Related Manuals for Firepower FP-18
Summary of Contents for Firepower FP-18
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Page 1: Service Manual
A-02032 Service Manual Includes: For Model: • 12 Amp Power Supply • 120VAC 60Hz • PCH-10 Torch with Leads • Work Cable with Clamp • Input Power Cable April 26, 2000 Manual No. 0-2692... - Page 3 The publisher does not assume and hereby disclaims any liabil- ity to any party for any loss or damage caused by any error or omission in the Firepower FP-18 Plasma Cutting System Service Manual, whether such error results from negligence, accident, or any other cause.
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Page 4: Table Of Contents
TABLE OF CONTENTS 1.0 GENERAL INFORMATION ......................1 1.1 Notes, Cautions, Warnings ....................1 1.2 Important Safety Precautions ..................1 1.3 Publications ........................2 1.4 Note, Attention et Avertissement ..................2 1.5 Precautions De Securite Importantes ................3 1.6 Documents De Reference ....................4 1.7 Declaration of Conformity .................... -
Page 5: General Information
• Use an air-supplied respirator if ventilation is not adequate to 1.0 GENERAL remove all fumes and gases. • The kinds of fumes and gases from the plasma arc depend on INFORMATION the kind of metal being used, coatings on the metal, and the different processes. -
Page 6: Publications
a water table unless the hydrogen gas can be eliminated or 7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN- dissipated. Trapped hydrogen gas that is ignited will cause an ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from explosion. American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8. -
Page 7: Precautions De Securite Importantes
1.5 Precautions De Securite CHOC ELECTRIQUE Importantes Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique AVERTISSEMENT haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail. -
Page 8: Documents De Reference
• Protégez les autres personnes se trouvant sur la zone de travail 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE contre les rayons de l’arc en fournissant des cabines ou des écrans SOUDAGE, disponible auprès de la National Fire Protection de protection. -
Page 9: Declaration Of Conformity
1.7 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 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 leg- islation for the enforcement of this Directive. -
Page 10: Statement Of Warranty
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The limited warranty periods for Firepower FP-18 shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the following further limitations on such two (2) year period. -
Page 11: Introduction
Department in West Lebanon for assistance. familiar with this equipment. 2.4 Technical Specifications Read this manual and the Firepower FP-18 Plasma Cut- ter Operating Manual, 0-2691, thoroughly. A complete A. System Specifications understanding of the capabilities and functions of the equipment will assure obtaining the performance for which it was designed. -
Page 12: Service Troubleshooting
4. Worn torch parts This section provides service diagnostics for the Fire- C. Excessive Dross Formation power FP-18 Plasma Cutter with PCH-10 Torch, aiding the technician to isolate faulty subassemblies. 1. Cutting speed too slow Under no circumstances are field repairs to be attempted 2. -
Page 13: Common Operating Problems
NOTE B. Power Source Related Although the FP-18 will cut using standoff, this This system draws about 20 amps rms from the 120 VAC unit is primarily a drag-cutting machine. service under normal operating conditions. If the 120V service available is saggy, pilot and cut performance will 3.5 Troubleshooting Guide... - Page 14 Replace Rectifier. If the circuit breaker or fuse opens after the power switch is switched on, go to step #D2. If the circuit breaker or fuse is okay, replace Fan. Firepower FP-18 Plasma Cutter Service Manual 0-2692...
- Page 15 If hum or buzzing noise exists, replace Bridge Rectifier. (replace lower Bridge Rectifier, clos- a. Check work cable connection. est to Chassis). 3. Restricted air flow. a. Check lead for kinks or pinching restricting air flow. Service Manual 0-2692 Firepower FP-18 Plasma Cutter...
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Page 16: Torch & Leads Troubleshooting
The torch leads alone Figure 3-1 PCH-10 Torch Head Parts Removal are not serviceable; problems encountered in the leads will require the torch & leads assembly to be replaced. Firepower FP-18 Plasma Cutter Service Manual 0-2692... -
Page 17: Removing Cover/Handle
2. Remove six screws from torch handle assembly (A). A-02295 Orange Torch Sleeving 3. Remove both torch handle halves from the torch (Optional) and leads assembly , then complete the following: Figure 4-1 Removing Torch HeadAssembly Service Manual 0-2692 Firepower FP-18 Plasma Cutter... -
Page 18: Torch Switch Only Replacement
4-2 Installing Torch Head Assembly Make sure torch switch wires are seated in their guides so that the wires are not pinched when the handle is secured. 7. Install consumables parts in front end of torch. Firepower FP-18 Plasma Cutter Service Manual 0-2692... -
Page 19: Air Compressor Replacement
10. Connect the following as it pertains to your unit: • Rev C units (or earlier) - Connect black wire from Compressor to faston splice & wire #21. Connect red wire from Compressor to upper diode piggyback terminal. Service Manual 0-2692 Firepower FP-18 Plasma Cutter... -
Page 20: Control Pc Board Replacement
Replacement 1. Install replacement key slotted PC Board by plac- ing PC Board over standoffs and sliding Board The FIREPOWER Plasma Cutter has been manufactured down into position. using one of two styles of PC Board Assemblies. The 2. Push a white fastener plastic push on into each... -
Page 21: On/Off Power Switch Replacement
4.12 Resistor Replacement Transformer. 4.10 Fan Replacement NOTES The FIREPOWER has two Resistors. The top Re- 1. Remove cover/handle from unit per subsection sistor is 1K ohm and the bottom Resistor is .5 ohm. 4.2. These parts are not interchangeable. Be sure to 2. -
Page 22: Transformer/Ferrite Core Assembly Replacement
Pull L4 through loose tie wrap if available. b. Position wire connector L4 so that it runs along side the Transformer, NOT across the top of the Transformer or near any metal parts. Firepower FP-18 Plasma Cutter Service Manual 0-2692... -
Page 23: Parts Replacement
FIREPOWER 120V 60Hz, PCH-10 1445-0047 . Torch & Leads Only Includes Torch & Leads, 90° Nylon Air Compressor Fitting. Torch Leads alone are not replaceable. PCH-10 (70°) w/20 ft. (6 m) Leads 2-1020 Service Manual 0-2692 Firepower FP-18 Plasma Cutter... -
Page 24: Power Supply Replacement Parts
ON/OFF Switch , DPST, 125V 15A, RED NEON (5 Prongs ) 9-0015 ON/OFF Switch, DPST, 125V 22A, RED NEON (4 Prongs) 9-0021 CD Transformer/Ferrite Core Assembly 9-0018 Bridge Rectifier 7-3345 Handle, Molded 9-8115 Firepower FP-18 Plasma Cutter Service Manual 0-2692... - Page 25 To remove cover, unfasten: • 4 side panel screws • 2 handle screws • 2 end panel screws (BR2) (BR1) Chassis Rotation Direction Torch & Leads A-02337 Air Flow Direction Service Manual 0-2692 Firepower FP-18 Plasma Cutter...
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Page 26: Torch Replacement Parts
Torch Switch Button Springs 9-6292 * To be replaced by Qualified Technician only. A-02360 HARDWARE #2-56 x 5/16" LG Phillips Pan Head #6 Internal Star Washer #6-32 x 3/16" Phillips Pan Head M.S., Zinc Plated Firepower FP-18 Plasma Cutter Service Manual 0-2692... -
Page 27: Appendix I - Leads Connections
Hole Location Strain Relief Torch 1" Clearance Lead Torch Leads Assembly Note: Do not remove strain relief from torch lead. Strain A-02009 Relief 2-Pin Connectors Torch Lead Faston Connector (Red) (Connect to Bottom Resistor) Service Manual 0-2692 Firepower FP-18 Plasma Cutter... -
Page 28: Appendix Ii - Interconnecting Diagram
APPENDIX II - INTERCONNECTING DIAGRAM NOTE: Use this diagram for all rev C units (or earlier). Check the data tag on the unit for rev level. Firepower FP-18 Plasma Cutter Service Manual 0-2692... - Page 29 Service Manual 0-2692 Firepower FP-18 Plasma Cutter...
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Page 30: Appendix Iii - Interconnecting Diagram
APPENDIX III - INTERCONNECTING DIAGRAM A-02361 Firepower FP-18 Plasma Cutter Service Manual 0-2692... - Page 31 NOTE: Use this diagram for all rev D (or later) units. Check the data tag on the unit for rev level. A-02361 Service Manual 0-2692 Firepower FP-18 Plasma Cutter...