ARC STARTER BOX Used With Merlin 6000 Cutting System A-01435 Instruction Manual March 13, 2002 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. Thermal Dynamics Arc Starter Box Instruction Manual No. 0-2572 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 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... 1 Important Safety Precautions ........................................................................ 1 Publications ...................................................................................................
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.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. PLASMA ARC RAYS • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected. • Extra care must be taken when the workplace is moist or damp.
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. • 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 parties du circuit de soudage. • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz. • Réparez ou remplacez toute pièce usée ou endommagée.
ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement. 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 : • 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. 1.
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 & DESCRIPTION 2.01 Scope of Manual NOTE The information in this Manual covers different revision levels of the product. As equipment improvements and updates are made the actual units may differ from the illustrations shown in this Manual. This manual contains description, installation instructions and maintenance procedures for the Thermal Dynamics Arc Starter Box.
INTRODUCTION & DESCRIPTION 10 Manual 0-2572
SECTION 3: INSTALLATION PROCEDURES 1. Remove the four screws securing the cover to the base assembly of the Arc Starter Box. A-01436 3.01 Introduction This Section describes installation of the Arc Starter Box. These instructions apply to the Arc Starter Box Assembly only; installation procedures for the Plasma Power Supply, Torch and Torch Leads, Options, and Accessories are given in Manuals specifically provided for those units.
To Plasma Power Supply 5. Feed the torch leads through the supplied Hose Clamp. Four Mounting Bolts And Washers (Customer Supplied) 6. Connect the torch leads connectors to the bulkhead connections per the following figure. NOTE The Revision Letter is the last digit of the Serial Number on the Data Tag. Coolant Return (Left-Hand Thread) Base Assembly Secondary Gas To Torch A-01970 Figure 3-3 Mounting Bolt Installation 3.
NOTE 3.06 Connecting Torch Supply Leads The shielding braid must not make contact with the four mounting studs. WARNING Torch Leads Shield Assembly (Brass Hub) Disconnect primary power at the source before disassembling the torch or torch leads. Connect one end of the Torch Supply Leads to the internal bulkhead inside the Arc Starter Box per the following: 1. Remove the cover from the Arc Starter Box if installed. Mounting Stud 2.
5. Connect the other end of the Torch Supply Leads fittings onto the mating connections at the input panel of the Master Plasma Power Supply. 7. Feed the pilot lead through the boot and connect to the pilot connection per the following procedure: Master Power Supply Bulkhead a. Remove the nut and external star washer from the pilot connection bolt. Control Cable b. Place the ring lug on the pilot wire over the end of the bolt. Plasma Gas Lead Secondary Gas Lead c.
Star Washer c. Secure the power lead to the connection with the nut removed above. Ground Terminal Pilot Terminal Nut 3.07 Dual Power Supply Connecting To Slave Unit Small Strain Relief For systems that are using the dual power supplies, Master and Slave, additional connections must be made inside the Arc Starter Box. 1. Remove the cover from the Arc Starter Box. 2. Feed the Slave Power Supply pilot lead through the boot at the end of the Arc Starter Box. Black Wire of Pilot Lead 3.
5. Connect the power lead to the buss bar per the following procedure: Star Washer Ground Terminal Pilot Terminal Nut a. Remove the nut and washer from the upper bolt. Small Strain Relief b. Remove the bolt and washer from the upper hole of the buss bar. c. Place the ring lug on the power lead over the end of the bolt. d. Re-install the bolt and washer with the lug into the upper hole of the buss bar. e. Re-install the nut and washer to secure the lead.
SECTION 4: CUSTOMER/OPERATOR SERVICE This guide is set up in the following manner: X. Symptom (Bold Type) Any Special Instructions (Text Type) 1. Cause (Italic Type) a. Check/Remedy (Text Type) 4.01 Introduction This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than Thermal Dynamics Trained personnel. WARNING Locate your symptom, check the causes (easiest listed first) then remedies.
C. Start signal given to Power Supply. Gas flows for selected pre-flow time then Pilot and DC LEDs are ON steady. Pilot doesn't come ON and there is no spark (no repetitive snapping sound) from the spark gap in Arc Starter Box. 1. Defective Arc Starter PC Board, blown fuse, or faulty connections in the 24 VAC circuit. a. Refer to Section 4.04 Test Procedures to isolate the defective assembly. 4.04 Test Procedures A. Fault Isolation • If red LED is OFF proceed to Step 6 6.
• If present, check for open in Torch Supply Leads Assembly signal wires. 15. If the Arc Starter PC Board 24 VAC red LED was ON from the test in Step 5 or 9, place RUN/SET/ PURGE to RUN position. 16. Press start and go through a start sequence. After pre-flow the PILOT and DC LEDs are ON. When the Power Supply is activated and the DC and PILOT LED's are ON, there should be greater than 220 VDC between the torch tip (+) and electrode (-). WARNING High voltage (300-400vdc) is present in Arc Starter Box. 17.
SERVICE 20 Manual 0-2572
SECTION 5: PARTS LISTS 5.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. The Arc Starter Box Assembly is field serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows: Section 5.03: Replacement Parts - Box Section 5.04: Replacement Parts - Base Assembly Bulkhead Side Section 5.
5.03 Replacement Parts - Box Item # Qty 1 1 Description Cat # COMPLETE ARC STARTER BOX ASSEMBLY 3-6820 BASE ASSEMBLY BULKHEAD SIDE - REFER TO SECTION 5.04 FOR PARTS LIST SIGNAL SIDE - REFER TO SECTION 5.05 FOR PARTS LIST 2 1 COVER, ARC STARTER BOX 9-6821 3 4 #10-32 X 3/8" PPH, SQ CONE WASHER See Note NOTE: Item can be purchased locally.
Units Before Revision Letter 'C' 2 3 3 1 A-01450 Units Revision Letter 'C' or Later 2 3 3 1 A-01979 Manual 0-2572 23 PARTS LISTS
5.04 Replacement Parts - Bulkhead Side Item # Qty 1 Description Cat # BASE ASSEMBLY SIGNAL SIDE - REFER TO SECTION 5.
15 Units Before Revision Letter 'C' 14 13 3 1 2 2 2 12 12 11 10 10 9 10 4 3 6 A-01493 8 5 7 15 Units Revision Letter 'C' or Later 14 13 3 1 2 2 2 12 11 10 2 12 8 3 4 7 6 9 10 5 Manual 0-2572 25 A-01978 PARTS LISTS
5.05 Replacement Parts - Signal Side Item # Qty 1 1 Description Cat # ASSEMBLY, ARC STARTER BASE Units Before Revision Letter 'C' Units Revision Letter 'C' or Later 9-6820 ---- 2 1 ASSEMBLY, CD TRANSFORMER, ARC STARTER BOX 9-6835 3 1 ASSEMBLY, ARC STARTER/RF FILTER PCB 9-6849 4 1 HARNESS, ARC STARTER 9-6836 5 1 LABEL, DATA 10-2359 6 5 SCREW, #6-32 X 3/8 PPH STL ZINC, SQU CONE WASHER See Note NOTE: Item can be purchased locally.
3 6 Units Before Revision Letter 'C' 6 4 6 5 6 1 A-01936 2 Units Revision Letter 'C' or Later 3 6 6 4 6 6 5 1 A-01935 Manual 0-2572 2 27 PARTS LISTS
PARTS LISTS 28 Manual 0-2572
APPENDIX I: INTERCONNECTING DIAGRAM A-01575 Manual 0-2572 29 APPENDIX
APPENDIX II: 24VAC WIRING BLOCK DIAGRAM Merlin 6000 Power Supply F3 (1A, 250V) (108) 24 VAC (109) APPENDIX Arc Starter Box Torch Control Connector Panel Connector J14-5 J2-1 J14-8 J2-2 Arc Starter Box Control Cable (Part of Torch Supply Leads) 30 (14) (15) Arc Starter PC Board J1-1 J1-3 24 VAC Present (Red LED On) A-01255 Manual 0-2572
Manual 0-2572 Side Edge of Arc Starter Box 4.253" (108.03 mm) To End Edge of Arc Starter Box 0.911" (23.14 mm) MOUNTING HOLE TEMPLATE 31 3.760" (95.5 mm) 6.305" (160.15 mm) APPENDIX 0.375" (9.
