MERLIN 3000 Air Plasma Cutting Power Supply A-00907 Operating Manual November 30, 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. Merlin 3000 Air Plasma Cutting Power Supply Operating Manual No. 0-2532 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.
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 .................................................................... 1-1 Important Safety Precautions ...................................................................... 1-1 Publications .................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................................................................................................................... 5-1 5.01 Introduction .................................................................................................. 5-1 5.02 General Maintenance ................................................................................... 5-1 5.03 Common Operating Faults .........................................................................
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 A typical system configuration will contain the following: • Power Supply with Running Gear and Handles • Arc Starter Box • Maximizer 300 Machine Torch with Mounting Assembly 2.01 Scope of Manual • Torch with Leads This manual contains descriptions, operating instructions and basic maintenance procedures for the Merlin 3000 Plasma Cutting Power Supply.
4. Output Power 2.04 Theory Of Operation Continuously adjustable by potentiometer from 50 to 150 amps 5. Duty Cycle 100% 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 A. Plasma Arc Cutting and Gouging Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive.
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. F. Interlocks The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the torch switch (or control device) must be used to restart the system. 1.
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 with 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 that can be connected to the Power Supply.
SECTION 3: INSTALLATION 3.01 Introduction This Section describes installation of the Power Supply. These instructions apply to the Power Supply Assemblies only; installation procedures for Options and Accessories are given in Manuals specifically provided for those units. The complete installation consists of: 3.03 Unpacking Each component of the system is packaged separately and protected with a carton and packing material to prevent damage during shipping. Components are packaged as follows: A.
3.04 Removing Skid 3.05 Filling Power Supply Coolant The Power Supply is mounted on the skid with two brackets. Remove the Power Supply from the skid per the following procedure: The ambient temperature of the environment where the Power Supply will be located determines the coolant to be used. The Standard Torch Coolant supplied with the system can be used in ambient temperatures down to 10° F (-12° C). 1. Remove the six bolts connecting the brackets to the base of the Power Supply.
4. Carefully pour enough of the supplied Thermal Arc Torch Coolant into the reservoir to fill it to the FULL mark on the rear panel. NOTE C. Opening Power Supply Enclosure The left side panel (viewed from the front) of the Power Supply must be removed to make electrical connections and to select the proper input voltage. After operating the system more coolant may need to be added. Allow the pump to operate for ten minutes to properly purge any air from the coolant lines before using the system.
3.07 Voltage Selection The Power Supply can be wired to use input voltages from 200 - 575 VAC. Power Supply is factory-wired for 460 VAC, three-phase input. Voltage selection is accomplished by switching busbar connections on the input voltage terminal board inside the Power Supply. Busbar Connections For Input Voltages 200, 208, 380, 415, 220, or 230 or 460 500, or 575 1. Locate the input voltage terminal board on the left side of the power supply.
3.09 Work Cable And Ground Connections Input Voltage Terminal Board NOTE Refer to Appendix III for a block diagram of a typical mechanized system work and ground cable connections. L3 L2 A. Electromagnetic Interference (EMI) Primary Power Cable Busbars L1 Ground Connection Strain Relief Fitting Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations. For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame.
3.10 Plasma And Secondary Gas Connections CAUTION No other connections should be made at the ground rod being tested. This test assumes that the 115 or 230-VAC source neutral is connected to the utility earth ground. 2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help.
The optional Two Stage Air Line Filter is shipped with the following components: 4. Thread the 90° street elbow into the inlet side of the air filter assembly. • Air Line Filter Assembly (For Plasma Line) - 1 each 5. Connect one side of the Y-hose assembly into the other side of the 90° street elbow. • Hex Nipples - 2 each 6. Thread the 90° female elbow onto the other end of the second hex nipple. Fasten both sides securely.
C. Using Water Secondary NOTES A-00999 Tap water should only be used as a secondary gas on machine torches. Secondary Gas Fitting Secondary Gas Supply Hose The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended. Tap water can be used as a secondary gas and is connected to the Power Supply as follows: 1. The tap water source must be capable of delivering a minimum water pressure of 50 psi (3.
D. Plasma and Secondary Gases With Optional Gas Control The required plasma and secondary gases are connected to the rear of the Power Supply. The secondary selection switch on the front panel of the Power Supply must always be set to GAS for all secondary gases when the Gas Control Option is installed. The type of gas to be used will be selected at the Gas Control Option front panel.
6. Connect the torch leads extension connectors to the bulkhead connections. Torch Leads Extension Connector Plasma Gas Lead Secondary Gas Lead Coolant Return Lead A-00652 Coolant Supply Lead Arc Starter Box Hose Clamp Torch Leads Extension Assembly Torch Leads Extension Torch Leads Extension Boot A-01008 Figure 3-15 Leads Extension Connection to Arc Starter Box Figure 3-14 Torch Leads Extension Connection to Power Supply 10.
B. Computer Control Interface (CNC) 3.12 External Cable Connections Depending on the options installed there are various cables to be connected the Power Supply. The computer control interface allows a mechanized system to interface with a computer or other control device. NOTE A. Optional RC 6010 Remote Control For mechanized systems, the optional RC 6010 Remote Control allows the operator to control all system functions from a remote location.
e . Secure the CNC cable by tightening the two screws on the strain relief. f. Reinstall the Left Side Panel. Refer to Appendix VI for CNC Interface Schematic. C. Optional SC-10 Standoff Control Cable D. Optional High-Flow Water Shield Cable The High Flow Water Shield surrounds the main cutting arc with a spray of water to reduce arc glare, noise, and fumes. Use of the water shield device reduces the system’s overall cutting capacity.
E. Optional Gas Control Connection 3.13 Lifting Options The optional GS3000 Gas Control allows the connection of various multiple plasma and secondary gases to be connected to the Power Supply. The proper plasma and secondary gas is selected with switches on the front panel of the Gas Control Option. WARNING Do not lift the power supply by the handles.
A. Lower Front Panel SECTION 4: OPERATION 3 4.01 Introduction This Section provides a description of the Power Supply operating controls and procedures. Identification of the Front and Rear Panel Controls is followed by operating procedures. 2 4.02 Functional Overview 4 1 The system is a high performance plasma cutting system which can cut most metals from gauge thickness up to two inches. With a quick change of torch parts, power supply can also be used for plasma arc gouging.
8. Coolant Conductivity Indicator B. Control Front Panel Yellow light indicates proper coolant conductivity. Light out indicates excessive coolant conductivity (resistivity less than 0.1 MW). Replace coolant and deionizer cartridge. NOTE This hinged panel is the access cover to the Logic Control PC Board. 1. ON/OFF Switch 9. DC Indicator ON position activates all system control circuits when remote or CNC enable is ON.
6. Plasma Pressure Control 4. SECONDARY WATER Fitting Adjusts plasma gas pressure. Pull knob out and turn clockwise to increase plasma pressure to desired level. 1/4" NPT female fitting used for connection of tap water to the Power Supply. The water can be used as a secondary gas for the torch when the front panel SECONDARY switch is in the WATER position or the Gas Control Option is installed. C. Rear Panel 1. Fan Assembly Fan used to move the air across the internal components for cooling purposes.
9. Remote Control and CNC Interface Connector 13. Optional PLASMA GAS Selection NOTE Optional panel with multiple ports (manifolds) for connection to four plasma gases. The gas manifolds are controlled by the Gas Control Accessory. Each fitting is an inert B type. For use with Remote Control RC6010 or Standoff Control SC10. Refer to the Remote Control (RC6010) Instruction Manual 0-2478 or the Standoff Control (SC10) Instruction Manual 0-2479 for more information.
4.04 Operating Unit Without Gas Control Option F. Secondary Gas Supply Connect desired secondary gas. Make sure gas sources meet requirements (refer to Torch Instruction Manual). Check connections and turn secondary supplies on. NOTE This Subsection describes the normal operation of the system without the Gas Control Option installed. Refer to Section 4.05 for systems with the Gas Control Option installed. Select the desired secondary gas per the following: 1.
Move the Power Supply ON/OFF switch to the ON position. An automatic gas purge will remove any condensation that may have accumulated in the torch and leads while the system was shut down. The gas purge duration is the same as the post-flow duration (factory set to twenty seconds but adjustable to 5, 10, 20, or 40 seconds). After the purge is complete, if the RUN/SET/PURGE switch is in SET position, gases will flow. If the switch is in PURGE position only plasma gas will flow.
ON/OFF switch to the ON position. The Enable Signal must be turned ON either by a switch or contact closure G. Plasma Gas Purge Enable the system by doing one of the following: • Turn the Enable switch to ON at the front panel of the RC6010 Remote Control E. Plasma Gas Supply NOTE • Signal supplied through the CNC control cable Refer to the Gas Control Option Instruction Manual 0-2477 for more information.
B. Using Corner Slowdown for Mechanized Cutting 4.06 System Operation NOTE The corner slowdown (CSD) function provides a reduction in output current which corresponds with the reduced travel speed of a mechanized torch as it changes direction at a sharp corner. When activated (by CNC or other control device) corner slowdown eliminates excessive metal removal in corners. Frequently review the safety precautions at the front of this manual.
4.07 Optional Power Supply Settings The following functions can be used to tailor a system for special application requirements or unique user preferences. These functions are controlled by DIP switches located on the Logic Control PC board in the power supply. Locate the Logic Control PC Board under the front panel access cover and set the functions as required.
Auto-Restart Mode SW2-1 Position SW2-2 Position Pre-Flow Time (Seconds) SW3-1 Position SW3-2 Position Normal * 0 (Off) 0 (Off) 2* 0 (Off) 0 (Off) Delayed 0 (Off) 1 (On) 4 0 (Off) 1 (On) Delayed 1 (On) 0 (Off) 7 1 (On) 0 (Off) Delayed 1 (On) 1 (On) 10 1 (On) 1 (On) * = Factory Setting * = Factory Setting C. Gas Pre-Flow Delay (SW3) D.
Post-flow delay allows gases to flow after the main cutting arc is interrupted. Post-flow is factory-set at 10 seconds, but can be reset to 5, 20, or 40 seconds. Post-Flow Time (Seconds) SW4-1 Position SW4-2 Position 5 0 (Off) 1 (On) 10 * 0 (Off) 0 (Off) 20 1 (On) 0 (Off) 40 1 (On) 1 (On) To use the contact closure for the OK-To-Move signal the switch should be in the up position (factory setting). To use 24 VAC for the OK-To-Move signal the switch should be in the down position.
OPERATION 4-12 Manual 0-2532
SECTION 5: SERVICE 5.01 Introduction This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel. B. Coolant Filter Assembly (Rear Panel) The rear panel filter screen should be cleaned periodically. Remove the filter screen by unscrewing the filter holder from the Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water.
D. Coolant Level and Conductivity 5.03 Common Operating Faults 1. Coolant Level The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50mm) from the top of the reservoir then add Torch Coolant. Listed below are common cutting problems followed by probable causes of each. If the problems are caused by a torch problem, refer to the appropriate Torch Manual. 1. Insufficient Penetration a. Cutting speed too high 2.
5.04 Troubleshooting Troubleshooting Specific Problems General A. Main disconnect fuse blows when primary power is connected Troubleshooting and repairing the this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment. 1. Voltage selection busbars connected incorrectly a. Check and correct if necessary. 2. One leg of three-phase primary connected to chassis ground WARNING a.
3. Clogged In-Line Coolant Filter Assembly (Behind Side Panels) D. TEMP indicator ON (red). 1. Unit overheated a. Remove screen from filter and clean or replace as necessary. a. Clean radiator and check for obstruction b. Check for adequate air flow around unit 4. Plugged or damaged coolant hoses 2. Faulty power supply a. Inspect all coolant hoses and clean or replace as necessary. a. Isolate and replace component(s) per Service Manual 5. Plugged or damaged torch head E. GAS indicator OFF a.
3. Faulty power supply 5.05 Basic Parts Replacement a. Isolate and replace component(s) per Service Manual. NOTE For more detailed Parts Replacement Procedures and Replacement Parts refer to Power Supply Service Manual 0-2533 M. Weak or sputtering pilot; HF stays on during pilot 1. Plasma gas pressure too high a. Adjust pressure 2.
3. Remove the side panels from the Power Supply. C. In-Line Filter Assembly Replacement 4. Reinstall the panels by reversing the above steps. The In-Line Filter Assembly is located inside behind the Left Side Panel (viewed from the front of the unit). The filter is attached to the radiator inside of the Lower Front Panel. B. Fuse Replacement There are three fuses located on the Power Supply as follows: • Two fuses are located in the torch leads connection area under the hinged cover at the Front Panel.
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: Complete Power Supply Replacement Parts List Section 6.04: Basic Component Replacement Parts List Section 6.05: Power Supply Options And Accessories NOTE Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers shown. B.
6.03 Complete Power Supply Replacement Parts List Qty. Description Catalog # Merlin 3000 Power Supply (with Running Gear and Work Cable) 1 Without Gas Control 3-5100 1 With Gas Control 3-5101 1 Work Cable with Clamp - 25 ft (7.
6.04 Basic Component Replacement Parts List Qty.
6.05 Power Supply Options And Accessories Qty. Description Catalog # Gas Regulators 1 Nitrogen Regulator 9-2722 1 CO2 Regulator 9-2759 1 Argon/Hydrogen Regulator 9-3053 1 High Pressure Air Regulator 9-3022 1 Oxygen Regulator 9-4379 1 Water Regulator 8-6118 1 Two Stage Air Line Filter Assembly 7-3139 1 Replacement First Stage Filter Element 9-1021 1 Replacement Second Stage Filter Element 9-1022 1 Plasma Gas Supply Line - 10 ft (3.
APPENDIX I: INPUT WIRING REQUIREMENTS Input Voltag Freq.
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 WORK AND GROUND CABLE CONNECTIONS Remote Control Power Supply Standoff Control Earth Ground 3-Phase Input Earth Ground Workpiece Work Ground Work Cable Manual 0-2532 CNC Control A-01015 A-3 APPENDIX
APPENDIX IV: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM SC-10 Standoff Control POWER SUPPLY A RC6010 Remote Control D GC3000 Gas Control Option B Torch Lifter Assembly C CNC CONTROL A-01014 E WORK GROUND APPENDIX Cable Description Letter Designation Remote Control to Power Supply A Torch Lifter Assembly to Power Supply B Remote Control to CNC Controls C Gas Control Option to Power Supply D Work (Ground) to Power Supply E A-4 Manual 0-2532
MERLIN 3000 REMOTE CABLES FOR RC 6010 & SC11 APPENDIX V: INTERFACE CABLES FOR REMOTE CONTROL (RC6010) AND STANDOFF CONTROL (SC10) A-00983 Manual 0-2532 A-5 APPENDIX
APPENDIX VI: CNC INTERFACE A-00982 APPENDIX A-6 Manual 0-2532
APPENDIX VII: LADDER DIAGRAM - 120 VAC T1 F2 SW1-A 10 NEON IND1 9 8 5A, 250 VAC K1 AC 15 VOLTAGE SELECTION BOARD 14 K4 (HV) K3 (LV) 3 K3 (LV) SWITCHING CONTROL BOARD (Energized by Enable Switch) MC1 K4 (HV) 4 MC2 110 LOGIC BOARD K5 (LV) 24 21 K2 23 W1 K5 (HV) 22 W2 SOL1 - PLASMA GAS K4 50 SECONDARY SELECTION SWITCH SW3-A K3 75 SOL2 - SECONDARY GAS 88 SEC 02 N/C SOL3 - SECONDARY WATER 89 PCR K5 5 24 110 HFWS K1-A 93 A-01012 Manual 0-2532 A-7 APPENDIX
APPENDIX VIII: 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 TP4 7 PS1 6 WATER CONTACTOR DISABLE (Only after main contactor initially closes) SENSE BRIDGE VOLTAGE <60VDC To disable this circuit for troubleshootin
APPENDIX IX: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR WATER COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of water 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. 3.
APPENDIX X: SYSTEM SCHEMATIC Art # A-04881 APPENDIX A-10 Manual 0-2532
Art # A-04881 Manual 0-2532 A-11 APPENDIX
