English dropdown-ico

Thermal Comfort 3000 manual

1
2
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
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Thermal Comfort 3000, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Thermal Comfort 3000 one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Thermal Comfort 3000. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Thermal Comfort 3000 should contain:
- informations concerning technical data of Thermal Comfort 3000
- name of the manufacturer and a year of construction of the Thermal Comfort 3000 item
- rules of operation, control and maintenance of the Thermal Comfort 3000 item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Thermal Comfort 3000 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Thermal Comfort 3000, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Thermal Comfort service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Thermal Comfort 3000.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Thermal Comfort 3000 item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 1

    Manual No. 0-2533 October 6, 1999 MERLIN 3000 Plasma Cutting Power Supply Service Manual A-00907[...]

  • Page 2

    WARNING WARNING Read and understand this entire Service Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Service Manual repre- sents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. MERLIN 3000 Plasma Cutting Power Supply[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1: GENERAL INFORMA TION .................................................................................................. 1 1.01 Notes, Cautions and W arnings ...................................................................... 1 1.02 Impor tant Saf ety Precautions ......................................................[...]

  • Page 4

    T ABLE OF CONTENTS (continued) SECTION 6: P AR TS LISTS .................................................................................................................... .5 1 6.01 Introduction .................................................................................................. 51 6.02 Ordering Information ..........................[...]

  • Page 5

    Date: 6/22/99 1 GENERAL INFORMA TION SECTION 1: GENERAL INFORMA TION 1.01 Notes, Cautions and W arnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high- lights are categorized as follows: NOTE An operation, procedur e, or background informa- tion which requir es additional emphasis or is[...]

  • Page 6

    GENERAL INFORMA TION 2 Date 6/22/99 • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publica- tions. • Disconnect power source befor e performing any ser - vice or repairs. • Read and follow all the instructions in the Operat- ing Manual. FIRE AND EXPLOSION Fire and explosion can be caused by hot sla[...]

  • Page 7

    Date: 6/22/99 3 GENERAL INFORMA TION 8. NFP A Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- CESSES, obtainable from the National Fir e Protection Association, Batterymarch Park, Quincy , MA 02269 9. NFP A Standard 70, NA TIONAL ELECTRICAL CODE, obtainable from the National Fir e Protection Asso- ciation, Batterymarch Par[...]

  • Page 8

    GENERAL INFORMA TION 4 Date 6/22/99 • Les sortes de gaz et de fumée provenant de l’ar c de plasma dépendent du genre de métal utilisé, des revêtements se tr ouvant sur le métal et des différents procédés. V ous devez pr endre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants: antimo[...]

  • Page 9

    Date: 6/22/99 5 GENERAL INFORMA TION • Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1: Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro Moins de 300* 8 9 300 - 400* 9 12 400 - 800* 10 14 * Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L ’experienc[...]

  • Page 10

    GENERAL INFORMA TION 6 Date 6/22/99 14. Norme A WSF4.1 de l’Association Américaine de Soudage, RECOMMANDA TIONS DE PRA- TIQUES SURES POUR LA PRÉP ARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUY AUX A Y ANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American W elding Society , 550 N.W . LeJeune Rd., Miami, FL 33126 15. N[...]

  • Page 11

    Date: 6/22/99 7 GENERAL INFORMA TION 1.07 Dec laration of Conf ormity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 W est Lebanon, New Hampshir e 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low V oltage Direc- tive’ (European Council Dir ective 73/23/EEC as[...]

  • Page 12

    GENERAL INFORMA TION 8 Date 6/22/99 1.08 Statement of W arranty LIMITED W ARRANTY : Thermal Dynamics ® Corporation (hereinafter “Thermal”) warrants that its products will be fr ee of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Therma l products as stated bel[...]

  • Page 13

    Manual 0-2533 9 INTRODUCTION SECTION 2: INTR ODUCTION 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 oper- ating procedur es. Information in this edition is therefore particularly applicable to the T roubleshooting and Repair of the equ[...]

  • Page 14

    INTRODUCTION 10 Manual 0-2533[...]

  • Page 15

    Manual 0-2533 11 INTRODUCTION & DESCRIPTION SECTION 3: INTR ODUCTION & DESCRIPTION 3.01 Scope of Manual The information in this Section is the same information contained in Section 2 of the Operating Manual. It is sup- plied here to familiarize the Service T echnician with the capabilities and limitations of the equipment. This infor- matio[...]

  • Page 16

    INTRODUCTION & DESCRIPTION 12 Manual 0-2533 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 A vailable with Remote 8. Coolant Pressure Internal Service-adjustable 130 psi (8.8 BAR) at zero flow 120 - 125 psi (8.2 - 8.5 BAR) at 0.6 gpm (2.6[...]

  • Page 17

    Manual 0-2533 13 INTRODUCTION & DESCRIPTION E. RF Shielding All machine torch systems ar e shielded to minimize ra- dio frequency (RF) interfer ence which results from the high frequency ar c initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded tor ch and contr ol leads. F . [...]

  • Page 18

    INTRODUCTION & DESCRIPTION 14 Manual 0-2533 G. Hour/Counter Meters Meter assembly containing two meters. One meter indicates the total number of hours that the main cut- ting 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 r[...]

  • Page 19

    Manual 0-2533 15 SER VICE TROUBLESHOO TING SECTION 4: SER VICE TR OUBLESHOO TING DIA GNOSTICS 4.01 Intr oduction This Section provides service diagnostics for the Merlin 3000 Power Supply , allowing the T echnician to islolate any faulty Subassemblies. Refer to Section 5, Repairs & Replacement Procedur es, for parts replacement instruc- tions. [...]

  • Page 20

    SER VICE TROUBLESHOO TING 16 Manual 0-2533 hot soapy water . Remove soap residue by rinsing with clean hot water . Be sur e that all the soap has been removed and the scr een is dry of water before re-in- stalling in the Internal Filter Assembly . E. Coolant Level and Conductivity 1. Coolant Level The coolant level should be checked every day at th[...]

  • Page 21

    Manual 0-2533 17 SER VICE TROUBLESHOO TING C. Switch-Mode P ower Suppl y Operation Primary three-phase power is r ectified by the three- phase bridge diodes D1-D6. The resulting negative DC voltage (approximately -320 VDC) is applied to the switching transistor (Q1). The switching transis- tor controls the output curr ent by pulse width modu- latio[...]

  • Page 22

    SER VICE TROUBLESHOO TING 18 Manual 0-2533 nector and an internal terminal strip are pr ovided for CNC connections. The remote includes internal con- nections to interface to the SC10 standoff contr ol so the single remote cable works for both. A Merlin 3000 system may include the following: • No Remote Control (RC6010) • Remote Control Only (R[...]

  • Page 23

    Manual 0-2533 19 SER VICE TROUBLESHOO TING The advanced tr oubleshooting covered in this Service Manual requir es Power Supply disassembly and live mea- surements. It is helpful for solving many of the common problems that can arise with the Merlin 3000 Plasma Cut- ting System. If major complex subassemblies are faulty , the unit must be returned t[...]

  • Page 24

    SER VICE TROUBLESHOO TING 20 Manual 0-2533 E. Fuse blown at disconnect when primary power is connected 1. V oltage selection busbars connected incorr ectly a. Check and correct if necessary . 2. One leg of three-phase primary connected to chassis ground a. Rewire input cable per Operating Manual. 3. Main transformer shorted a. Replace main transfor[...]

  • Page 25

    Manual 0-2533 21 SER VICE TROUBLESHOO TING 3. Gas Control (GC3000) on wr ong setting a. Select input that has gas connected. 4. Gas supply turned off (or tank empty) a. Check gas supply 5. Faulty solenoid valve: SOL1 - plasma gas, SOL2 - secondary gas, SOL3 - secondary water , SOL4 through SOL9 - Optional Gas Select a. Check solenoid for sticking o[...]

  • Page 26

    SER VICE TROUBLESHOO TING 22 Manual 0-2533 M. DC indicator off (after pre-flow); Main contactor comes on momentarily; No pilot arc; No main arc transfer 1. Switching transistor (Q1) not turning on a. Refer to Section 4.05-M, Switching Contr ol Check (Q1). N. No pilot arc; DC indicator on; Pilot indicator OFF; PCR not energized 1. Faulty Logic PC Bo[...]

  • Page 27

    Manual 0-2533 23 SER VICE TROUBLESHOO TING U. Main arc transfers and pierces through the plate, but cutting machine doesn’t move 1. Incorrect or missing OK-T o-Move signal. a. Many cutting machines require an AC voltage to activate the motion input. Refer to Operat- ing Manuals for setting OK-T o-Move signal. b. Check for missing OK-T o-Move sign[...]

  • Page 28

    SER VICE TROUBLESHOO TING 24 Manual 0-2533 work check continuity from TB2, wir es 102 & 103, to J50-10 & 1 1. If correct, r eplace the Switching Contr ol PC Board. A-01137 K1 RC6010 Switching Control PCB ON ENABLE T o AMP/VOL T Displa y Enable TB2-2 J1-5 J1-4 E2 E3 J37-17 J15-5 J50-12 J50-10 J15-33 J37-27 J37-26 J15-32 TB2-1 J50-11 Merlin 3[...]

  • Page 29

    Manual 0-2533 25 SER VICE TROUBLESHOO TING 2. High frequency pr otection for the input rectifier diodes (D1-6) is provided by capacitors C1 - C6 and MOV 1-3, which ar e 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 . T o be safe, the com[...]

  • Page 30

    SER VICE TROUBLESHOO TING 26 Manual 0-2533 2. If the coolant conductivity indicator is not lit with the probe disconnected, measur e between the Logic PC Board common (TP1) and J3-1. If the voltage measur es below +12 VDC, replace the LED PC board. If the voltage measur es above +12 VDC, replace the Logic PC Boar d. K. P ower Suppl y Star t Circuit[...]

  • Page 31

    Manual 0-2533 27 SER VICE TROUBLESHOO TING lem is in the Standoff Contr ol (SC10) or the ribbon cable. Refer to Section 5, Customer/Operator Service, in the Standoff Contr ol Instr uction Manual. If the Standoff Contr ol (SC10) isn’t used or the Power Supply didn’t start with the ribbon cable disconnected, there ar e two approaches you can take[...]

  • Page 32

    SER VICE TROUBLESHOO TING 28 Manual 0-2533 The PWM compares shunt amp output on J9-5 with the current contr ol signal (3.3 - 10 VDC) fr om the re- mote (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 of f the PWM and thus producing no DC. If the shunt amp [...]

  • Page 33

    Manual 0-2533 29 SER VICE TROUBLESHOO TING If 24 V AC is not present, r emove J14 contr ol connec- tor at the torch bulkhead and measur e for 24 V AC be- tween pins 5 and 8 of the receptacle. The 24 V AC comes fr om T3, is fused by F3, 1A 250v , and passes through the filter FL1 to J14. If voltage is not pr esent at J14 the most likely fault is the[...]

  • Page 34

    SER VICE TROUBLESHOO TING 30 Manual 0-2533 The display signal at J7-2 should be equal to the control pot wiper voltage at J7-18 measur ed in Step 3 above. If this is not correct, the Switching Contr ol PC Board is defective. After arc transfer the display signal switches to repr esent actual cutting curr ent as monitored by the Shunt Amp and Switch[...]

  • Page 35

    Manual 0-2533 31 SER VICE TROUBLESHOO TING Q. OK-T o-Move T ests 1. The Shunt Amp sends a voltage level to the Switch- ing Contr ol PC Board that corr esponds to the work lead or cutting current. When that curr ent is greater than 25 amps, a circuit on the Switching Contr ol PC Board sends an active low signal called CSR to the Logic PC Board, J3-1[...]

  • Page 36

    SER VICE TROUBLESHOO TING 32 Manual 0-2533 CAUTION Move the clamps only what is necessary for a steady pilot. T oo much adjustment can cause increased parts wear . DO NOT move each clamp mor e than a total of 2 inches (50.8 mm). If a steady pilot cannot be achieved with the adjust- ment, then something else is wrong.[...]

  • Page 37

    Manual 0-2533 33 REPLACEMENT PR OCEDURES SECTION 5: REP AIRS & REPLA CEMENT PR OCEDURES 5.01 Intr oduction This Section describes parts replacement pr ocedur es and all repairs which may be performed on the Merlin 3000 Power Supply . Under no circumstances ar e field r epairs to be attemped on Printed Circuit Boar ds or other Subassemblies of t[...]

  • Page 38

    REPLACEMENT PR OCEDURES 34 Manual 0-2533 W ARNING Disconnect primary power from the source befor e opening or disassembling the power supply . Make sure AC indicator on the Power Supply fr ont panel is OFF . Before disassembling any part of the Power Supply first read the pr ocedur e for the part to be r eplaced, then pro- ceed with the disassembly[...]

  • Page 39

    Manual 0-2533 35 REPLACEMENT PR OCEDURES 2. Loosen the two screws of the W ork Cable strain relief securing the W ork Cable at the Front Panel. 3. Remove the nut (under the Horizontal Chassis Panel) securing the W ork Cable connection to the Shunt Assembly . 4. Pull the W ork Cable fr om the unit. 5. Install the replacement W ork Cable by reversing[...]

  • Page 40

    REPLACEMENT PR OCEDURES 36 Manual 0-2533 3. Remove the Coolant Hose from the Internal Cool- ant Filter Assembly . 4. Remove the Internal Coolant Filter from the fitting on the Radiator . 5. Install the replacement Internal Coolant Filter As- sembly by reversing the above pr ocedure and not- ing the following: • Clean the old thread sealer fr om t[...]

  • Page 41

    Manual 0-2533 37 REPLACEMENT PR OCEDURES 7. Locate and remove the four bolts and lock nuts securing the Fan Assembly to the Rear Panel As- sembly . 8. Car efully pull the Fan Assembly from the Rear Panel Assembly feeding the wiring through the hole. 9. Install the replacement Fan Assembly by reversing the above procedur e. B. Three-Phase Contactor [...]

  • Page 42

    REPLACEMENT PR OCEDURES 38 Manual 0-2533 G. Coolant T ank Replacement 1. Remove the Left, Right, and T op Side Panels per Section 5.04-B. 2. Drain the coolant from the Coolant T ank per Sec- tion 4.02-F . CAUTION Handle and dispose of the used coolant per recom- mended procedur es. 3. Remove the two wires fr om the Conductivity Sen- sor located on [...]

  • Page 43

    Manual 0-2533 39 REPLACEMENT PR OCEDURES CAUTION Handle and dispose of the used coolant per recom- mended pr ocedur es. 3. Remove the two wires fr om the Conductivity Sen- sor Assembly . 4. Remove the Conductivity Sensor Assembly from the Coolant T ank. 5. Install the replacement Conductivity Sensor As- sembly by reversing the above pr ocedur e. 6.[...]

  • Page 44

    REPLACEMENT PR OCEDURES 40 Manual 0-2533 6. Install the replacement T ransformer Assembly by reversing the above pr ocedur e. C. Main Contactor (W1 or W2) Replacement NOTE The Main Contactors, W1 and W2, are r eplaced in the same manner . 1. Depending on which Main Contactor Assembly is to be replaced, r emove the Left or Right Side Panel per Secti[...]

  • Page 45

    Manual 0-2533 41 REPLACEMENT PR OCEDURES Driver PC Board Rear of F ront Panel A-01083 5. Note and label the two wiring connectors that con- nect to the Driver PC Board. 6. Disconnect the two wiring connectors fr om the Driver PC Board. 7. Press in the securing tab knob on the PC Boar d Guide to release the PC Boar d fr om the PC Boar d Guides. Ther[...]

  • Page 46

    REPLACEMENT PR OCEDURES 42 Manual 0-2533 PTC Resistor Assembly Q1 Main Heatsink A-01089 17. Remove the four screws securing the Switching T ransistor module to the Main Heatsink. 18. Pry between the Main Heatsink and the faulty Switching T ransistor Assembly until it slides eas- ily . 19. Remove the faulty Switching T ransistor Assem- bly from the [...]

  • Page 47

    Manual 0-2533 43 REPLACEMENT PR OCEDURES C. Pressure Gaug e Replacement NOTE Both the Plasma and Secondary gauges are r eplaced in the same manner 1. Remove the T op Panel per Section 5.04-B. 2. Disconnect the wiring tho the desired Pr essure Switch. 3. Remove the Pressur e Switch fr om the desired Pr es- sur e Gauge Assembly . 4. Disconnect the in[...]

  • Page 48

    REPLACEMENT PR OCEDURES 44 Manual 0-2533 3. Disconnect the gas Hose Assembly from the fitting at the end of the Gas Input Fitting. 4. Remove the fitting screwed into the end of the Gas Input Fitting. 5. Remove the first nut from the Gas Input Fitting. 6. Remove the second nut securing the Gas Input Fit- ting to the Upper Chassis/Gauge Assembly . 7.[...]

  • Page 49

    Manual 0-2533 45 REPLACEMENT PR OCEDURES Symbol Direction Of Flow Check Valve A-00370 5. Install the replacement Check V alve by reversing the above procedur e and noting the following: • Coat the threads of the Fittings with a teflon sealer before installing on the r eplacement Check V alve. M. Secondary Gas Check V alve Replacement 1. Remove th[...]

  • Page 50

    REPLACEMENT PR OCEDURES 46 Manual 0-2533 d. Re-solder the wire lead to the r eplacement di- ode. e. Apply a layer of R TV over the top of the Diode Assembly to encapsulate the lead and top of the diode. RT V 70 Amp Diode Wire Lead A-01166 f. Close up the Power Supply . B. Relay Replacement 1. Remove the Right Side Panel per Section 5.04-B. 2. Move [...]

  • Page 51

    Manual 0-2533 47 REPLACEMENT PR OCEDURES 7. Make sure the r eplacement diode is a direct re- placement for the old one. 8. Install the replacement diode by r eversing the above procedur e and noting the following: a. W ipe the surface clean where the replacement diode is to be installed. NOTE The thermal interface pads must be properly aligned when[...]

  • Page 52

    REPLACEMENT PR OCEDURES 48 Manual 0-2533 NOTE Refer to Subsection 6.08, Upper Chassis Replace- ment Parts for part numbers and detail drawing. 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 Pr essure Gauge connec- tor . 3. Disconnect the other end of the Hose Assembl[...]

  • Page 53

    Manual 0-2533 49 REPLACEMENT PR OCEDURES 3. Remove the Hose Assembly from the unit. 4. Install the replacement Hose Assembly by revers- ing the above procedur e. 5. Refill the Coolant T ank with Thermal Arc T orch Coolant before applying power . I. Coolant Return Hose (Internal Filter to Flow Switch) Assembl y Replacement The Coolant Return Hose As[...]

  • Page 54

    REPLACEMENT PR OCEDURES 50 Manual 0-2533[...]

  • Page 55

    Manual 0-2533 51 P ARTS LISTS SECTION 6: P AR TS LISTS 6.01 Intr oduction A. Parts List Breakdown The parts list provides a br eakdown of all basic replace- able 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 Re[...]

  • Page 56

    P AR TS LISTS 52 Manual 0-2533 A-01220 1 2 3 4 5 6 6.03 External P o wer Supply Replacement P arts List Item # Qty . Description Catalog # Complete Merlin 3000 Power Supply W ith Running Gear and W ork Cable 1 W ithout Gas Control GC3000 3-5100 1 W ith Gas Control GC3000 3-5101 1 1 W ork Cable with Clamp - 25 ft (7.6 m) 9-4380 2 1 Panel, T op 8-330[...]

  • Page 57

    Manual 0-2533 53 P ARTS LISTS 6.04 Access P anel Replacement P arts Item # Qty . Description Catalog # 1 Access Panel Assembly Includes: 8-3257 1 1 Access Panel W ith Overlay 8-6302 2 1 Access Panel Overlay 8-3306 3 1 ON/OFF Rocker Switch, DPST 8-3258 4 1 Switch, Rocker , SPDT , Center Off 8-3259 5 1 LED/Curr ent Contr ol PC Board Assembly 9-5759 6[...]

  • Page 58

    P AR TS LISTS 54 Manual 0-2533 6.05 Front P anel/Chassis Replacement P arts Item # Qty . Description Catalog # 1 1 Front Panel W ith Overlay 8-6304 2 1 Front Panel Overlay ------ 3 1 Cord Grip 8-6307 4 1 T o rch Leads Panel Boot 9-4210 5 1 Radiator 8-1347 6 1 #6 JIC x 3/8 NPT Male Union 8-6141 7 1 Coolant Filter 8-4276 8 1 Support, Inner Coolant Fi[...]

  • Page 59

    Manual 0-2533 55 P ARTS LISTS 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 19 18 17 20 21 A-01217 22 23[...]

  • Page 60

    P AR TS LISTS 56 Manual 0-2533 6.06 Rear P anel Replacement P ar ts Item # Qty . Description Catalog # 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 V oltage S[...]

  • Page 61

    Manual 0-2533 57 P ARTS LISTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 21 22 23 24 25 26 27 28 29 30 31 18 18 20 32 20 20 3 A-01216 11[...]

  • Page 62

    P AR TS LISTS 58 Manual 0-2533 6.07 Base Assembly Replacement P ar ts Item # Qty . Description Catalog # 1 1 Base 8-5145 2 2 Caster , 5" Diameter 8-5578 3 2 Wheel, 8" Diameter 8-5579 4 1 Axle 9-1243 5 2 Retaining E-Ring, 1/2 Diameter Shaft 9-5539 6 1 Mat, Inductor Base 8-6143 7 1 DC Inductor Assembly 8-6145 8 1 29 KV A T ransformer 8-6670[...]

  • Page 63

    Manual 0-2533 59 P ARTS LISTS 9 10 1 2 11 12 3 4 13 14 5 6 15 16 7 8 17 18 19 20 21 22 23 24 21 20 A-00894 26 25 9[...]

  • Page 64

    P AR TS LISTS 60 Manual 0-2533 6.08 Upper Chassis Replacement P ar ts Item # Qty . Description Catalog # 1 1 Panel, Upper Chassis/Gauge 9-1302 2 1 Power Driver PC Board Assembly Includes: 7-3360 1 Thermstrate, T ransistor (Refer to Section 6.09 Item # 7) 9-1406 1 T ransistor , 300A, 550V Darlington (Refer to Section 6.09 Item # 8) 8-6154 1 Current [...]

  • Page 65

    Manual 0-2533 61 P ARTS LISTS Item # Qty . Description Catalog # 43 1 Check V alve, Male, 1/4 NPT , 5 PSI 8-4512 44 1 Hose Assembly , Secondary W ater , Gauge T o T -Fitting 8-4513 45 1 Hose Assembly , Secondary Gas/W ater to Bulkhead 8-4514 46 1 Hose Assembly , Secondary Gas Inlet to Regulator 8-4515 47 1 Hose Assembly , Bulkhead to Coolant Pressu[...]

  • Page 66

    P AR TS LISTS 62 Manual 0-2533 6.09 Main Heatsink Assembl y Replacement P ar ts 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, T ransistor 9-1406 8 [...]

  • Page 67

    Manual 0-2533 63 P ARTS LISTS 1 2 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 29 30 31 32 33 34 11 19 9 2 2 2 17 17 11 11 28 A-00971 32 32 32 32 32 32[...]

  • Page 68

    P AR TS LISTS 64 Manual 0-2533 6.10 P o wer Supply Options And Accessories Item # Qty . Description Catalog # 1 1 Remote Control (RC6010) 3-6106 2 1 Standoff Contr ol (SC10) 3-61 10 3 1 Gas Contr ol (GC3000) 7-341 1 4 1 Air Line Filter Assembly 7-3139 5 1 Replacement First Stage Filter Element 9-1021 6 1 Replacement Second Stage Filter Element 9-10[...]

  • Page 69

    Manual 0-2533 65 P ARTS LISTS A-01218 OUTPUT AMPS PLASMA ENABLE ON START REMOTE POWER SUPPLY CONTROL SD (%) 25 75 100 50 TRAVEL SPEED 125+ IPM 0-125 IPM RUN PURGE SET PLASMA ON ARC VOLTS REMOTE STANDOFF CONTROL T.H.C. ACTIVE PIERCE HT (inches) 0.1 0.3 0.4 0.5 0.2 END OF CUT RETRACT (%) 0 25 75 100 UP DN TORCH TORCH MODE MODE LIFTER SPEED SPEED PIER[...]

  • Page 70

    P AR TS LISTS 66 Manual 0-2533[...]

  • Page 71

    Manual 0-2533 67 APPENDIX APPENDIX I: INPUT WIRING REQUIREMENTS I nput P ow e r I npu t Curre nt S ugge st e d S i ze s ( S e e Not es ) V o ltag e F r eq . 3-P h 3-P h F u se (A m p s) W i r e (A W G ) W i r e (C an ad a) (V o l ts) ( H z ) (kV A ) (A m p s) 3-P h 3-P h 3-P h 200 50/60 34 98 110 A W G 2 2 208 50/60 34 95 110 A W G 2 2 220 50/60 34[...]

  • Page 72

    APPENDIX 68 Manual 0-2533 APPENDIX II: SEQUENCE OF OPERA TION BLOCK DIA GRAM A-01016 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 t[...]

  • Page 73

    Manual 0-2533 69 APPENDIX APPENDIX III: TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS Ca bl e De s cr i pt i o n Let t er Des i g na t i on Po w e r S u pp l y to R e m o te C o ntrol A St andof f Contr ol t o T or c h Li ft er As s em bl y B Re mo t e Co nt r o l t o CNC Con t r o l C Pow er Supp l y to G as Co ntr ol D Pow er Supp l y W or k Ca bl [...]

  • Page 74

    APPENDIX 70 Manual 0-2533 APPENDIX IV : INTERF A CE CABLES FOR REMO TE CONTROL (RC6010) AND ST ANDOFF CONTROL (SC11) A-00983 MERLIN 3000 REMOTE CABLES FOR RC 6010 & SC11[...]

  • Page 75

    Manual 0-2533 71 APPENDIX APPENDIX V : CNC INTERF A CE A-00982[...]

  • Page 76

    APPENDIX 72 Manual 0-2533 APPENDIX VI: 120 V A C CIRCUIT DIA GRAM K1 J28 TO OPTIONAL ST ANDOFF CONTR OL PCR (881) (89) SW3-A (5) K5 LOGIC PCB (75) K3 (110) SOL3 SOL2 SOL1 (50) K4 K2 T2 -1 -3 (24) V OL T AGE SELECTION PCB (24) (23) K5 K5 (22) (21) W2 W1 MC2 MC1 (4) (3) K4 K3 K3 K4 (15) (14) T1 SW1-A ON/OFF (10) F2 (9) (8) SWITCHING CONTROL PCB A-011[...]

  • Page 77

    Manual 0-2533 73 APPENDIX APPENDIX VII: LADDER DIA GRAM - 15 VDC 3 LOGIC CONTROL BO ARD 13 11 19 15 5 9 7 24 11 12 18 14 4 8 6 22 12 K4 K3 K2 K5 K1 PLASMA SECOND AR Y GAS CONTROL CIRCUIT PRE-FLO W & POST -FLO W CIRCUIT SWITCH RECOGNITION RU N SET PURGE SW2 ST ART/ST OP (CNC) ST ART/ST OP (Hand) FS1 D57 ST ART INDICA T OR CONT ACT OR CONTROL W C[...]

  • Page 78

    APPENDIX 74 Manual 0-2533 APPENDIX VIII: SIGNAL FLO W BLOCK DIA GRAM A-01139[...]

  • Page 79

    Manual 0-2533 75 APPENDIX APPENDIX IX: ST ART CIRCUIT DIARGRAM A-01080 Standoff Control SC11 Merlin 3000 or Merlin 6000 or Merlin 6000GST J15-24 J15-25 J42-3 J42-4 J8-11 J8-10 K10 ST AR T OPT O- Isolator K10 ST AR T FIND HT PLASMA ON ST AR T D79 FIND HT OFF J8-17 J40-3 J40-4 J8-18 J11-3 J11-4 CNC ST AR T A-01079[...]

  • Page 80

    APPENDIX 76 Manual 0-2533 APPENDIX X: CURRENT CONTR OL / DISPLA Y CIRCUIT DIA GRAM A-01138[...]

  • Page 81

    Manual 0-2533 77 APPENDIX APPENDIX XI: CSD (CORNER SLO WDO WN) CIRCUIT DIA GRAM A-01140[...]

  • Page 82

    APPENDIX 78 Manual 0-2533 APPENDIX XII: OK-T O-MO VE CIRCUIT DIA GRAM A-01081 PIERCE DELA Y 0 - 3 seconds OFF = OK-T o-Move 24 V A C Source Merlin 3000 or Merlin 6000 or Mer lin 6000GST with Remote Control RC6010 / Standoff Control SC10 OK-T o-Move Circuit OK Logic PCB J2-14 J2-16 J15-11 J15-10 J42-12 J42-14 OK PS D82 OK OUT D37 Pierce Delay 0 - 3 [...]

  • Page 83

    Manual 0-2533 79 APPENDIX APPENDIX XIII: HOSE BLOCK DIA GRAM Coolant Filter Assembly (Rear Panel) Internal Filter Assembly Gas Connections (Rear Panel) Plasma Gas (+) Secondary Gas Secondary Water Radiator In Out Bulkhead (Front Panel) Coolant Supply (-) Coolant Return Plasma Gas (+) Secondary Gas Check Valve Coolant Pressure Gauge (Front Panel) Ta[...]

  • Page 84

    APPENDIX 80 Manual 0-2533 APPENDIX XIV : SYSTEM SCHEMA TIC A-00981[...]

  • Page 85

    Manual 0-2533 81 APPENDIX A-00981[...]

  • Page 86

    APPENDIX 82 Manual 0-2533 APPENDIX XV : RECOMMENDED R OUTINE 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 adjuste[...]