section 6, Parts Lists, provides catalog numbers and ordering information. A. Single-Stage Air Filter Kit For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns. B. Two-Stage Air Filter Kit This two-stage air filter is for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.
SECTION 3: INSTALLATION 3.1 Unpacking 1. Use the packing lists to identify and account for each item. 2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation. 3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual. 3.2 Lifting Options The Power Supply includes a handle for hand lifting only.
3.3 Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.03. This power supply includes a factory - installed input power cable and plug. 1. Check your power source for correct voltage before plugging in the unit. 2.
3.4 Gas Connections A. Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders. Refer to subsection 3.4-B if a single-stage air line filter is to be installed. 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. Other fittings may be used. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
B. Installing Optional Single - Stage Air Filter Additional filtering is recommended when using air from a compressor to insure that moisture and debris from the supply hose do not enter the torch. Although the Pressure Regulator does have its own filter, the optional Single-Stage Air Filter is recommended for improved filtering. The in-line filter is highly effective at removing moisture and particulate matter from the air stream to at least 0.85 microns. 1.
C Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present. 3.
3.5 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the model SL60 torch (with ATC connector) to this power supply. WARNING Disconnect primary power at the source before connecting the torch. 1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure. 2.
B. Check Air Quality To test the quality of air: 1. Put the ON / OFF switch in the ON (up) position. 2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position. 3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible on the lens.
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SECTION 4: OPERATION 4.01 Front Panel Controls and Indicators AC Indicator (A) Output Current Control Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective interlock mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details. Sets the desired output current. Output settings up to 40 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or standoff cutting.
4.02 Preparations for Operation At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. A. Torch Parts Selection Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (40 amps maximum). Refer to Section 6.05 for torch parts selection. B.
F. Power On Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator turns on if there is sufficient gas pressure for power supply operation. NOTE Minimum pressure for power supply operation is lower than minimum for torch operation.
G. Set Operating Pressure 1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow. A 30 25 35 1 2 20 40 A-03690 2. Adjust gas pressure to 75 psi /5.2 bar. 75 psi / 5.2 bar Pressure Control Knob / Bouton De Contrôle de Pression Firepower PC-500 Air Pressure Settings SL60 Leads Hand Torch Length 75 psi 20' / 6.1 m 5.
H. Select Current Output Level 1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops. 2. Set the output current output level. A 2 30 25 35 1 20 40 A-03747 I. Cutting Operation Refer to the manual supplied with the torch for details on cutting operation, cutting speeds, parts selection and replacement, etc.
K. Postflow Release the trigger to stop the cutting arc. Gas continues to flow for approximately 6 seconds. During post - flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece. L. Shutdown Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.
SECTION 5: SERVICE 5.01 General Maintenance A. O-Ring Lubrication An o-ring on the Torch ATC Male Connector requires lubrication on a scheduled basis. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential performance problems. It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.
B. Filter Element Replacement The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter element should be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced. 1. Remove power from the power supply; turn off the gas supply and bleed down the system. 2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly. The filter element will be visible and still attached to the main body of the Regulator/Filter. 3.
C. Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement filter element catalog number. 1. Remove power from power supply. 2.
5.02 Common Faults 1. Insufficient Penetration a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting current too low f. Non - Genuine Firepower parts used g. Incorrect gas pressure 2. Main Arc Extinguishes a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non - Genuine Firepower parts used 3. Excessive Dross Formation a. Cutting speed too slow b.
5.03 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. A. Basic Troubleshooting: Overview This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this system.
6. Unit internal fuse blown or loose a. If blown, double-check input voltage and replace fuse per Section 5.04-C. If fuse blows again, return unit to an authorized service center. 7. Actual input voltage does not correspond to voltage of unit a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements. 8 . Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. B.
G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON 1. Starter cartridge missing from torch a. Shut off power supply. Remove shield cup, install starter cartridge. Reinstall torch tip and shield cup. Turn power supply ON / OFF switch to ON (up). 2. Shield cup is loose on torch a. Check shield cup; tighten if necessary. NOTE When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and torch handle.
I. Torch cannot be activated; AC indicator indicator flashing; Gas indicator ON; Temp indicator OFF; DC OFF 1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.) a. Release torch trigger. 2. System is in protective interlock mode. (Torch parts are missing or loose.) a. Release torch trigger, and set power supply ON / OFF switch to OFF (down). Open main disconnect switch. Check torch parts. Replace parts as needed.
5. Excessive oil or moisture in torch a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contaminants in the gas, additional filtering may be needed. 6. Fluctuations in input power a. Have electrician check input line voltage. 7. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. M.
5.04 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual. A. Cover Removal 1. Remove the upper screws which secure the cover to the main assembly. NOTE There is a ground wire connection to the inside of the unit.
B. Cover Installation 1. Reconnect the ground wire, if necessary. 2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws. 3. Tighten lower screws. 4. Reinstall and tighten the upper screws. C. Fuse Replacement 1. Remove the unit cover per paragraph "A" above. 2. Locate the internal fuse on the left side of the center chassis. 3. Replace the fuse. A replacement fuse is located inside the power supply.
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SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 Power Supply Replacement Parts Section 6.05 Torch Replacement Parts NOTE 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.
6.
6.05 Torch Parts Art # A-03826 Large O-Ring, No. 1445-0040 Small O-Ring, No. 1445-0048 Electrode, No. 1445-0049 Starter Cartridge, No. 1445-0054 40 Amp Cutting Tip, No. 1445-0923 Shield Cup, No.
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APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: Close external disconnect switch. ACTION: ON / OFF switch to ON RESULT: RESULT: Power to system. AC indicator Fan(s) ON. ON. GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. RUN / Rapid Auto Restart / SET switch to SET RESULT: Gas flows to set pressure.
APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Model: Date of Mfr: Type of Power Supply (Note 1) 1/3 S/N Made in USA Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code Regulatory Standard Covering This Type of Power Supply f1 f2 Output Current Type Duty Cycle Factor Output Range (Amperage/ Voltage) Plasma Cutting Symbol X U0 = Duty Cycle Data (Note 3) I U2 Rated NoLoad Voltage Conventional Load Voltage Rated Maximum Supply Curr
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. Check torch consumable parts, replace if damaged or worn. 2. Inspect torch for any cracks or exposed wires, replace if necessary. 3.
APPENDIX 4: TORCH PIN - OUT DIAGRAM 8 - Open 4 - Green / Switch 3 - White / Switch ATC Female Receptacle Front View ATC Male Connector Front View Negative / Plasma 8 - Ground 4 - Switch 4 3 2- Orange / PIP 2 1 6 5 8 7 7 - Open 7 - Open 6 - Open 6 - Open 8 7 5 - Open 5 - Open 1 - Black / PIP 6 5 2 1 4 3 3 - Switch 2 - PIP 1 - PIP Pilot Pilot APPENDIX Negative / Plasma A-03701 A-4 Manual 0-4601
APPENDIX 5: TORCH CONNECTION DIAGRAM Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Torch Head Male ATC Leads Connector ATC Female Receptacle Torch Leads PIP Switch Torch Switch Black 1 1 Orange 2 2 5 5 6 6 Green 4 4 White 3 3 8 8 7 7 Negative / Plasma Power Supply To Power Supply Circuitry To Power Supply Circuitry Negative / Plasma Pilot Pilot Art # A-03797 Manual 0-4601 A-5 APPENDIX
APPENDIX 6: SYSTEM SCHEMATIC 1 2 3 4 5 E6 E8 E5 E13 W1 L1 A 208 / 230V INPUT E18 (1) W1 L2 E14 E16 (2) INPUT DIODE ASSY 19X2073 CHASSIS GND E2 E3 E1 COPPER STRAP E14 E11 (FILTERING) P8 (3) 1 2 3 4 (4) J8 1 2 3 4 K4 K4 E12 F1 (6/10A 600V) B T1 R95 M1 FAN1 P26 (6) 230V 1 2 3 4 (5) J26 E13 (0 ohm) E15 1 2 3 4 28VAC B 28VAC A J21 K3 P3 ON/OFF SW GATE DRIVE B RTN GATE DRIVE B 28VAC A 28VAC B T5 SET K4 E4 INRUSH CURRENT ADJUST: 20 - 40 AMPS D J14 P14 P
6 7 8 9 10 COMP E29 14 13 12 GATE DRIVE J18 28 FUSE, 6/10A 600V KTK B3 W1 MAIN CONTACTOR F5 SW1 SW ITCH, ON/OFF C2 SW2 SW ITCH, RUN/SET/RAR C2 M1 FAN, 4.5" 220VAC B2 SOL1 GAS SOLENOID F5 PS1 PRESSURE SWITCH F5 TS1 TE MP. S E NSOR, IGBT HEATSINK D2 TS2 TEMP. S ENSOR, INDUCTOR E2 2 1 1 AUX TRANSFORMER B3 T5 MAIN TRANSFORMER C5 L1 OUTPUT INDUCTOR E6 A NOTES: UNLESS OTHERWISE SPECIFIED 1.
