MERLIN 3000 Plasma Cutting Power Supply A-00907 Service Manual October 6, 1999 Manual No.
WARNING Read and understand this entire Service Manual and your employer’s safety practices before installing, operating, or servicing the equipment. WARNING While the information contained in this Service Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. MERLIN 3000 Plasma Cutting Power Supply Service Manual Number 0-2533 Published by: Thermal Dynamics Corporation Industrial Park No.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION .................................................................................................. 1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... 1 Important Safety Precautions ........................................................................ 1 Publications ...................................................................................................
TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ..................................................................................................................... 51 6.01 6.02 6.03 6.04 6.05 6.06 6.07 6.08 6.09 6.10 Introduction .................................................................................................. 51 Ordering Information .................................................................................... 51 External Power Supply Replacement Parts List ..................
SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • 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.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. • To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. • Disconnect power source before performing any service or repairs. • Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. • Read and follow all the instructions in the Operating Manual.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 AVERTISSEMENT 9.
• 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.
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1: Courant Arc Nuance Minimum Protective Numéro Nuance Suggerée Numéro Moins de 300* 8 9 300 - 400* 9 12 400 - 800* 10 14 4. Norme ANSI Z87.
14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA 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.
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 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 provides Service Instructions for Thermal Dynamics Merlin 3000 Power Supply. Refer to Operating Manual (0-2532) for individual operating procedures. Information in this edition is therefore particularly applicable to the Troubleshooting and Repair of the equipment, and is intended for use by properlytrained Service Technicians familiar with this equipment. 2.
INTRODUCTION 10 Manual 0-2533
• Power Supply with Running Gear and Handles SECTION 3: INTRODUCTION & DESCRIPTION • Arc Starter Box • Maximizer 300 Machine Torch with Mounting Assembly and Leads • Torch Leads Extension • Maximizer 300 Spare Parts Kit 3.01 Scope of Manual • 25 ft (7.6 m) Work Cable and Clamp The information in this Section is the same information contained in Section 2 of the Operating Manual. It is supplied here to familiarize the Service Technician with the capabilities and limitations of the equipment.
5. Duty Cycle 3.04 Theory Of Operation 100% A. Plasma Arc Cutting and Gouging 6. Pilot Modes Auto-Restart, Pre-Flow Delay, Recycle 7. CNC Signals Enable Start/Stop, OK-to-Move, Pilot Sensing Relay (PSR), Full CNC Available with Remote 8. Coolant Pressure Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece.
E. RF Shielding All machine torch systems are shielded to minimize radio frequency (RF) interference which results from the high frequency arc initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads. ply lead. At the torch, the coolant is circulated around the torch tip and electrode, where the extra cooling helps to prolong parts life. Coolant then circles back to the power supply through the return lead.
G. Hour/Counter Meters Meter assembly containing two meters. One meter indicates the total number of hours that the main cutting arc has been on. The second meter counts the number of times that the cutting arc has been started. Both meters display a maximum of 999999 hours or starts and cannot be reset. H. Plasma/Secondary Gas Control A remote control to select one of various plasma and secondary gases, including secondary water, that can be connected to the Power Supply.
To clean the unit, first make sure that the power is disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air especially from the radiator. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used. SECTION 4: SERVICE TROUBLESHOOTING DIAGNOSTICS While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected. 4.
hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before re-installing in the Internal Filter Assembly. E. Coolant Level and Conductivity 4. Reconnect the hose to the filter assembly. 5. Install new coolant and deionizer bag. 6. Reinstall the top and right side panels. 4.03 System Theory 1. Coolant Level The coolant level should be checked every day at the rear panel coolant gauge.
run, set, and purge modes by turning on the plasma and secondary solenoids. The Logic PC Board also controls pre-flow and post-flow durations, which are selectable by DIP switches on the board. The Logic PC Board drives the sequence status LED indicators and contains the circuit for measuring coolant conductivity. C. Switch-Mode Power Supply Operation Primary three-phase power is rectified by the threephase bridge diodes D1-D6.
Move signals which are optically isolated. A remote cable connects from the Power Supply to connector J41 supplying the Standoff Control power. The cable connected to J42 supplies control signals between Power Supply and the Standoff Control. Refer to the individual Instruction Manuals supplied with the equipment for more detailed information. nector and an internal terminal strip are provided for CNC connections.
The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live measurements. It is helpful for solving many of the common problems that can arise with the Merlin 3000 Plasma Cutting System. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair. 3. Faulty voltage selection board a. Refer to Section 4.05-A, Voltage Selection PC Board Check. Replace Voltage Selection PC Board if necessary B.
4. Faulty LED/Current Control PC Board E. Fuse blown at disconnect when primary power is connected a. Refer to Section 4.05-F, Thermal Sensing Circuit Check. Replace LED/Current Control PC Board if necessary. 1. Voltage selection busbars connected incorrectly a. Check and correct if necessary. 2. One leg of three-phase primary connected to chassis ground H. No GAS indicator; Motor and Pump operating; Other LED indicators normal; Both gases flow 1.
3. Gas Control (GC3000) on wrong setting NOTE a. Select input that has gas connected. With a clogged internal coolant filter or Torch and leads the Coolant Pressure Gauge will be normal, but the Pressure LED, indicates flow, will be OFF. 4. Gas supply turned off (or tank empty) a. Check gas supply 3. Clogged torch or leads 5. Faulty solenoid valve: a. Check torch and leads and replace if necessary. Flush the old coolant from the system (see note above). SOL1 - plasma gas, SOL2 - secondary gas, 4.
3. Broken conductor in torch lead M. DC indicator off (after pre-flow); Main contactor comes on momentarily; No pilot arc; No main arc transfer a. Check and replace if necessary 4. Shorted torch lead 1. Switching transistor (Q1) not turning on a. Check and replace if necessary a. Refer to Section 4.05-M, Switching Control Check (Q1). N. No pilot arc; DC indicator on; Pilot indicator OFF; PCR not energized 1. Faulty Logic PC Board, Switching Control PC Board, or Shunt Amp PC Board. 5.
2. Check the AC voltage from J6-24 to both J6-17 and J6-18 for 16 - 22 VAC. U. Main arc transfers and pierces through the plate, but cutting machine doesn’t move 3. If input voltages are correct, check output from J624 to both J6-19 and J6-21 for 14 - 18 VAC. 1. Incorrect or missing OK-To-Move signal. a. Many cutting machines require an AC voltage to activate the motion input. Refer to Operating Manuals for setting OK-To-Move signal. 4.
the Switching Control PC Board) to wire #8, through the ON/OFF switch (SW1A) to wire #9, through fuse F2 to wire #10 and T1. work check continuity from TB2, wires 102 & 103, to J50-10 & 11. If correct, replace the Switching Control PC Board. Only one of the MC contactors should have voltage applied. If the red LED indicator (D18) on the voltage selection board is lit, MC2 should be energized. If D18 is not lit, MC1 should be energized.
1. Check the voltage at J1-7 for less than 1 VDC with gases flowing and operating pressure greater than 35 psi (2.4 BAR). 2. High frequency protection for the input rectifier diodes (D1-6) is provided by capacitors C1 - C6 and MOV 1-3, which are located between each side of the diode heatsink on the input filter PC board. Except for the shorts, these components can not be checked with a volt/ohm meter. To be safe, the complete input filter board should be replaced any time an input diode fails. 3.
2. If the coolant conductivity indicator is not lit with the probe disconnected, measure between the Logic PC Board common (TP1) and J3-1. If the voltage measures below +12 VDC, replace the LED PC board. If the voltage measures above +12 VDC, replace the Logic PC Board. and the 120 VAC should go to W2 otherewise it goes to W1. The first step is to measure for 120 VAC from Logic PC Board J2-9 to wire #110 (PCR coil, MC1 or MC2 coils). If no voltage, the Logic PC Board is faulty.
lem is in the Standoff Control (SC10) or the ribbon cable. Refer to Section 5, Customer/Operator Service, in the Standoff Control Instruction Manual. Switching Transistor Q1 If the Standoff Control (SC10) isn’t used or the Power Supply didn’t start with the ribbon cable disconnected, there are two approaches you can take. Either disconnect the remote and see if the Power Supply will start without it or check if the start signal is getting to the Remote Control (RC6010).
The PWM compares shunt amp output on J9-5 with the current control signal (3.3 - 10 VDC) from the remote (J7-18) or the panel control (J10-15). A faulty shunt amp could cause the output, normally 0 VDC with no cutting arc, to go higher, shutting off the PWM and thus producing no DC. If the shunt amp ribbon connector is disconnected or pin 1 is open, approximately 12 VDC is applied to J9-5, shutting down the PWM in the same manner as a shunt amp failure. shorted (pilot resistors will get very hot).
(+3.3 VDC) signals from J50-8 and J50-6 on the Switching Control PC Board sent to the remote via the remote cable. If 24 VAC is not present, remove J14 control connector at the torch bulkhead and measure for 24 VAC between pins 5 and 8 of the receptacle. The 24 VAC comes from T3, is fused by F3, 1A 250v, and passes through the filter FL1 to J14. If voltage is not present at J14 the most likely fault is the fuse. T3 and the FL1 are other possibilities. If F3 is blown replace it and leave J14 disconnected.
For the Standoff Control (SC11) used without the Remote Control (RC6010), the CNC input for CSD is through J40-10 and J40-11 or J11-1 and J11-2 of the Standoff Control (SC11). For the Power Supply, corner current reduction is only available when using the Remote Control (RC6010). The CSD relay output at J42 is not used with the Power Supply. The display signal at J7-2 should be equal to the control pot wiper voltage at J7-18 measured in Step 3 above.
in J6-15 (24 VAC) measure for 24 VAC at J6-13 to J6-16. If OK, the problem is in the CNC cable connections to the cutting machine or the controller. Q. OK-To-Move Tests 1. The Shunt Amp sends a voltage level to the Switching Control PC Board that corresponds to the work lead or cutting current. When that current is greater than 25 amps, a circuit on the Switching Control PC Board sends an active low signal called CSR to the Logic PC Board, J3-11, that turns on K1, the OK-To-Move relay.
CAUTION Move the clamps only what is necessary for a steady pilot. Too much adjustment can cause increased parts wear. DO NOT move each clamp more than a total of 2 inches (50.8 mm). If a steady pilot cannot be achieved with the adjustment, then something else is wrong.
2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end. SECTION 5: REPAIRS & REPLACEMENT PROCEDURES 3. Attach the copper foil to a convenient and exposed electrical ground. 4. Connect the equipment primary cable ground to the same electrical ground as the wrist strap. 5.01 Introduction 5. Open the equipment enclosure (see instruction manual for the appropriate equipment) and remove the failed PC board.
WARNING Left Side Panel Disconnect primary power from the source before opening or disassembling the power supply. Make sure AC indicator on the Power Supply front panel is OFF. Before disassembling any part of the Power Supply first read the procedure for the part to be replaced, then proceed with the disassembly. 5.04 External Parts Replacement NOTE Refer to Section 6.03, External Power Supply Replacement Parts, for parts list and overall detail drawing. A.
2. Loosen the two screws of the Work Cable strain relief securing the Work Cable at the Front Panel. D. LED/Current Control PC Board Assembly Replacement 3. Remove the nut (under the Horizontal Chassis Panel) securing the Work Cable connection to the Shunt Assembly. 1. Remove the Current Knob per paragraph 'A' above. 2. Unlatch the Access Panel to gain access to the LED/ Current Control PC Board. 4. Pull the Work Cable from the unit. 3.
3. Remove the Coolant Hose from the Internal Coolant Filter Assembly. 4. Carefully remove the Transformer Assembly from the unit. 4. Remove the Internal Coolant Filter from the fitting on the Radiator. 5. Install the replacement Transformer Assembly by reversing the above procedure. 5. Install the replacement Internal Coolant Filter Assembly by reversing the above procedure and noting the following: E.
7. Locate and remove the four bolts and lock nuts securing the Fan Assembly to the Rear Panel Assembly. 7. Install the replacement Solenoid Valve Assembly by reversing the above procedure and noting the following: 8. Carefully pull the Fan Assembly from the Rear Panel Assembly feeding the wiring through the hole. • Remove the fittings from the old assembly and install on the replacement assembly. 9. Install the replacement Fan Assembly by reversing the above procedure. E.
12. Place the Deionizer Basket and Bag into the Coolant Tank filler hole and install the Coolant Tank Cap. G. Coolant Tank Replacement 1. Remove the Left, Right, and Top Side Panels per Section 5.04-B. 2. Drain the coolant from the Coolant Tank per Section 4.02-F. H. Flow Switch Assembly Replacement 1. Remove the Top Panel per Section 5.04-B. 2. Drain enough of the coolant from the Coolant Tank, per Section 4.02-F, to lower the coolant level below the Flow Switch Assembly hole.
5.08 Base Assembly Parts Replacement CAUTION Handle and dispose of the used coolant per recommended procedures. NOTE Refer to Section 6.07, Base Assembly Replacement Parts, for parts list and overall detail drawing. 3. Remove the two wires from the Conductivity Sensor Assembly. 4. Remove the Conductivity Sensor Assembly from the Coolant Tank. A. DC Inductor (L2) Assembly Replacement 5. Install the replacement Conductivity Sensor Assembly by reversing the above procedure. WARNING 6.
6. Install the replacement Transformer Assembly by reversing the above procedure. 4. Note the orientation of the Pump Assembly to the Pump Mounting Plate. 5. Remove the three nuts securing the Pump Assembly to the Pump Mounting Plate. C. Main Contactor (W1 or W2) Replacement NOTE 6. Remove the Pump Assembly from the unit. The Main Contactors, W1 and W2, are replaced in the same manner. 7. Install the replacement Pump Assembly by reversing the above procedure and noting the following: 1.
Switching Transistor Q1 Rear of Front Panel A-01083 Transistor/Coil Bracket Driver PC Board 5. Note and label the two wiring connectors that connect to the Driver PC Board. Large Blue Capacitors 6. Disconnect the two wiring connectors from the Driver PC Board. A-01085 11. There are two different styles of the Switching Transistor (Q1). The style can be identified by looking at the top of the transistor casing. 7.
Wire #84 PTC Resistor Assembly Wire #83 X B E B Q1 Q1 A-01089 A-01086 Main Heatsink Wire #82 Wire Connections (Q1 With E Terminal) 17. Remove the four screws securing the Switching Transistor module to the Main Heatsink. 18. Pry between the Main Heatsink and the faulty Switching Transistor Assembly until it slides easily. Wire #83 X B B 19. Remove the faulty Switching Transistor Assembly from the unit by sliding it towards the center of the Main Heatsink.
C. Pressure Gauge Replacement E. Pressure Switch Replacement NOTE NOTE Both the Plasma and Secondary gauges are replaced in the same manner Both the Plasma and Secondary Pressure Switches are replaced in the same manner 1. Remove the Top Panel per Section 5.04-B. 1. Remove the Top Panel per Section 5.04-B. 2. Disconnect the wiring tho the desired Pressure Switch. 2. Disconnect the two wires connected to the Pressure Switch Assembly. 3.
3. Disconnect the gas Hose Assembly from the fitting at the end of the Gas Input Fitting. 4. Disconnect the three connectors from the old Control Logic PC Board. 4. Remove the fitting screwed into the end of the Gas Input Fitting. 5. Note the orientation of the old Control Logic PC Board. 5. Remove the first nut from the Gas Input Fitting. 6. Remove the old Control Logic PC Board. 6. Remove the second nut securing the Gas Input Fitting to the Upper Chassis/Gauge Assembly. 7.
A. 70 Amp STR. Diode Replacement Check Valve The Diode Replacement Kit (Cat # 8-1168) is a direct parts replacement for the failed Diode Assembly in the Power Supply. Symbol The following parts are supplied with each replacement assembly: • 70 Amp, 600V Str Diode Assembly (1 each) • 0.75 inch diameter Thermal Interface Pad (1 each) Direction Of Flow • Tube of RTV (1 each) A-00370 1. Turn OFF main input power to the Power Supply both at the Power Supply ON/OFF switch and at the main power disconnect.
d. Re-solder the wire lead to the replacement diode. 6. Remove the nut securing the diode wire lead to the PC Board. e. Apply a layer of RTV over the top of the Diode Assembly to encapsulate the lead and top of the diode. 7. Make sure the replacement diode is a direct replacement for the old one. 8. Install the replacement diode by reversing the above procedure and noting the following: Wire Lead a. Wipe the surface clean where the replacement diode is to be installed.
5. Install the replacement Hose Assembly by reversing the above procedure. 7. Make sure the replacement diode is a direct replacement for the old one. 8. Install the replacement diode by reversing the above procedure and noting the following: B. Coolant Return Hose (RETURN Connector to Radiator) Assembly Replacement a. Wipe the surface clean where the replacement diode is to be installed. The Coolant Return Hose Assembly goes from the RETURN Connector to the inlet side of the Radiator.
3. Disconnect the Other end of the Hose Assembly from the T-Fitting at the Plasma Pressure Gauge Assembly. NOTE Refer to Subsection 6.08, Upper Chassis Replacement Parts for part numbers and detail drawing. 4. Remove the Hose Assembly from the unit. 1. Remove the Right Side Panel per Section 5.04-B. 2. Disconnect the Hose Assembly from the T-Fitting at the front panel Coolant Pressure Gauge connector. 3. Disconnect the other end of the Hose Assembly from the Coolant Pressure Gauge. 5.
3. Remove the Hose Assembly from the unit. 4. Install the replacement Hose Assembly by reversing the above procedure. 5. Refill the Coolant Tank with Thermal Arc Torch Coolant before applying power. 5. Install the replacement Hose Assembly by reversing the above procedure. K. Plasma Gas Hose (Plasma Gas Solenoid to Plasma Gas Regulator) Assembly Replacement The Plasma Gas Hose Assembly goes from the Plasma Gas Solenoid Assembly at the rear panel to the Plasma Gas Regulator at the front panel.
REPLACEMENT PROCEDURES 50 Manual 0-2533
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all basic replaceable parts. The parts lists are arranged as follows: Section 6.03: External Power Supply Replacement Parts List Section 6.04: Access Panel Replacement Parts Section 6.05: Front Panel/Chassis Replacement Parts Section 6.06: Rear Panel Replacement Parts Section 6.07: Base Assembly Replacement Parts Section 6.08: Upper Chassis Replacement Parts Section 6.
6.03 External Power Supply Replacement Parts List Item # Qty. Description Catalog # Complete Merlin 3000 Power Supply With Running Gear and Work Cable 1 Without Gas Control GC3000 3-5100 1 1 1 With Gas Control GC3000 Work Cable with Clamp - 25 ft (7.6 m) 3-5101 9-4380 2 1 Panel, Top 8-3300 3 1 Panel, R.H. Side With Overlay 8-6301 4 1 Panel, L.H.
6.04 Access Panel Replacement Parts Item # Qty.
6.05 Front Panel/Chassis Replacement Parts Item # Qty.
9 8 7 6 22 10 11 12 21 17 16 1 2 18 13 20 19 14 4 15 23 3 5 A-01217 Manual 0-2533 55 PARTS LISTS
6.06 Rear Panel Replacement Parts Item # Qty. 1 1 Rear Panel 8-4505 2 1 Fan, 16" Axial 8-6312 3 2 Contactor, 25 amp, 2-pole, 120V Coil 8-5143 4 1 3 PH Contactor 8-1373 5 1 4 mfd, Capacitor 9-3210 6 2 Capacitor Mounting Bracket 8-6308 7 1 330k Ohms Resistor Assembly 9-5545 8 1 Voltage Selection PC Board 8-5144 9 4 P.C.
17 14 23 13 24 22 16 25 11 18 18 15 32 20 18 20 21 19 21 26 27 20 12 28 11 10 6 30 8 9 5 7 31 4 3 3 29 2 1 A-01216 Manual 0-2533 57 PARTS LISTS
6.07 Base Assembly Replacement Parts Item # Qty.
20 21 10 9 8 12 20 25 13 14 11 26 23 15 21 24 22 16 17 18 19 3 7 9 4 1 5 2 6 A-00894 Manual 0-2533 59 PARTS LISTS
6.08 Upper Chassis Replacement Parts Item # Qty. 1 2 1 1 1 1 1 2 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 3 1 2 2 1 10 2 1 3 1 1 4 1 1 1 1 1 1 1 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PARTS LISTS Description Catalog # Panel, Upper Chassis/Gauge Power Driver PC Board Assembly Includes: Thermstrate, Transistor (Refer to Section 6.09 Item # 7) Transistor, 300A, 550V Darlington (Refer to Section 6.
Item # Qty.
6.09 Main Heatsink Assembly Replacement Parts Item # Qty. Description Catalog # 1 1 Main Heatsink 9-1404 2 4 Capacitor, 550 mfd, 400VDC 9-1303 3 1 Bracket, Capacitor/Heatsink 8-4521 4 1 Support, Air Foil 8-2176 5 2 Capacitor Clamp 9-4212 6 1 Support, Heatsink Assembly 9-1304 7 1 Thermstrate, Transistor 9-1406 8 1 Transistor, 300A, 550V Darlington (Refer to Section 6.08 Item #2) 8-6154 9 2 Capacitor, 10 mfd, 400V Poly.
21 28 11 14 20 11 32 16 13 10 15 11 31 29 22 19 19 32 18 32 23 17 9 12 32 17 6 9 32 24 2 32 2 27 11 17 32 25 2 5 26 2 34 3 1 7 8 33 4 30 A-00971 Manual 0-2533 63 PARTS LISTS
6.10 Power Supply Options And Accessories Item # Qty.
MO DE AU TO HT FIN HTD PL ENASMA AB LE LIF SP TER EE D ON PL AS MA ON HI LO ST AR T RE MO TE OU TP UT AM PS AR PO WE R SU PP LY 25 50 0.2 C VO LT S RE 0.3 MO TE ST AN 0.1 DO FF 0.4 CO NT RO L SD (% ) 0.5 0.2 5 75 12 5+ IPM 100 0-1 25 IPM PIE HT RC (inc E hes ) CO 0.7 NTRO 5 L 1 PU RG E SE T T.H .C. 0.1 25 PIE DE RC LAY E (se c) RU N TR AV SP EL EE D 0.
PARTS LISTS 66 Manual 0-2533
APPENDIX I: INPUT WIRING REQUIREMENTS In p u t P o w er In p u t C u r r en t S u g g ested S iz es (S ee N o tes) V o ltag e F r eq .
APPENDIX II: SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION Close external disconnect switch RESULT • Power to system ACTION Enable ON at Remote or TB2 ON/OFF switch to ON RESULT • AC indicator ON • TEMP Indicator ON • GAS indicator ON • Fan and pump ON • 40 second auto-purge ACTION RUN/SET/PURGE switch to SET ACTION RUN/SET/PURGE switch to RUN RESULT • Gas solenoids open, gases flow to set pressures • GAS indicator ON RESULT • Gas flow stops • Power circuit ready • GAS indicator OFF ACTION Protect eyes
APPENDIX III: TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS System With Remote Control RC6010, Standoff Control SC10 And Gas Control GC3000 J53 GC3000 Gas Control Option SC-10 Standoff Control J37 D J43 RC6010 Remote Control J29 Torch Lifter Assembly B CNC CONTROL C Workpiece A J15 Power Supply J63 Earth Ground 3-Phase Input E System With Standoff Control SC11 And Gas Control GC3000 J37 SC-11 Standoff Control J53 J43 B J40 GC3000 Gas Control Option Torch Lifter Assembly CNC CONTROL C Wo
MERLIN 3000 REMOTE CABLES FOR RC 6010 & SC11 APPENDIX IV: INTERFACE CABLES FOR REMOTE CONTROL (RC6010) AND STANDOFF CONTROL (SC11) A-00983 APPENDIX 70 Manual 0-2533
APPENDIX V: CNC INTERFACE A-00982 Manual 0-2533 71 APPENDIX
APPENDIX VI: 120 VAC CIRCUIT DIAGRAM K1 SWITCHING CONTROL PCB J28 TO OPTIONAL STANDOFF CONTROL -3 -1 F2 (9) (8) (10) (110) (24) SW1-A ON/OFF MC1 MC2 W1 SOL1 W2 T1 (3) (14) K4 K3 (15) K3 K4 (4) (21) (22) (881) K5 K5 (5) (75) (23) (24) PCR (89) SW3-A (50) VOLTAGE SELECTION PCB K2 K4 K3 K5 LOGIC PCB A-01136 APPENDIX SOL3 SOL2 T2 72 Manual 0-2533
APPENDIX VII: LADDER DIAGRAM - 15 VDC LOGIC CONTROL BOARD D2 SW2 RUN 13 GAS CONTROL CIRCUIT PLASMA K4 RUN SET 12 PURGE 11 START/STOP (CNC) SECONDARY PRE-FLOW & POST-FLOW CIRCUIT K3 19 18 START/STOP (Hand) 14 15 D57 SWITCH RECOGNITION START INDICATOR FS1 W CONTACTOR 5 CONTACTOR CONTROL K2 4 TS3 TS4 TS5 TS2 TS1 9 D4 PWM ENABLE GAS OXYGEN J3-9 TP1 TP4 7 PS1 6 WATER CONTACTOR DISABLE (Only after main contactor initially closes) SENSE BRIDGE VOLTAGE <60VDC To disable this circu
APPENDIX VIII: SIGNAL FLOW BLOCK DIAGRAM A-01139 APPENDIX 74 Manual 0-2533
APPENDIX IX: START CIRCUIT DIARGRAM A-01079 Standoff Control SC11 PLASMA ON START D79 FIND HT OFF J40-3 J40-4 CNC START J8-17 FIND HT J8-18 J11-3 J11-4 J8-10 OPTOIsolator J42-3 J15-24 K10 START J42-4 J15-25 J8-11 Manual 0-2533 A-01080 K10 START 75 Merlin 3000 or Merlin 6000 or Merlin 6000GST APPENDIX
APPENDIX X: CURRENT CONTROL / DISPLAY CIRCUIT DIAGRAM A-01138 APPENDIX 76 Manual 0-2533
APPENDIX XI: CSD (CORNER SLOWDOWN) CIRCUIT DIAGRAM A-01140 Manual 0-2533 77 APPENDIX
APPENDIX XII: OK-TO-MOVE CIRCUIT DIAGRAM Merlin 3000 or Merlin 6000 or Merlin 6000GST with Remote Control RC6010 / Standoff Control SC10 OK-To-Move Circuit OFF = OK-To-Move PIERCE DELAY 0 - 3 seconds 24 VAC Source A-01081 Standoff Control SC11 OK OUT D37 OK PS D82 Merlin 3000, 6000 or 6000GST + K12 OK TB2-9 Logic PCB J2-14 J15-10 J42-12 Pierce Delay 0 - 3 Seconds K12 Energized prior to and during pierce delay OK 24VAC Source J2-16 J15-11 J11-7 J42-14 TB2-10 J11-6 J8-24 J40-14 OK E1 J11-
Manual 0-2533 Gas Connections (Rear Panel) Plasma Gas (+) Plasma Gas Hose Assembly Rear Panel To Regulator Plasma Gas Regulator (Front Panel) Solenoid Secondary Gas Regulator (Front Panel) Secondary Gas Check Valve Secondary Gas/Water Hose Assembly T-Connection To T-Connection Secondary Water T-Fitting Check Valve Solenoid T-Fitting Plasma Gas Hose Assembly T-Connection To Pressure Gauge Secondary Water Hose Assembly Check Valve To T-Connection Check Valve Symbol Secondary Gas Pressure Gauge (
APPENDIX XIV: SYSTEM SCHEMATIC A-00981 APPENDIX 80 Manual 0-2533
A-00981 Manual 0-2533 81 APPENDIX
APPENDIX XV: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of 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 Arc Hours: 1. Check torch parts, replace if damaged. 2. Check plasma and secondary supply and pressure/flow.
