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merlin 6000 slave power supply

1. NEG DIODE HEATSINK METAL tissues 1841 T 184 DA se wi 1 L2 A Ds ZN Wy w2 66 R3 Dia A cs pi 129 1 184 1 199 Mov2 1671 T wi INPUT AT 2 meme Lite PCB 85 X Tu ian ZN 11 2 SUPPRESSION m 184 82 4 427 2 J27 3 MA 21 2 c4 LEE DRIVER PCB wi s my c38 ci6 18 28122 JN NA y 2i S Wo m SEES UN R46 B w2 ad ccr L 7 7 i 7 8 Dz D4 55 A m 158 7997 199 POS 1 DIODE amp MAIN HEATSINK aa ss us 2538 2 ow 8 sar 347 1 BL 32 j7 RB i ASA 8 12 MEZ Mos 2 5 1 sel ft lez I SWITCHING Fi iak 381 CONTROL PCB 1 21 fr 2 38 3 250 1241 118 Bi 142 ENABLE RELAY F2 ON DFF 250 SWI A I2 VAC RETURN Sn me 17 22 212 4 pe 18 T gt 3OREH VOLTAGE sm B DIVIDED BY 23 127 128 061 92 5 212 8 mu 1221 2748 V7 5 3745 2312 12 LV 4 H VOLTAGE
2. COMPONENTS LOCATION LN jUF IKV 1821 SZ C7 10 55 UF 45 VDC a CHAZ IBUF 400 1831 CI3 14 15UF SHIELD 5 17 19 21 2 2 3KV 841 UN CI6 18 20 22 4 7NF 3KV IB5 A C23 3 488VDC 1861 c29 2 2NF 3KV 86 c38 4 7 BB c32 5UF 400 01 3 5 15 REV 21 D2 4 6 158A STR 82 7 1 7804 600 200 5 STR 1851 168 Dit 14 72 600 20055 STR 41 FI FUSE 10 25 VAC IMOTORI C21 ARC F2 FUSE 25 VAC CONTROL C21 STARTER INDI RED 25VAC NEON INDICATOR ICH LI 4 TURN SUPPRESSION COIL 1841 L2 MAIN INDUCTOR 2 SECTIONS A5861 MCI MC2 MOTOR CONTROL CONTACTOR 25A 2 POLE 2 31 2 FAN MOTOR 230VAC 50760 HZ 2 3 428 V RMS 20 JOULES 1821 at 300 558 1841 B 2 RI OHM 183 2 3 190 OHM 20W R4 6 8 10 OHM 184 88 88 SHUNT 180 WORK R5 7 9 11 5 OHM law 185 4 I RI2 OHM 120W OHM 320W AB i WIRE RIBBON CABLE J11 SHUNT AMP 8 R14 22K OHM 1 2W 186 RI5 IK OHM IW 86 180 OHM 180 86 REMOTE DEMAND 17 18 1321 215 1 SIG 27 17 1331 Signe sw ON OFF DPST ROCKER SW IDPSTI C21 NE 7 OUTPUT SIG 17 2 1341 di5 3 SHUNT 250A 187 TO MASTER 27
3. T NEG i DIODE HEATSINK METAL s 184 184 D7 wi H L2 A D3 DS ZN A w2 166 183 _ Dia Lo Les Les Lev 181 RIZ 129 184 E 199 157 2 Li wi INPUT 4T Cin izi FILTER L lt gt ve rcs T Sap m a oe SUPPRESSION 227 2 427 3 4271 15 17 19 2 ls je le DRIVER PCB T wi In o om ci6 18 28 22 wo wo v N N N NN N 14 gt 2 2 20 B B wz fx RER 1 C29 52 44 44 55 7 84 Tm 188 1891 POS I DIODE amp MAIN HEATS INK igi e 1997 112 9 NO 17 6 lt N N N 274 4 Nes Jig z 5 i 2 5 12 ez m fatal 2 2 25 2 s SWITCHING Fl IQA 1 CONTROL m 4 7 ie 4812 250 241 me ag dal ENABLE RELAY 120 RETURN 47 22 T T TORCH VOLTAGE DIVIDED BY 23 20 122 y 3749 22 5 3745 37 12 13 14 VOLTAGE SELECTION iv iki i20 ii PCB 35 617 1 I D M 415 1221 126 ES VOLT SEL PCB MONITORS INPUT VOLTAGE AND CLOSES EITHER LV OR HV CONTACTS WHEN POWER 15 TURNED ON TO SELECT PROPER TAPS ON SECONDARY 1621 4113 112 4 15 5 123 123 J2 8 J6 14 i241 I20VAC 241 425 J6 21 251 25
4. Arc Starter Box Shield J58 J59 P J60 e 1 I l DT J L ii 8012 SOL N SOL3 5014 Fa 7 E 7 1 C Ti m bu JT B Arc Starter PCB Work Cable UN UN Workpiece y 7 Art 01790 Work Cable Manual 0 2604 11 APPENDIX APPENDIX 9 QUICK REFERENCE TO CABLES AND HOSES For Merlin 6000GST System Cable Hose Diameter Cable Description Catalog Inches A Power Supply CNC Cable 25 ft 7 6 m 8 3380 3 8 50 ft 15 2 m 8 3381 3 8 75 ft 22 9 m 8 3382 3 8 100 ft 30 5 m 8 3383 3 8 B Remote Control Cable 25 ft 7 6 m 9 5961 1 2 50 ft 15 2 m 9 5962 1 2 75 ft 22 9 m 9 5963 1 2 100 ft 30 5 m 9 5964 1 2 C Gas Control Cable 10 ft 3 0 m 9 6934 1 2 15 ft 4 6 m 9 6935 12 20 ft 6 1 m 9 6936 1 2 25 ft 7 6 m 9 6937 1 2 30 ft 9 1 m 9 6938 1 2 35 ft 10 7 9 6939 1 2 40 12 2 9 6940 1 2 50 ft 15 2 9 6941 1 2 75 ft 22 9 m 9 6942 1 2 100 ft 30 5 m 9 6943 1 2 125 ft 38 1 m 9 6944 1 2 D Arc Starter Control Cable 10 ft 8 0 m 9 6945 1 4 15 ft 4 6 9 6946 1 4 20 6 1 9 6947 1 4 25 ft 7 6 9 6948 1 4 30 ft 9 1 m 9 6949 1 4 35 ft 10 7 m 9 6950 1 4 40 ft 12 2 m 9 6951 1 4 50 ft 15 2 m 9 6952 1 4 75 ft 22 9 m 9 6953 1 4 100 ft 30 5 m 9 6954 1 4 125 ft 38 1 m 9 6955 1 4 E Positive Pilot Supply Cable 35 ft 10 7 m 9 69
5. SLAVE SCHEMATIC 42X964 8 8 10 Art A 06022 Manual 0 2604 A 25 APPENDIX APPENDIX 26 Manual 0 2604
6. 347 1 BL BN A 174 37 5 22 5 2 MC2 yy wa Y Fe E SWITCHING FI A 2 JB 1 CONTROL PCB 1 21 2 418 8 JB 3 258VAC 338 B 1241 01101 ENABLE RELAY Bi 47 24 F2 BA ON OFF SWI A uid 250vAC v ci 128VAC RETURN J 22 UN TORCH VOLTAGE SW 8 DIVIDED BY 23 271 9 mza v 5 m zu 1221 1748 17 15 2745 17 2 Ji8 16 23 6 16 ZEN 8 m J6 12 31 HV LV J6 18 Y 16 7 14 1 VOLTAGE 1581 58 SELECTION ty psg 20 25 35 er 26 17 LV 08 AX es D 1 HV a ee 18 22 i VOLT SEL MONITORS INPUT VOLTAGE AND CLOSES EITHER LV OR HV CONTACTS WHEN POWER IS TURNED ON TO SELECT PROPER TAPS ON TI SECONDARY 1621 J3 3 JB 24 112 J1 24 A 26 5 23 23 12 8 54 1 L 1 32 9 48 20 N 38 1241 120 42 5 Tw AN 1 1251 113 A 162 125 3 281 16 18 J6 18 26 21 281 ZE vat 13 AN 181 Ja COMM 158 158 118 reu E 1382 f NJ38 3 681 601 J 8 z be be 6 J12 15 7 l J12 16 TS2 HEATSINK m TS TS4 TS5 mu TH PRIMARY CONNECTIONS n EMI FILTER PCB 42 825 SCHEMATIC SYSTEM VOLTAGES 114x282 50 O 1021 PACE L3 BUS BAR PRI VOLTS 58 58HZ ONLY VOLTAGE CONNECTIONS 386 415 75 Zi 22 500 LINE 1 29 388 415 LED PCB jeg 2 8 57 VOLS STATUS LEDS 29
7. Pad NOTE Kit 7 3360 includes several parts If any of these parts fail all must be replaced at the same time along with additional parts in the kit Failure to replace all parts together may lead to parts failure Manual 0 2604 6 11 PARTS LISTS PARTS LISTS 6 12 Manual 0 2604 APPENDIX 1 INPUT WIRING REQUIREMENTS Power Input Current Suggested Sizes See Note Voltage Freq 3 Ph 3 Ph Fuse Amps Wire AWG ire Canada Wire mm2 Volts Hz kVA Amps 3 Ph 3 Ph 3 Ph 3 Ph pos Le Le Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested sizes are based on flexible power cable with power plug installations For hard wired installations refer to local or national codes Cable conductor temperature used is 167 F 75 C An energy limiting fuse UL Class RK 1 examples BUSS LPS LPN RK or Gould Shawmut AZK A6K should be used to minimize damage to Plasma Cutting Welding or power distribution equipment NEVER use replaceable element fuses like UL Class H or one time fuses like UL Class K5 Manual 0 2604 1 APPENDIX APPENDIX 2 TYPICAL MECHANIZED SYSTEM WORK AND GROUND CABLE CONNECTIONS Remote Control or Standoff Control CNC C
8. 6010 Internal Ribbon Cable SC10 GAS CONTROL GC3000 C A 01517 APPENDIX 30 ue INPUT p d Parallel Cable MASTER POWER SUPPLY PCR J15 J63 J54 J14 Bulkhead S 30 INPUT SLAVE POWER SUPPLY J15 6 Manual 0 2604 D ARC STARTER BOX Arc Starter Control J2 ARC STARTER PCB PILOT CABLE eZ SECONDARY GAS F PLASMA GAS N COOLANT N G COOLANT N 1 CABLE SHIELD PILOT CABLE Kw WORK CABLE WORKPIECE TORCH CABLE WORK CABLE A 01517 Manual 0 2604 A 7 APPENDIX APPENDIX 7 QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES For Merlin 6000 System Cable Hose Diameter Description Catalog Power Supply CNC Cab m Torch Cable 25 351 50 ft 75 f 100 115 125 W ork Cable 3 NS 335223 25 35 ft 50f 3333 100 115 125 558 3 38 30 ft 9 1 APPENDIX 8 Manual 0 2604 Manual 0 2604 A 9 APPENDIX APPENDIX 8 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM For Merlin 6000GST System NOTE Refer to
9. 71 C29 2 2NF 3kV 86 c30 4 7 86 2 SUF 4BBVAC C31 01 3 5 58 889 REV 142 D2 4 5 152A 80 V STR 182 97 18 78 600 200NS STR 88 Dn 14 70A 6B V 20ONS STR fA41 Fi FUSE 10 250 IMOTOR C2 F2 FUSE 5A 250 ICONTROL C2 INDI RED 125 NEON INDICATOR cir bt 4 TURN SUPPRESSION COIL 184 L2 MAIN INDUCTOR 12 SECTIONS tA5865 2 MOTOR CONTROL CONTACTOR 25A 2 POLE C2 C3 M2 FAN MOTOR 23DVAC 50 60 HZ 63 MOV1 2 3 420 V RMS 29 JOULES 82 PCR PILOT CONTROL 48 3 POLE 388 558 84 Ri OHM 182W R2 3 188 OHM Baw tA4 R4 6 8 1D 8 1 OHM IBW 184 R5 7 9 11 5 OHM law 85 IT Pi Riz OHM 120W 51 RI3 OHM tAB REMOTE DEMAND 37 18 132 luis 4 22K OHM 1 SIG J7 17 133 15 2 RIB 4 5 OHM IKW IPILOT 87 m OUTPUT SIG 4 R17 330K OHM 0 59 A7 TO MASTER 171 1351 J15 3 RIS OHM 1 BE 1728 J15 4 ma 100 OHM IDOW 88 PARALLEL TABLE 136 J15 26 R21 22 2 2 OHM IKW IPILOT 87 INSTALLED 515 17 18 1371 J15 27 sw ON OFF DPST ROCKER SW IDPST C2 SHUNT 258A 100 87 28 CURRENT mul J5 38 TI MAIN TRANSFORMER 3BKVA 3 PHASE an SOURCE 2278 1145 5 31 T2 NSVAC PRI 25 2VCT SEC Car RMI TSLTS4 TSS TI TEMP SW 120 DEG C 121 152 BB DEG MAIN HEATSINK TEMP 2 BH 158 18 1021 nor n wi w2 MAIN I W CONTACTOR 75A 3 POLE 09 ENABLE 258 m 15 32 s SW 1 am
10. Open the hinged cover at the Front Panel torch leads connection area Locate and remove the cap from the fuse holder Pull the faulty Fuse from the fuse holder Install the replacement Fuse by reversing the above procedure D Control Logic PC Board Assembly Replacement 1 REPLACEMENT PROCEDURES Open the front panel access panel cover at the front of the Power Supply Fasten the access cover open with string or rubber band Note where each connector is located on the old Control Logic PC Board Disconnect the three connectors from the old Con trol Logic PC Board Note the orientation of the old Control Logic PC Board Remove the old Control Logic PC Board On the new Control Logic PC Board set the switches SW1 through SW5 the same as the old Control Logic PC Board Install the replacement Control Logic PC Board by reversing the above procedure E Switching Control PC Board Assembly Replacement 1 Remove the Top and Right Side Panels per Section 5 04 B Note the orientation of the old Switching Control PC Board Remove the Switching Control PC Board from the rear of the Upper Chassis Gauge Panel far enough to disconnect the wiring connections Note where each connector is located on the Switching Control PC Board Disconnect the connectors from the Switching Con trol PC Board Reconnect the original wiring connectors to the replacement Switching Control PC Board before installing the
11. SELECTION tv isi i20 125 313 5 JB 17 J6 3 1221 28 VOLT SEL MONITORS INPUT VOLTAGE AND CLOSES EITHER LV OR HV CONTACTS WHEN 15 TURNED ON SELECT PROPER TAPS ON T SECONDARY 1521 31 ia J1 Ji 2 J1 55 1231 123 428 L 120 w 14 14VAC e ni COMM a 159 159 J 9 2 y 04 43 f 138 3 168 tear 31 8 J12 18 5 i TSZ HEATSINK TS 54 TS5 E m ITU E PRIMARY CONNECTIONS m EMI FILTER 42 825 SCHEMATIC 5 SYSTEM VOLTAGES 114x282 PCB 14 10 380 415V L3 mO n INPUT BUS BAR PRI VOLTS ONLY VOLTAGE CONNECTIONS 388 415 LINE 1 10 59 LED REC VOLTE ISTATUS LEDS 509 258 VAC LINE 2 2 388 415 195 460 B B2 245 9 7 SAFETY END D DI 14 D D2 Boc 3 Di Di 28 2 2 33 2 E E 26 E E 1 32 5 6 32BVDC Art A 06022 1 2 3 4 5 APPENDIX A 24 Manual 0 2604 V 7 8 18 COMPONENTS LOCATION Ci 6 IKV c7 10 55 UF 45 VDC Enaz 180 4B8VDC 83 C13 14 I5UF IKV 4 15 17 19 21 2 2 184 C16 18 20 22 4 7 185 C23 3001 480VDC 86 C28 4UF 370VDC
12. lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail GENERAL INFORMATION 1 4 e Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage e R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes Ao ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives Necoupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibl
13. 8 23 PWM Enable 2 k ce 1 V2 Switching Control PCB 20 ma 07 16 1045 Ji amp 30 454 5 142 iJ71 48 Current I i LS J10 23 Source ina lus J5410 141 971 16 3i J10 9 Parallel Cable Installed I 107 14 in 1 36 J15 26 amp 20 V Shunt 10 27 Slave is On Signal sn 1 i 0 10 v Display SUM i 7 11 Sig From J54 8 139 071 13 H i CSE 1071 14 1 0 1 i M 710 29 This is Slave 1071 11 J71 10 H i ENABLE 171 7 Relay mS u UU E E 02035 1 APPENDIX 16 0 2604 DNA BRASH AS RAS ECAR OR Aa A dA n RSR ARR ARR SATA DK AARAA H i Logic PCB i gas I i 124 i8 lt Thisis Slave 4 9 120 1 15 35 _ 5 5 i i 44 10 3 29 This is Slave I lt 4 Lt J15 36 1 1 15 V i I s Slave is 70 24 129 14 4 2 gt Slave is Ji 2
14. Motor Control Contactors MC1 and MC2 MC1 is for the high voltage tap and is for the low voltage tap Three phase primary power is controlled by one of the Main Contactors W1 for the high voltage tap or W2 for the low voltage tap C Switch Mode Power Supply Operation Primary three phase power from the Main Transformer secondary is rectified by the three phase bridge diodes D1 D6 Theresulting negative DC voltage approximately 320 vdc is applied to the switching transistor O1 The switching transistor controls the output current by pulse width modulation PWM PWM varies the duty cycle or on time versus off time of the switch The greater the on time the higher the output current will be Com ponents D7 10 R2 3 C13 14 L1 and the Suppression PC Board are snubbers to limit voltage and current surges caused by switching Q1 on and off 011 14 are free wheel ing diodes When Q1 is on current flows through O1 into the output network When O1 is off D11 14 provide a path for current to continue flowing supported by en ergy that was stored in the output network during the time Q1 was on The switching transistor output is a se ries of pulses which are filtered back into pure DC volt age by theoutput network The output network consists primarily of the main inductor L2A and L2B resistor R13 and capacitor C23 D Switching Control PC Board PCB TheSwitching Control PC Board compares the shunt amp output with the
15. Power Supply Manual 0 2604 A System Description The system is designed for mechanized cutting only and consists of the following CE Merlin 6000 or CE Merlin 6000GST Master Power Supply Maximizer 300 Torch Torch Supply Leads Arc Starter Box Optional CE Merlin 6000 Slave Power Supply Optional Gas Control GC3000 for Merlin 6000 only e Optional Remote Control RC6010 Optional Standoff Control SC10 The output current of the basic system is 50 150 amperes A Systems with the Optional Merlin 6000 Slave Power Supply the output current of the system is 100 to 300 amperes A A second Master Power Supply may also be used as the Slave Power Supply Outputs between 50 to 100A are still available by shutting off the Slave Power Supply gas controls including gas solenoids gas pressure regulators and gauges are in the Merlin 6000 Master Power Supply Optional Gas Control GC3000 for Merlin 6000 only Re mote Control RC6010 and Standoff Control SC10 re fer to note may be used in various combinations NOTE The Standoff Control SC10 must be used with the Remote Control RC6010 The Optional Gas Control GC3000 for Merlin 6000 only contains the gas select control switches and a switch for the set functions An Optional Remote Dual Meter with Hour Meter and Arc Starts Counter is available with all Merlin 6000 Sys tems The meters are mounted to the front panel of the unit A
16. capabilities and limitations of the equipment This infor mation will also provide the Service Technician with an overall understanding of the equipment which will in turn allow proper training of the customer s operating personnel 3 02 General Description The Slave Power Supply may be connected in parallel to double the cutting current of the Merlin 6000 or Merlin 6000GST Master Power Supply All signal inputs out puts gas and torch connections are still connected to the Master Power Supply when the Slave Power Supply is used The Slave Power Supply has the same power cir cuits as the Master Power Supply A second Master Power Supply can also be used as a Slave Unit when connected to the Master Power Supply The equipment will auto matically be configured when the parallel cable is installed NOTES Refer to the Merlin 6000 Plasma Cutting CE Mas ter Power Supply Operating Manual 0 2601 for more information on the Master Power Supply Refer to the Merlin 6000GST Plasma Cutting CE Master Power Supply Operating Manual 0 2653 for more information on the Master Power Sup ply Manual 0 2604 A 01526 Figure 3 1 Slave Power Supply A typical system configuration will contain the following OneCE Master Power Supply with Running Gear One CE Slave Power Supply with Running Gear e Arc Starter Box Maximizer 300 Machine Torch with Leads and Mounting Assembly Torch Supply Leads Components Paral
17. of chlorinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq A SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL 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 code refer to item 9 in Subsection 1 03 Publica tions Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable ma terial in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Prov
18. 1 1351 PARALLEL CABLE 17 28 1361 115 4 TI MAIN TRANSFORMER 3 KVA 3 PHASE lA dz 525 J 5 26 T2 HSVAC PRI 25 2VCT SEC C4 INSTALLED SIG 318 7 2 TSLTS4 TS5 T TEMP SW 128 DEG C E21 T52 6 DEG C MAIN HEATSINK TEMP IE2 71 14 w C3 A181 28 CURRENT J7 16 30 WLW2 MAIN WI CONTACTOR 75A 3 POLE SOURCE 4 17 8 IE 31 15 20 1 i 158 a i221 PT J50 n ENABLE 315 32 SW 1 amp 2 OFF FOR MERLIN 6888 10 WIRE RIBBON CABLE 34 WIRE RIBBON CABLE SW 1 amp 2 ON FOR MERLIN 8000GST PIN 1 CABLE IN PLACE INTERLOCK PIN 4 TEMPERATURE LED GND WITH CABLE CONNECTED 5 DC LED 5 SHUNT AMP OUTPUT 6 14 UNFILTERED 9 I5VDC 8 PW ENABLE CSR ALL OTHER GND 21 OVERCURRENT SHUTDOWN 23 ENABLE2 OTE 25 DRAGING N PCB COMMON 27 SLAVE O D EARTH OR UTILITY GROUND 29 SLAVE UNIT WU EHASSIS GROUND ALL EVEN 8 34 ARE GND 971 DRAG SENSE 1 4 41 20 45 iei J1 4 LOGIC 41 18 48 15 LED START STOP 215 24 2118 1471 26 VOLTAGE SELECTION LOGIC PCB 47 18 SWITCHING CONTROL 2 SHUNT 312 13 MAIN TRANSFORMER IT 1418 ma J15 PARALLEL CABLE meo J15 36 J19 CONTROL TRANSFORMER T2 SLAVE UNIT 315 35 126 27 DRIVER E 438 MAIN HEATSINK PTC 339 FAN MOTOR 147 FAN MOTOR CAPACITOR C32 458 SWITCHING CONTROL PCB REV REVISIONS Bv REV REVISIONS DATE THERMAL DYNAMICS park 2 PCB Assy No 8 25
19. 20 APPENDIX 15 SYSTEM SCHEMATIC Unit Rev AG A 22 APPENDIX 16 SYSTEM SCHEMATIC Unit Rev AH or later A 24 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system Emm CAUTION A procedure which if not properly followed may cause damage to the equipment G iaswan ann 8 rr genna A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Per sons who work near plasma arc cutting applica tions should consult their medical health profes sional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603
20. 3 to 10 vdc go from the Master Power Supply to the Slave Power Supply One digital signal SLAVE IS ON and one analog signal OUTPUT SIGNAL TO MASTER 0 to 10 vdc go from the Slave Power Supply to the Master Power Sup ply Both the inputs and outputs of the digital signals are low when the signal is ON and high when signal is OFF The diagram at Appendix 12 Parallel Interface Diagram shows the expected voltages A 14 vdc 1 vdc indicates when the signal is OFF high it should be 14 vdc and when ON low it should be 1 vdc If an input is correct and the output is not the Isolation PCB is probably faulty although the circuit that the signal goes to could be load ing it down The ENABLE signal should be ON whenever the Master Power Supply ENABLE is ON The START signal comes ON when the Master Power Supply contactor comes ON at the end of the Master Power Supply preflow The SLAVEIS ON signal should be ON when the Slave Power Supply is powered ON even if it s not enabled The analog outputs should be the same as the analog in puts If the output is low and power supply V1 or 4 V2 is correct the Isolation PCB is faulty Manual 0 2604 M Pilot Resistor Adjustment G Disconnect primary power at the source before as sembling or disassembling power supply torch parts or torch and leads assemblies This Sub Section applies only to the following Slave Power Supplies Slave Power Supplies with the revision lette
21. 5 8 bly IGBT Suppressor PC Board and the replacement wire harness included in this kit in the sequence shown Note the torque requirements Connect the other end of the harness to the terminal from which the previous harness was disconnected on the driver PC board 6 Connect Harness 5 Install IGBT TE Suppressor PC Board i S Torque hardware to 14 in lbs e 1 6 N m re nct I 4 Torque IGBT AEA hardware only to 26 in lbs s 2 9 N m Ke E e 3 Remove Er copper tape 2 Install IGBT lt S Art A 06083 1 Install Thermal IGBT Installation Sequence Manual 0 2604 Shunt Amp PCB Replacement Locate the Shunt Amp mounted to the Shunt on the main heatsink Use the grounding wrist strap provided separately in this kit Follow all static handing instructions on the separate instruction sheet Open two locking tabs securing the ribbon cable con nector to the Shunt Amp PCB Carefully remove the cable connector from the Shunt Amp PCB Loosen but do not remove the bolt securing the Shunt to the main heatsink to allow access to screws secur ing the Shunt Amp PCB to the Shunt Rear of Power Supply Art A 03839 Shunt Amp PCB Disconnection Manual 0 2604 9o 10 11 5 9 Loosen but do not remove the screws securing the Shunt Amp PCB to the Shunt Refer to the illustration Remove the Shunt Amp from the power su
22. And Components Including 1 Year 1 Year 1 Year 1 Year But Not Limited To Starting Circuit Contactors Relays Solenoids Pumps Power Switching Semi Conductors Consoles Control Equipment Heat 1 Year 1 Year 1 Year Exchanges And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 1 Year SureLok Torches 1 Year 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Effective November 15 2001 GENERAL INFORMATION 1 8 Date January 27 2004 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This Manual provides Service Instructions for Thermal Dynamics Merlin 6000 CE Master Power Supply Infor mation in this manual is therefore particularly applicable to the Troubleshooting and Repair of the equipment and is intended for use by properly trained Service Techni cians familiar with this equipment For setup of this equipment individual operating proce dures and basic t
23. Appendix 9 for complete data on the Cables and Hoses iL El LE N K D Gas Control Cable a toe J37 Master Power Supply J29 RC 6010 J55 B OR Secondary H20 437 L Pre Flow Gas RC 6010 Internal Plasma Gas Ri Secondary Gas us J15 Coolant a Coolant J E J54 i Torch PCR Pilot ds cable 30 H AC Input Torch Cable H Parallel Cable Slave Power l pply 2 J15 Pilot Cable 5 E 39 ic Art 01790 Input APPENDIX 10 Manual 0 2604 Secondary Water Hose O J56 Gas Control Module GCM6000 Optional Secondary Water Secondary RAS M Plasma RAS M Pre Flow RAS N J57 Flow Control Module L Arc Starter EUM Cable
24. Assembly by reversing the above procedure 29KVA Transformer T1 Assembly Replacement G The removal of this Assembly requires the use of a mechanical lift 1 Remove the Left and Right Panels per Section 5 04 A 2 Disconnect all the wiring at the Transformer As sembly 3 Remove the six bolts star washers and flat washers securing the Transformer Assembly to the Base 4 Place a mechanical lift next to the left side of the Power Supply 5 Carefully slide the Transformer Assembly out the left side of the unit and onto the mechanical lift 6 Install the replacement Transformer Assembly by reversing the above procedure Manual 0 2604 55 Main Contactor W1 or W2 Replacement NOTE The Main Contactors W1 and W2 are replaced in the same manner 1 Depending on which Main Contactor Assembly is to be replaced remove the Left or Right Side Panel perSection 5 04 A 2 Labelallthe wiring connected to the Main Contac tor Assembly 3 Disconnect the wires from the Main Contactor As sembly terminals 4 Remove the two screws and star washers secur ing the Main Contactor Assembly to the Base 5 Install the replacement Main Contactor Assem bly by reversing the above procedure Thermostat Assembly Replacement There are three Thermostat Assemblies mounted to the 29KVA Transformer The Thermostat Assemblies are all replaced in the same way To replace a Ther mostat Assembly use the fo
25. BRACKETS C6 17 101 RI2 12 126 2 D N DRIVER PCB N 1 J26 J26 5 1731 1721 198 185 SUPPRESSION 17 19 21 ci6 18 28122 4 6 8 Jc 199 rrry yw GND I POS DIODE amp MAIN HEATSINK J39 2 1991 C32 s Aa J12 9 247 1 T BN iz I 1 25 2 18 T2 25 AVET SWITCHING E eA CONTROL PCB 1 412 1 J 121 Jig 2 stg g Sw 258VAC 339 5 241 110 HA A RELAY Bi 37 24 ENABLE HEE F2 ON OFF gt 258 SWI A 122 RETURI 112 4 ug y y 08 me wa 27 22 AIT TORCH VOLTAGE A v DIVIDED BY 23 1271 9 281 IND 412 8 n de 21 221 3 ix 28V N J7 12 222 NEON J8 23 6 16 ZX 141 J6 9 m m JS 12 d d LV 151 18 18 16 7 141 1H VOLTAGE SELECTION
26. SLAVE signal The sig nal goes to the Slave Power Supply Logic PCB Check for 0 vdc from TP1 ground to J4 9 on the Logic PCB e Ifthe voltage is correct and the TEMP LED is green the Slave Power Supply Logic PCB is faulty TROUBLESHOOTING 4 10 H Switching Control Check Q1 To produce DC output the main switch Q1 must be turned on and off rapidly Power Supply output is controlled by the on time At the same time the Main Contactor W1 or W2 closes the Logic PC Board grounds pins 9 and 23 of the 34 pin ribbon cable J3 9 on the Logic PC Board J10 9 on the Switching Control PC Board This enables the pulse width modulator PWM on the Switching Control PC Board The Logic PCB has protection circuits to remove PWM Enable signal if certain conditions are detected The cir cuits can be disabled for troubleshooting purposes only but first verify that 1 is not faulty Q1 Transistor Coil Switching Transistor Bracket or IGBT Large Blue Capacitors Q1 Location To check for a defective O1 remove power from the unit and disconnect J27 from the Driver PC Board A 01083 Driver PC Board Driver PC Board Location mE CAUTION There are two types of J27 wiring harness connected to Q1 For units with a 3 wire J27 harness refer to section H 1 For units with a 2 wire J27 harness refer to section H 2 Manual 0 2604 H 1 There are two types of Switching Transistor IBGT The types can be identified by
27. Slave Power Supply has the same power circuits as the Master Power Supply but the gas controls heat exchanger torch coolant and pilot circuits have been removed When a Master Power Supply is used as a Slave those circuits are automatically disabled The Merlin 6000 Sys tem uses the same Slave Power Supply as the Merlin 6000GST System A switch on the Switching Control PC Board PCB configures the power supply for Merlin 6000 operation refer to Switching Control PCB description for details 41 TROUBLESHOOTING B Input Voltage Selection The main transformer T1 has busbar connections to se lect one of three input voltage ranges Each main trans former secondary has two taps One secondary tap is automatically selected by the Voltage Selection PC board when primary power is applied If input voltage is within the lower half of the selected voltage range for example 380V or 415V in the 380 415 460V range the higher voltage taps are selected If input voltage is within the upper half of the selected voltage range 460V in the 380 415 460V range the lower voltage taps are selected This arrangement provides secondary voltages close to the optimum levels When the lower voltage taps are selected a red indicator D18 on the Voltage Selection PC Board will be ON The auxiliary voltage taps 115 VAC and 28 VAC circuits are selected directly by relays on the Voltage Selection PC Board The fan and pump motors are supplied by the
28. Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND ISIN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MA
29. VAC and the pilot resistor setting should be 9 ohms to have a good pilot The next time the system is turned ON the input AC line voltage may have gone up to 420 VAC causing the pilot to sputter because 420 VAC requires set ting of 4 5 ohms 340 30 6 6 Wires are attached to the pilot resistors with metal clamps or taps Locate and loosen the screw that secures the wire 99 tap on resistor R16 Deter mine from the Figure below the correct position for the tap on R16 and tighten the screw Example To set for 6 ohms measure 5 from the right side of R16 where wire 96 attaches and secure the 99 tap at that position TROUBLESHOOTING 4 18 Wire 99 Tap o pe BE eE cE Bowe we BE fie Eo EE EE EE ED th 58 SS SS 58 52 55 55 53 oF of ol oF z o DN Mig NE Oi CE VT N Z o 96 ep Cp Toi x l Y Y Y Y Y Y Y Y Wire 96 R16 4 5 ohms R22 2 2 ohms R21 2 2 ohms A 02598 Wire 74 Figure 4 5 Resistance Value Diagram 7 Test the pilot at 300A output current If it still sput ters move the wire 99 tap to the right toward wire 96 1 inch 25 4 mm at a time until the pilot no longer sputters Manual 0 2604 SECTION 5 REPLACEMENT PROCEDURES 5 01 Introduction This Section describes parts replacement procedures and all repairs which may be performed on
30. Voltage Selection PCB automatically selects the cor rect taps NOTE The connector for the following tests on the Volt age Selection PC Board is labelled J1 The System Schematic and the other supplied data refers to this connector as 6 A one second delay after wall power is turned ON when the voltage at J6 20 to J6 22 is greater than 28 VAC up per half of range the Voltage Select PCB enables relays K1 K4 and labeled HV on the system schematic and the red LED D18 The relays and LED will not turn ON unless switch SW1 front panel ON OFF Switch is ON If the voltage at J6 20 to J6 22 is less than 28 VAC then relays K2 and K3 labeled LV on the system sche matic are enabled and LED D18 will not come ON IfLED D18 is ON and the voltage is less than 28 VAC replace the Voltage Selection PCB 28 VAC Test 1 Check the AC input from J6 24 to both J6 20 and J6 22 for 12 18 VAC 2 Check the AC voltage from J6 24 to both J6 17 and J6 18 for 16 22 VAC 3 If input voltages are correct check output from J6 24 to both J6 19 and J6 21 for 14 18 VAC Manual 0 2604 4 If output is not present at J6 19 and J6 21 check between J6 24 and both J6 16 and J6 23 for 12 16 vdc If voltage is present at both points or neither replace the Voltage Selection PC Board If voltage is found at J6 23 but not at J6 16 check SW1 B and all wiring and connections 120 VAC Test NOTE Refer to App
31. each 1 06 inch diameter Thermal Interface Pad 1 each 1 Turn OFF main input power to the Power Supply both at the Power Supply ON OFF switch and at the main power disconnect 2 Wait at least two minutes to allow the input ca pacitors to discharge 3 Openthe PowerSupply to gain access to the faulty Diode Assembly 4 Locate the old Diode Assembly inside the Power Supply 5 Remove the nut and washer securing the old di ode assembly to the mounting surface 6 Remove the nut securing the diode wire lead to the PC Board 7 Make sure the replacement diode is a direct re placement for the old one 5 12 8 Install the replacement diode by reversing the above procedure and noting the following a Wipe the surface clean where the replacement diode is to be installed NOTE The thermal interface pads must be properly aligned when replacing the diode b Position the thermal interface pad between the diode and contact surface where the diode will be installed wmm CAUTION Diodes can overheat if not properly installed c Install the diode Torque the nut securing the diode to 100 125 in Ibs 11 3 14 1 Nm d Reinstall the nut and washer securing the re placement diode wire lead to the PC Board Manual 0 2604 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provides a breakdown of all basic replace able parts The parts lists are arranged as follows Sect
32. firing check for 24 VAC Arc Starter Box PC Board LED is ON and DC greater than 250V at E1 amp E2 fastons on Arc Starter PC Board DC will only be on for 3 sec onds see note If both voltages are present the ArcStarter PC Board is faulty NOTE PWM enable LED D9 indicator is ON momentarily less then 1 2 second then OFF 1 START LED is ON for preflow time then PWM Enable signal LED D9 comes ON for less than Logic PC Boards with Reo D or later on the PC Board have a test point TP7 connected to the an odes of D67 and D72 Installing a jumper from TP7 to TP1 will defeat the pilot sensor allowing more than three seconds for troubleshooting 1 2 second then both LEDs are OFF a No DC or DC less than 60 vdc Front Panel DC LED does not come ON Check for shorted Q1 per Section 4 05 H If O1 checks okay then install a jumper from TP4 to TP1 on the Logic PC Board to bypass the DC sensing circuit If the problem is no DC then the PWM enable signal LED D9 should now stay ON for3 seconds then go OFF If PWM enable signal LED D9 still drops out in less than 1 2 second problem is not a loss of DC but may be a shorted torch b Shorted torch head leads consumables etc Remove and insulate wire 7 from W7 faston on Logic PCB mmm CAUTION 300 volts may be present on the wire If contactor stays on for about 3 seconds after remove wire 7 the problem is a shorted torch tip to electrode with
33. ground as the wrist strap Open the equipment enclosure see instruction manual for the appropriate equipment and re move the failed PC board Carefully open the ESD protective bag and re move the replacement PC board Install the replacement PC board in the equipment and make all necessary connections Place the failed PC board in the ESD protective bag and seal for return shipping Reassemble the equipment enclosure see instruc tion manual for the appropriate equipment Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equip ment REPLACEMENT PROCEDURES 5 03 Parts Replacement General Information The parts replacement procedures described in this manual except for external Fuse s replacement require that the Power Supply be disassembled Depending on the part to be replaced will determine to what extent the Power Supply must be disassembled NOTES Before removing any electrical connection mark each wire with the connection designation When reassembling this makes sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit Each Subsection is referenced to Section 6 for parts lists and overall detailed drawing A G Disconnect primary power from the source before opening or disassembling the power supply Make sure AC indi
34. or later See Note C28 Capacitor Mounting Bracket Rev F units or later See Note 330k Ohms Resistor Assembly Rev F units or later See Note R17 NOTE Catalog 9 9030 8 6312 8 3390 8 5144 9 5333 8 5576 8 4249 9 7554 9 3210 8 3391 9 5545 Location shown is for current product offering Refer to Section 6 07 for units retrofitted with Pilot Resistor Circuit A 02394 Manual 0 2604 6 5 PARTS LISTS 6 07 Base Assembly Replacement Parts Item Qty AND WN 13 14 15 16 17 FM M Description Base Caster 5 Diameter Wheel 8 Diameter Axle Retaining E Ring 1 2 Diameter Shaft Mat Inductor Base DC Inductor Assembly 29 KVA Transformer Main Contactor Assembly Capacitor Connection 1 1 4 Strain Relief Thermostat Assembly Replacement Kit Includes Thermostat Normally Closed Opens at 115 C Tie Wraps EMC Filter PC Board Assembly Bracket Mounting Filter PCB Pilot Resistor Retrofit Kit Includes Reference T1 W1 W2 C32 Catalog 9 6657 8 5578 8 5579 9 1243 9 5539 9 6662 8 6145 8 6670 9 1244 8 3263 9 3164 TS1 TS4 TS5 9 7013 Resistor Air Cooled 4 5 Ohm Power Rib Rev F units or later R16 Resistor 2 2 Ohm Adjustable Rev F units or later Support Pilot Resistor Mounting Rev F units or later See NOTE below for the following 18 19 2
35. sO L3 13 1 i2 A A 250 VAC LINE 2 AI A 288 Ni RZ 388 415 B BI 195 468 8 B2 245 DNE o0 79 190 SAFETY C C2 122 F GND sO 14 11 D D2 16 39 Di Di 28 D2 D2 33 1 2 26 13 328VDC G G 328VDC GND Art A 02657 2 3 4 3 APPENDIX A 20 Manual 0 2604 NOTE System Schematic for units with the letter on the data tag Z 8 S 10 COMPONENTS LOCATION ci 6 IUF KV 182 c7 10 S6QUF 45 VDC 143 cuz 180 488VDC 183 13 14 I5UF KV C15 17 19 21 2 2NF 3 184 CI6 18 20 22 4 7 3KV 185 C23 3BAUF 48 VDC 1861 C28 4UF 378VDC 71 C28 2 2NF 3 186 c3a 4 7 186 c32 400VAC IC3 01 3 5 888 REV 21 32 4 8 158A 800 STR 1821 07 10 70 200 5 STR 185 01 14 70 600 20055 STR 41 FI FUSE IBA 25 VAC MOTOR C2 STARTER F2 FUSE 25 VAC CONTROL I IC21 INDI RED 125 NEON INDICATOR ul 4 TURN SUPPRESSION COIL 841 2 MAIN INDUCTOR 2 SECTIONS 2 MOTOR CONTROL CONTACTOR 25A 2 POLE 62 53 M2 FAN MOTOR 238VAC 58 68 HZ C3 2 3 4
36. second delay After the 1 2 second delay the Logic PCB Manual 0 2604 removes the PWM enable signal This1 2 second delay allows time for the Switching Control PCB toramp the output current down until the arc goes out Units with Logic Control PCB 19x1247 or 19x1360 reo AE or earlier The Main Contactor will also shut off at the end of the 1 2 second delay Units with Logic Control PCB 19x1360 reo AF or later The Main Contactor will stay ON until post flow is complete Post flow timer initiated at removal of the START signal keeps the plasma and secondary gases flowing for a period of time The post flow time is selectable from 5 to 40 seconds using DIP switch SWA so gas is immediately available during the selected time to restart the arc without waiting for preflow For more information on setting DIP switch SW4 refer to the Operating Manual tion 4 07 Optional Power Supply Settings Units with Logic Control PCB 19x1360 reo AF or later The Main Contactor is kept ON during post flow time If the time between cuts is less than the post flow time the Main Contactor will not cycle ON and OFF This will extend the life of the Main Contactor It may be necessary to select a longer post flow time to reduce Main Contactor cycling between cuts F LED Current Control PC Board The LED Current Control PC Board contains the se quence status LED indicators and the front panel current control pot 43 TROUBLES
37. the Power Sup ply Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other Subassemblies of this unit Evidence of unauthorized repairs may void the fac tory warranty 5 02 Anti Static Handling Procedures A General Em CAUTION PC boards can be irreparably damaged by improper handling due to electrostatic discharge ESD Replacement PC boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping Included with each replacement board is a ground strap to prevent static damage during installation GS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC board from its protective enclosure Disconnect primary power to the system before dis assembling the torch torch leads or power supply enclosure Do not operate the equipment or test equipment under power while wearing the grounding wrist strap wa cO ha i Manual 0 2604 B Procedure 5 1 1 10 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Unroll the rest of the band and peel the liner from the copper foil at the opposite end Attach the copper foil to a convenient and exposed electrical ground Connect the equipment primary cable ground to the same electrical
38. to possible circuit s 2 Determine symptom and isolate to defective assem bly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type 3 Locate your symptom in the appropriate Sub Section TROUBLESHOOTING Check the causes easiest listed first for the symptom Check the remedies listed for each cause 6 Repair as needed being sure to verify that unit is fully operational after any repairs NOTE Many signals are transferred between Printed Cir cuit Board Assemblies on Ribbon Cables If these cables become faulty they can then cause various problems Do not forget about these cables when troubleshooting No front panel LED indicators ON Fan not operating 1 No primary power Refer to symptoms C and D also a Check for proper three phase power at input terminal board 2 Faulty ON OFF switch SW1 a Disconnect primary power Check each sec tion for continuity Replace switch if necessary 3 Faulty voltage selection board a Refer to Section 4 05 A Voltage Selection PC Board Check Replace Voltage Selection PC Board if necessary AC indicator ON Fan not operating 1 Parallel cable not connected Slave Power Supply a Install Parallel Cable 2 No ENABLE to Slave Power Supply a Refer to Section 4 05 T Isolation PCB and Par allel Cable Interface 3 Blown fuse F1 or F2 a Check and replace fuse if ne
39. voltage on the tip exceed ing 220 volts PWM enable LED D9 is on for 3 seconds then OFF No pilot 1 START LED is ON for preflow time then PWM Enable signal LED D9 comes ON for3 seconds Both LEDs then go OFF a Pilot must start in 3 seconds after DC comes ON Both pilot enable U15 2 and tip voltage U27 14 signals must be high within 3 sec onds If the spark gap in Arc Starter Box is firing during the 3 seconds check for wrong pilotresistor setting refer to Master Power Sup ply Service Manual Section 4 05 S Pilot Resis tor Adjustment bad torch parts or open con nection in the torch leads Manual 0 2604 4 13 Pilot starts but Main Contactor W1 or W2 and PWM enable signal LED D9 shuts off immediately upon arc 1 PWM Enable signal LED D9 shuts OFF at arc transfer a Current Control signal DEMAND greater than 10 vdc Measure for 10 vdc on the Switching Control PC Board from TP1 ground to Front Panel CURRENT Control J10 15 or to the Remote Current Control J7 18 see NOTE NOTE Measure the voltage while attempting to cut as the voltage may be correct prior to cutting If voltage exceeds 10 vdc may be momentarily perform checks at Section 4 05 K Steps 2 and 3 Shorted allows no current control output exceeds 175A over current shutdown Signal at J3 21 goes low turning the START signal OFF This happens very fast and is difficult to see Best way is to check O1 with an o
40. 0 11 12 13 14 15 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CON TAINERS WHICH HAVE HELD COMBUSTIBLES ob tainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 MENDED SAFE PRACTICES FOR THE PREPARA TI
41. 0 45 1917 n High sets Remote 1 1 1 1 me we jus n V 1J3 27 Slave is On MEME Start to Slave J70 20 127 4 6 Start to Slave Start Stop J1 19 46 J15 24 Start from Remote L TB2 or CNC 14 V 8 5 v i J3 9 PWM Enable J1 18 47 J15 25 OPTO Las 41 18 23 PWM Enable 2 I I Switching Control PCB 20 ma 47 16 145 J15 30 i Current i J10 23 Source i I Y V1 i J7 8 1146 115 31 15 v r J10 9 Parallel Cable Installed I LL 415 v J70 3 143 14714 po 36 1715 26 Reg nx J70 1 i u t J10 27 Slave is On H g I CSR 115 27 0 10 v Display J70 6 125 7 1 1 50 From Slave E J70 8 i Analog Opto 3 J15 3 Display signal to Remote E 030v LES 0 10 v Analog Opto Y to Slavel S To PWM Demand 70 16 103 50 11 103 N 14V 0V 14 TB2 1 2 ES Enable J50 10 au Y 22 Relay 9 x 102 Manual 0 2604 A 17 3 3 to 10 v Demand from Remote or Front Panel To Enable SW TB2 or Remote A 02035 APPENDIX APPENDIX 13 SYSTEM SCHEMATIC or Earlier 2 3 4 NEG DIODE HEATSINK 84 1841 peut D7 METAL
42. 0 21 1 1 1 4 mfd Capacitor For Rev E units earlier Capacitor Mounting Bracket For units or earlier 330k Ohms Resistor Assembly For Rev E units or earlier PH Contactor For Rev units or earlier NOTE R21 R22 C28 R17 PCR 9 4541 9 4553 7 8912 9 3959 8 1361 9 4554 9 3210 8 3391 9 5545 9 7554 Location shown is for Power Supplies retrofitted with Pilot Resistor Circuit Refer to Section 6 06 for location of parts in current product PARTS LISTS 6 6 Manual 0 2604 02656 Manual 0 2604 6 7 PARTS LISTS 6 08 Upper Chassis Replacement Parts Item 1 2 Description Reference Panel Upper Chassis Gauge Power Driver PC Board Assembly Includes Thermstrate Transistor Refer to Section 6 09 Item 7 Switching Transistor IGBT Refer to Section 6 09 Item 8 Power Driver PC Board Assembly PC Board Guide With 16mm Screw Auxiliary Transformer Assembly Capacitor 300mfd 400VDC Capacitor Mounting Clamp 1 3 4 Diameter Fuse Holder For 1 4 x 1 Fuse Fuse 5A 250V F2 Fuse Holder Buss HPS Fuse 10A 250V F1 PC Board Support Assembly Logic PC Board Assembly Switching Control PC Board Bracket Access Mounting Panel Divider All parts in kit 57 3360 must be replaced at the same time PARTS LISTS 6 8 Catalog 9 6658 7 3360 9 1406 Not Available Sep
43. 0 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 1 6 Date January 27 2004 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 The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive Euro pean Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used SO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 appli
44. 0 and J2 1 on the Logic PC Board NOTE Refer to Appendix 5 for 120 VAC Circuit Diagram If not present replace the Logic PC Board If 120 VAC is present check to see if it is at the PCR coil If voltage is present the contactor is faulty LL High Voltage is present For the Arc Starter Box confirm that the OCV measured at the torch bulkhead is also present at E1 and E2 on the Arc Starter PC Board If not the torch leads extension may be open Check for 24 VAC from J1 1 to J1 3 on the Arc Starter PC Board see NOTE NOTE There is a red LED indicator on the Arc Starter Box PC Board that will be ON when the 24 VAC is present If both OCV and 24 VAC are present and no sparks are being generated the Arc Starter PC Board is faulty The 24 VAC comes from Transformer T3 through Fuse F3 passes through Filter FL1 and out connector J14 5 and J14 8 If the 24 VAC is not present at J14 Fuse F3 is the most likely cause Transformer and Filter FL1 are other possibilities If the Fuse is blown remove power disconnect J14 re place the Fuse 1A 250V and turn ON power If the fuse blows again Filter FL1 may be shorted If the Fuse does not blow then reconnect 14 If the fuse blows again the Arc Starter PCB is faulty or there is a short in the wiring between the Master Power Supply and the Arc Starter Box Manual 0 2604 K Current Control Display and CSD Checks NOTE Refer to Appendix 11 for Current Con
45. 06 1 4 50 ft 15 2 m 9 6907 1 4 75 ft 22 9 m 9 6908 1 4 100 ft 30 5 m 9 6886 1 4 115 ft 35 1 m 9 6857 1 4 125 ft 38 1 m 9 6909 1 4 F Plasma or Secondary Gas Hose 4 10 ft 3 0 m 9 6910 1 2 15 ft 4 6 m 9 6911 1 2 20 ft 6 1 m 9 6912 1 2 25 ft 7 6 m 9 6913 1 2 30 ft 9 1 m 9 6914 1 2 35 ft 10 7 m 9 6915 1 2 40 ft 12 2 m 9 6916 1 2 50 ft 15 2 m 9 6917 1 2 75 ft 22 9 m 9 6918 1 2 100 ft 30 5 m 9 6919 1 2 125 ft 38 1 9 6920 1 2 Coolant Hose 8 35 ft 10 7 m 9 6921 7 8 50 ft 15 2 m 9 6922 7 8 75 ft 22 9 m 9 6923 7 8 100 ft 30 5 9 6924 7 8 115 ft 35 1 9 6858 7 8 125 ft 38 1 m 9 6925 7 8 Torch Cable 25 ft 7 6 m 9 6892 3 4 35 ft 10 7 m 9 6926 3 4 50 ft 15 2 m 9 6927 3 4 75 ft 22 9 m 9 6928 3 4 100 ft 30 5 m 9 6896 3 4 115 ft 85 1 m 9 6856 3 4 125 ft 38 1 m 9 6929 3 4 APPENDIX Work Cable Description Cable Hose Diameter 25 ft 7 6 m 35 ft 10 7 m 50 ft 15 2 m 75 ft 22 9 m 100 ft 30 5 m 115 ft 85 1 m 125 ft 38 1 m Parallel Cable 8 f Parallel Cable 30 Pre Flow Gas Hose 4 Secondary RAS amp Plasma RAS Hoses Pre Flow RAS Hose A 12 25 ft 7 6 m 30 ft 9 1 m 50 ft 15 2 m 10 ft 3 0 m 15 ft 4 6 m 20 ft 6 1 m 25 ft 7 6 m 30 ft 9 1 m 85 ft 10 7 m 40 ft 12 2 m 50 ft 15 2 m 75 ft 22 9 m 100 ft 30 5 m 5ft 1 5 m 10 ft 3 0 m 15 ft 4 6 m 20 ft 6 1 m 25 ft 7 6 m 30 ft 9 1 m 8
46. 1 113 i J35 19 126 tt Mal vap Cas D2N 4 JI 1 L COMM 159 159 As 2 4 5 Ji 8 p 54 9382 J38 3 60 68 L z 112 18 21275 1 m 152 IMAIN HEATSINK n T54 t nn 8 PRIMARY CONNECTIONS Szxezs SCHEMA SYSTEM VOLTAGES 42X925 SCHEMATIC 14x202 Er 388 415 L3 aaay 45y PRI VOLTS 52 68HZ ONLY 388 415 21 22 1 c0 500 LINE 1 0 OT SEC VOLTS Y Yz 250 VAC LINE 2 LZ 208 x2 60 95 LINE 3 SA 7 wa 129 GND 9 9j Li s 6 29 28 33 2 o 13 3z vpt 32 vDt Art A 04884 p 3 4 5 4 APPENDIX A 22 Manual 0 2604 12 NOTE System Schematic for units with AG on the data tag COMPONENTS LOCATION CI 6 Q 1UF 182 C7 10 SSQUF 450 Cin i2 1QUF 40BVDC 183 13 14 Q IGUF IKV 144 CI5 17 19 21 2 2 184 8 20 22 4 7 185 C23 30QUF 400 185 c28 4UF 3780VDC A7 c29 2 2 BB c30 4 7NF 186 2 SUF 4BBVAC D1 3 5 150 800 REV 1421 D2 4 6 150A STR 182 D7 18 7BA 6BQV 200 5 STR 185 14 7BA 680 200 5 STR 144 ARC FI FUSE 10 250 MOTOR 2 STARTER F2 FUSE 5A 25 CONTROL 2 BOX INDI RED 125 NEON INDICATOR LI 4 TURN SUPPRESSION COIL 184 L2 MAIN INDUCT
47. 1071 14 071 13 J71 10 71 111 al J54 9 J54 8 1 J54 2 J54 1 YN MN MN Parallel Cable 1 4 7 4 15 4 015 3 15 2 J15 1 Slave Power Supply NZ J74 J7 2 J7 17 J7 18 49 6 02034 11 6 gt M Demand to Slave Manual 0 2604 Shunt Amp PCB J11 5K 2279 5 Switching Control PCB to PWM Circuits I 8 3 10 VDC l 15 APPENDIX APPENDIX 12 PARALLEL INTERFACE DIAGRAM ee 2 Slave Power Supply Wee pe ye ye ee TEE Logic Master Power Supply 123 i 124 4 8 This is Slave 44 9 120 J15 35 x lt i 5 5 F 4 10 18 29 This is Slave i 119 gi aa SR lt lt Isolation 15 V 14 4 3 gt Slave is 1 20 45 181 it 1 16 43 915 15 J54 121 132 1420 DIVAN 93 27 Slave is On hi lt EB 1 4 6 Start to Slave Start Stop 1 19 46 J15 24 J54 3 133 J71 4 t r J3 9 PWM Enable 01 18 1 47 15 25 J5441 134 J71 5 t Y i I
48. 28 V RMS 20 JOULES 182 PCR PILOT CONTROL 48A 3 POLE IDB A71 B 389 558V 184 Al OHM 183 BHUNT WORK n2 3 138 OHM iaaw 41 4 6 8 19 8 1 OHM 10W 184 10 WIRE RIBBON CABLE 1 SHUNT AMP PCB A por NEIGE eh 28 3 OHM REMOTE DEMAND J7 18 1321 lumi R14 22K OHM 1 IBW 1861 SIG 17 17 33 4 5 OHM IKW PILOT 1871 OUTPUT SiG 17 2 134 piste RI7 OHM G 5W 7 1 TO MASTER SE 315 3 RIS IK OHM 1 IW 861 4 RIB 188 OHM 128W 186 PARALLEL CABLE 37 20 36 26 R21 22 2 2 OHM IKW PILOT 87 INSTALLED SIG 1718 37 JIa 27 sw ON OFF DPST ROCKER SW DPSTI C21 SHUNT 250A 100 1871 28 CURRENT ire 1451 n MAIN TRANSFORMER 3BKVA 3 PHASE SOURCE Loz s 146 2 NSVAC PRI 25 2VCT SEC C4 C 51 754 755 T TEMP SW 120 DEG C 21 TS2 PTC 6 DEG C MAIN HEATSINK TEMP E21 1350 a 821 458 1 1931 WI W2 MAIN CONTACTOR 75A POLE IC3 AI BI ENABLE J15 32 lt SWI 1 amp 2 OFF FOR MERLIN 6000 18 WIRE RIBBON CABLE 34 WIRE RIBBON CABLE me SW 1 amp 2 ON FOR MERLIN 8889GST 4 EXBLE ANI PLAGETINTEBUBEE PIN 4 TEMPERATURE LED GND WITH CABLE CONNECTED 2 DE CE 5 SHUNT AMP OUTPUT 6 14 UNFILTERED 8 PW ENABLE I5VDC ALL OTHER GND 21 OVERCURRENT SHUTDOWN 23 PWM ENABLE2 P DRAGING OTE y o N M PEB COMMON 27 SLAVE ON D EARTH OR UTILITY GROUND 28 SLAVE UNIT T CHASSIS GROUN
49. 298 5711 or your local distributor if you have any questions m n l Date January 27 2004 1 1 amp 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 Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the in formation regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors
50. 5 Dia Capacitor 0 15 uf 630V Poly Hi Current 9 1408 Suppression Coil Assembly 9 1409 Bracket Diode Lead 8 6316 Assembly Heatsink Suppression PC Board 9 1410 Support Capacitor Bracket PC Board 8 6315 Resistor 100 Ohm 100W Style J 9 1405 Internal Wire Assembly Package 9 6661 Resistor 3k Ohm 100W Style J 8 6677 Plate Negative Diode 8 6675 Plate Positive Diode 8 6674 Diode Suppression PC Board Assembly 8 6155 150 Amp REV Diode Replacement Kit Includes 8 6153 Diode 150 Amp 800V REV Thermal Interface Pad 1 06 Dia 150 Amp STR Diode Replacement Kit Includes 8 6152 Diode 150 Amp 800V STR Thermal Interface Pad 1 06 Dia Assembly PTC Resistor TS2 8 4523 Bracket Transistor Coil 8 6676 Harness Assembly Transistor 8 6313 Standoff 3 8 Hex Nylon 8 5147 Washer Fiber Shoulder 8 6678 Shunt 250A 100 mV 9 4392 Shunt Amp PC Board Assembly Not Available Separately Included in Kit 7 3360 All parts in this kit must be replaced at the same time PARTS LISTS Manual 0 2604 x ao N x0 0 Sa GS Gs IS fy X lo A A FE T Y AE EN Z L dl Le 31 Part of 7 3360 Kit Art A 06759 Driver jIGBT PC Board Suppressor IPC Board TS S m l lt k gt Shunt Amp Thermal lt e PC Board
51. 5 ft 10 7 m 40 ft 12 2 m 5ft 1 5m 10 ft 3 0 15 ft 4 6 m 20 ft 6 1 m 25 ft 7 6 m 30 ft 9 1 m 35 ft 10 7 m 40 ft 12 2 m Manual 0 2604 APPENDIX 10 A LADDER DIAGRAM 15 vdc Rev AE or Earlier Logic Control PC Board START STOP CNC SWITCH RECOGNITION START INDICATOR W CONTACTOR CONTACTOR CONTROL TS3 TS4 TS5 TS1 152 T CONTACTOR DISABLE Only after main con tactor initially closes SENSE BRIDGE VOLTAGE lt 60VDC To disable this circuit for troubleshooting short test points together OVER CURRENT SHUTDOWN From Switching Control HF AND PILOT CONTACTOR TORCH VOLTAGE 23 CSR from Current Control Board EE C a E RR RR RR RR 1 28 VAC ALL PC BOARD INPUTS CENTER TAP ACTIVE LOW EXCEPT J1 24 AND J1 21 C REFERENCES J1 CONNECTOR O REFERENCES J3 CONNECTOR A 01534 Manual 0 2604 A 13 APPENDIX APPENDIX 10 B LADDER DIAGRAM 15 vdc Rev AF or Later Logic Control PC Board CONTACTOR START STOP CNC OFF DELAY SWITCH RECOGNITION START INDICATOR PWM CONTROL TS3 TS4 TS5 751 T S2 eel ool el AN m PWM DISABLE Only after main con tactor initially closes SENSE BRIDGE VOLTAGE lt 60VDC To disable this circuit for troubleshooting short test points together OVER CURRENT SHUTDOWN From Switching Control HF AND PILOT CONTACTOR TORCH VOLTAGE 23 CSR from Curren
52. Board An LED on the Logic PC Board will be ON when the enable signal is present Depending on the Logic PCB in the unit the PWM Enable signal LED D9 is labeled as follows Units with Logic Control 19x1247 or 19x1360 reo AE or earlier LED D9 is labeled W ON Units with Logic Control 19x1360 rev AF or later LED D9 is labeled PWM ON The possible symptoms in this subsection are Main Contactor W1 or W2 do not come ON PWMenable LED D9 indicator is ON momen tarily less then 1 2 second then OFF PWM enable LED 09 is on for 3 seconds then OFF No pilot Pilot starts but Main Contactor W1 or W2 and PWM enable signal LED D9 shuts off imme diately upon arc transfer The symptom must be carefully considered to determine where to look for the fault Listed under each symptom are a number of tests that need to be performed to isolate the problem Locate the symptom and proceed to that symptom area Main Contactor W1 or W2 do not come ON 1 READY or RUN LED on Logic PC Board is OFF a Unitovertemperature TEMP LED red input J1 9 will be greater than 7 volts b Logic PCB is Faulty Manual 0 2604 2 START LED on Logic PC Board is never ON not even momentarily a START signal active low not getting to 1 19 Check wiring between Logic PCB or J15 re mote connector Check Isolation PC Board and Parallel Cable refer to Section 4 05 L b Logic PCB faulty b Ifspark gap is not
53. D 31 DEMAND TO LOGIC EL y ALL EVEN 8 34 GND 121 x DRAG K5 SENSE PILOT 43 nS L 1 4 STAVE SON aee 1817 21 4 LOGIC J a8 146 15 LED STAR 1 4 1471 2 16 VOLTAGE SELECTION ot 17 18 SWITCHING CONTROL Jn SHUNT AMP PCB 312 13 MAIN TRANSFORMER E 115 PARALLEL CABLE 315 36 118 CONTROL TRANSFORMER T2 SLAVE UNIT J4 9 1201 J5 35 126 27 DRIVER 138 MAIN HEATSINK 339 FAN MOTOR 147 FAN MOTOR CAPACITOR C32 158 SWITCHING CONTROL REV REVISIONS BY DATE REV REVISIONS DATE THERMAL DYNAMICS rare 2 p assy VEST LEBANON NH 03784 7686 pan 527 CORPORATION 16031 298 571 8143 HAS 48283 INFORMATION PROPRIETARY TO THERMAL DYNAMICS DATE SUPERSEDED CORPORATION NOT FOR RELEASE OR DISTRIBUTION 88 25 87 ay Nore ENT REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE N D DENERS OMS VAW CAPACITORS ARE IN MICROFARADSIUF lox Tes o 1 MERLIN 6000 EMC 4 SLAVE SCHEMATIC 42x36 6 7 8 S I Art A 02657 Manual 0 2604 A 21 APPENDIX APPENDIX 15 SYSTEM SCHEMATIC Unit Rev
54. E 81 121 251 135 061 36 17 LV HV Js dz 26 22 Q7 VOLT SEL PCB MONITORS INPUT VOLTAGE AND CLOSES EITHER LV OR HV CONTACTS WHEN POWER IS TURNED ON TO SELECT PROPER TAPS ON SECONDARY 1621 313 J13 3 MB iB 24 12 J1 24 16 5 1231 1231 8 L K2 JB 14 1241 5 ZI 2 16 28 1241 120VAC w 1H 3 26 21 25 25 VARS ac 213 1 201 J6 18 JB 19 26 2 H 14VAC 13 AN 81 1 COMM i a 59 1591 3 tempor z 1841 38 2 J38 3 160 1601 8 2 J12 15 V i m TS2 HEATSINK D TS TS4 mn TH TH Pj E PRIMARY CONNECTIONS T EMI FILTER PCB SYSTE OL TAGES 42X925 SCHEMATIC Y M VOL 14x202 PCB 8X PASE L3 13 INPUT BUS BAR PRI VOLTS 2 ONLY VOLTAGE CONNECTIONS 388 415 J5 Zi 22 MER PE 500 LINE 1 SEC VOLTS Y2 mo 309 2 L3 13 0 12 A A 258 VAC LINE 2 L2 AI Al 20a xrox2 8 388 415 B B 195 460 2 245 LINE 3 N D 7 c ct wa SAFETY CE E 2 28 GND 59 4 ti ca D D2 Boc 3 DI DI 28 D2 D2 33 2 E E 26 32 VDC G G 328vDC A 01727 APPENDIX A 1 8 Manual 0 2604 NOTE System Schematic for units with the letter E or earlier the data tag
55. HOOTING 4 04 Troubleshooting Guide Troubleshooting and Repair Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques e Advanced Troubleshooting NOTE For basic troubleshooting and parts replacement procedures refer to Merlin 6000 Slave Power Sup ply Operating Manual 0 2603 The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live mea surements It is helpful for solving many of the common problems that can arise with the Merlin 6000 Slave Power Supply If major complex subassemblies are faulty the unit must be returned to an authorized service center for repair Follow all instructions as listed and complete each in the order presented Specific test procedures and LED status identification tables have been grouped together and are referenced by the troubleshooting guide How to use this Guide The following information is a guide to help the Service Technician determine the most likely causes for various symptoms This guide is set up in the following manner 1 Perform operational check s on the equipment to iso late problem
56. IHERMAL DYNAMICS THERMADYNE Company MERLIN 6000 CE Plasma Cutting Slave Power Supply Service Manual September 29 2005 Manual No 0 2604 Read and understand this entire Manual and your employer s safety practices before installing oper ating 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 6000 CE Plasma Cutting Slave Power Supply Service Manual No 0 2604 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 1999 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written per mission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date September 29 2005 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERALINFORMATION Rene ennemi nier 1 1 1 01 Notes Cautions and Warnings 1 1 1 02
57. Important Safety Precautions 2000 000 1 1 1 08 PUDIIGAIONS 1 2 1 04 Note Attention et 1 3 1 05 Precautions De Securite Importantes sse 1 3 1 06 Documents De Reference 44 0100000 1 5 1 07 Declaration of Conformity 200 01000 1 7 1 08 Statement of Warranty su 1 8 SECTION 2 INTRODUCTION eee lave ee soe 2 1 2 01 Scope OF Manual us aaa Kukaqa dundee 2 1 2 02 General Service PhilosoDhy uu uy u u sunsu ennt nnns 2 1 2 03 Service Responsibilities u 2 1 SECTION 3 INTRODUCTION amp DESCRIPTION iii 2 1 3 01 Introd tion E im 2 1 3 02 General Description sir 2 1 3 03 Specifications Design 2 2 2 8 04 Theory Of Operation eadera ree n e 2 2 SECTION 4 TROUBLESHOOTING pete Em 4 1 AOA INTOAUCLION 4 1 4 02 Periodic Inspection amp 4 1 4 03 System Theory sieurs 4 1 4 04 Troubleshooting Guide 4 4 4 05 Test Procedures c ate taie a uem i rm 4 7 SECTION 5 REPLACEMENT PROCEDURES rettet etre retener der rp Ent n eren E 5 1 5 0 5 1 5 02 Anti Static Handling 5 1 5 03 Parts
58. ON FOR WELDING AND CUTTING OF CONTAIN ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Dans ce manuel les mots note Avertissement attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me Date January 27 2004 ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL SOUDAGE L ARC AU JET DE PLASMA PEUVENT PRESENTER DES RISQUES ET DES DANGERS DE SANTE Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction pr
59. OR i2 SECTIONS 5 2 MOTOR CONTROL 25 2 POLE IC2 C3 2 FAN MOTOR 23QVAC 5050 HZ MOVI 2 3 420 v RMS 20 JOULES 182 p PCR PILOT CONTROL 40 3 POLE IDB A7 300 550 184 RI OHM 183 R2 3 122 OHM 1 144 R4 6 8 10 9 1 OHM 10 184 AUS RES R5 7 9 1 S OHM 10 185 Riz OHM IAS OHM REMOTE DEMAND qi 22K OHM 1 10W BB SIG FIG 4 5 OHM IKW PILOT 187 171 OUTPUT SIG 2 RI7 330K OHM 2 5W 1 7 MASTER 25 RIS IK OHM 1 1W 186 154 Rig 199 OHM 185 PARALLEL CABLE J15 26 R21 22 2 2 OHM IKW PILOT 187 INSTALLED 516 J15 27 sw ON OFF DPST ROCKER SW IDPST IC2 SHUNT 250A 100 187 z mA CURRENT Jis 30 TI MAIN TRANSFORMER 30 3 PHASE IA SOURCE pee T2 NSVAC PRI 25 2VCT SEC 4 C SN PE 51 754 755 TI TEMP SW 120 DEG IE2 52 60 DEG C MAIN HEATSINK TEMP IEZ 118733 WI W2 MAIN CONTACTOR 75A POLE 1 ENABLE J15 32 SWI 1 amp 2 OFF FOR MERLIN 68000 10 WIRE RIBBON CABLE 34 WIRE RIBBON CABLE el SWI 1 amp 2 GEOR CME REIN BEHADST PIN 1 CABLE IN PLACE INTERLOCK PIN X TEMPERATURE LED GND WITH CABLE CONNECTED 2 5 DR CE S SHUNT AMP DUTPUT B l4VDC UNFILTERED 9 ENABLE 8 I5VDC TR ALL OTHER X END 21 OVERCURRENT SHUTDOWN 55 23 ENABLE2 NOTE 25 DRAGING 4 PCB COMMON DM 4 EARTH OR UTILIT
60. PCB is faulty 2 Current Control The Slave power supply receives its current control signal from the master supply via It s Isolation PCB and The Parallel cable and the Slave s J15 connector Refer to Section 4 05 L Isolation PCB and Parallel In terface The Current Control signal from the Master Unit comes in J15 1 and goes to J7 18 on the Switching Control PCB It should vary between 3 3 to 10 vdc as the Master unit s control is moved from min to max If it does not problem is in the Master unit or Parallel cable If the voltage is correct problem is with Switching PCB Manual 0 2604 3 Remote AMPS Display 4 15 NOTE Refer to Appendix 11 for Current Control and Dis play Circuit Diagram The Remote Control RC 6010 AMPS displays the fol lowing Indicates the current control setting before cut ting preview Indicated by the right hand decimal point being ON Indicates the actual current while cutting e three decimals on indicates the remote is receiving the Corner Slowdown signal CSD Before cutting preview and with the three deci mals ON the display indicates the CSD poten tiometer setting instead of the main current control The Remote Control display full scale is 150A if one Power Supply is used or 300A if two Master and Slave are used The following describes the flow of the SLAVE IS ON signal through the system When the Slave Power Supply is present and turne
61. Replacement 1 2 Remove the Left Side Panel per Section 5 04 A Loosen the two screws of the Work Cable strain relief securing the Work Cable at the Front Panel Remove the nut under the Horizontal Chassis Panel securing the Work Cable connection to the Shunt Assembly Pull the Work Cable from the unit Install the replacement Work Cable by reversing the above procedure 5 05 Access Panel Parts Replacement NOTE Refer to Section 6 04 Access Panel Replacement Parts for parts list and overall detail drawing A ON OFF Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the ON OFF Switch Disconnect all the wiring to the ON OFF Switch Squeeze the top and bottom of the switch while pulling it out of the Access Panel Install the replacement ON OFF Switch by revers ing the above procedure Manual 0 2604 B LED PC Board Assembly Replacement 1 Unlatch the Access Panel to gain access to the LED PC Board Remove the four screws and washers securing the LED PC Board to the Access Panel Disconnect the connector at J5 of the LED PC Board Install the replacement LED PC Board by revers ing the above procedure C Access Panel Replacement 1 2 Remove the Right Side Panel per Section 5 04 A Remove the following components from the Ac cess Panel e ON OFF Switch per paragraph A above LED PC Board per paragraph B above Removethe four screws secur
62. Replacement General Information 5 2 5 04 External Parts 5 2 5 05 Access Panel Parts 5 3 5 06 Front Panel Chassis Parts 5 8 5 07 Rear Panel Parts Replacement 24420 400 5 4 5 08 Base Assembly Parts Replacement 5 5 5 09 Upper Chassis Parts Replacement 5 6 5 10 Main Heatsink Assembly Parts Replacement 5 10 TABLE OF CONTENTS Continued SECTION 6 PARTS 6 1 6 01 njirore eR 6 1 6 02 Ordering Information us 6 1 6 03 External Power Supply Replacement Parts List 6 2 6 04 Access Panel Replacement Parts 6 3 6 05 Front Panel Chassis Replacement Parts 6 4 6 06 Rear Panel Replacement Parts 6 5 6 07 Base Assembly Replacement Parts 6 6 6 08 Upper Chassis Replacement Parts 6 8 6 09 Main Heatsink Assembly Replacement Parts 6 10 APPENDIX 1 INPU
63. S LISTS 6 03 External Power Supply Replacement Parts List Item Qty 1 1 2 1 3 1 4 1 PARTS LISTS Description Catalog Complete CE Merlin 6000 Slave Power Supply w Running Gear amp Work Cable 3 6801 Work Cable with Ring Lug 25 ft 7 6 m Panel Top Panel Side With Overlay Panel L H Side With Overlay A 02391 6 2 9 6892 9 7752 9 6651 9 6652 Manual 0 2604 6 04 Access Panel Replacement Parts Item Qty Description Reference Catalog 1 Access Panel Assembly Includes 1 1 Access Panel With Overlay 9 9027 2 1 ON OFF Rocker Switch DPST SW1 8 3258 3 1 LED PC Board Assembly 9 9028 A 02392 Manual 0 2604 6 3 PARTS LISTS 6 05 Front Panel Chassis Replacement Parts Item Qty 1 1 2 1 3 1 4 1 5 1 6 1 PARTS LISTS Description Reference Front Panel With Overlay Strain Relief Strain Relief Horizontal Chassis Panel Resistor 8 ohm Resistor Mounting Bracket Kit A 02393 6 4 Catalog 9 9029 9 2179 8 6307 9 6655 9 3431 8 4234 Manual 0 2604 6 06 Rear Panel Replacement Parts Item Qty 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 Description Reference Rear Panel Fan 16 Axial Relay 25 amp 120 AC MC1 MC2 Voltage Selection PC Board P C Board Supoort Bracket Heatsink Support Strain Relief For 10 Stranded Wire 3 PH Contactor Rev F units or later See Note PCR Capacitor Rev F units
64. ST MES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la Na tional Fire Protection Association Batterymarch Park Quincy MA 02269 GENERAL INFORMATION 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupr s de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 55
65. START do not come ON not even momentarily No Pilot Arc 1 Master Power Supply not receiving START signal a Refer to Master Power Supply Service Manual 2 Slave Power Supply not receiving START signal a Master Power Supply starts but Slave does not Verify that the Slave Power Supply Logic PCB READY and RUN LEDs are ON e Ifthe LEDs are ON refer to section 4 05 L Iso lation and Parallel Cable Interface e If the LEDs are OFF refer to Section 4 05 G Power Supply Start Circuit TROUBLESHOOTING G Depending on the Logic Control PCB installed refer to TROUBLESHOOTING one of the following symptoms For Logic Control PCB 19x1247 or 19x1360 rev AE or Earlier After Pre Flow DC indicator OFF Logic Control PCB START LED is ON for preflow W ON LED only ON momentarily less than 1 2 second START LED goes OFF same time as W ON LED No Pilot Arc For Logic Control PCB 19x1360 reo AF or Later After Pre Flow DC indicator OFF Logic Control PCB START LED is ON for preflow PWM ON LED only ON momentarily less than 1 2 second START LED goes OFF same time as PWM ON LED No Pilot Arc 1 Shorted Torch or Faulty 01 a Isolate problem between torch and O1 Remove wire 7 from W7 faston tab on Logic PCB Insulate end of wire may have 300 vdc on it before applying power to unit IfSTART LED now stays ON for 3 seconds after preflow then fault is a short between torch tip and electrode circuits torch head leads arc st
66. T WIRING REQUIREMENTS sui A 1 APPENDIX 2 TYPICAL MECHANIZED SYSTEM WORK AND GROUND CABLE 2 APPENDIX 3 PARALLEL GABLE u u uuu oce da xau sss A 3 APPENDIX 4 ROUTINE MAINTENANCE SCHEDULE sisi A 4 APPENDIX 5 MERLIN 6000 SLAVE POWER SUPPLY 120 VAC CIRCUIT DIAGRAM A 5 APPENDIX 6 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM For Merlin 6000 A 6 APPENDIX 7 QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES For Merlin 6000 System A 8 APPENDIX 8 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM For Merlin 6000GST System A 10 APPENDIX 9 QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES For Merlin 6000GST A 12 APPENDIX 10 A LADDER DIAGRAM 15 vdc Rev or Earlier Logic Control PC A 13 APPENDIX 10 B LADDER DIAGRAM 15 vdc Rev AF or Later Logic A 14 APPENDIX 11 CURRENT CONTROL AND DISPLAY A 15 APPENDIX 12 PARALLEL INTERFACE A 16 TABLE OF CONTENTS Continued APPENDIX 13 SYSTEM SCHEMATIC Rev E or A 18 APPENDIX 14 SYSTEM SCHEMATIC Rev A
67. TB2 the signal goes to the Logic atJ1 19 and J1 18 This turns ON the START LED D8 Units with Logic Control PCB 19x1247 or 19x1360 rev AE or earlier Logic Control PCB W ON LED D9 and the Main Contactor W1 or W2 turn ON at the end of preflow Units with Logic Control PCB 19x1360 rev AF or later Logic Control PCB START LED and the Main Contactor W1 or W2 turn ON at the begin ning of preflow At the end of preflow the PWM ON LED D9 comes ON After preflow and at the same time that the Master Power Supply Main Contactor W comes ON the START TO SLAVE signal leaves the Master Power Supply Logic PCB at J4 6 and J4 5 e The signal then goes through the Isolation PCB and Parallel Cable to the Slave Power Supply J15 24 and J15 25 e Inside the Slave Power Supply the signal contin ues to the Logic Control PCB The signal then goes to J1 19 and J1 18 on the Logic Control PCB turning ON the START LED D18 e If the Master Power Supply starts but the Slave Power Supply does not get a START signal START LED is OFF refer to Section 4 05 L Iso lation PCB and Parallel Cable Checks e Ifthe START LED is ON even momentarily go to Section 4 05 I PWM Enable Signal Circuit If Slave Power Supply does not start do the following The Slave Power Supply has no coolant and requires the THIS IS SLAVE signal to disable the coolant in put A jumper in the Parallel Cable from J15 35 to J15 36 provides the THIS IS
68. Ther 5 09 Upper Chassis Parts Replacement NOTE Refer to Section 6 08 Upper Chassis Replacement Parts for parts list and overall detail drawing A Power Driver PC Board Kit Replacement wmm CAUTION All parts in replacement kit No 7 3360 must be replaced at the same time This kit includes the Power Driver PC Board Shunt Amp PC Board IGBT and a wire harness If any of these parts fail all must be replaced at the same time Failure to replace all parts together may lead to parts failure mostat Assembly stud threads The Kitreplaces the Driver PC Board Shunt Amp PC Board Switching Transistor IGBT Assembly and IGBT wire har ness in the Merlin Series Power Supplies The kit includes an IGBT Suppressor PC Board Kit Contents e Using a torch wrench torque the Thermostat Assembly to 7 in lbs 0 791 Nm Replace any removed tie wrap s Thermal Pad S amp Shunt Amp PC Board Wire Harness Art A 06082 REPLACEMENT PROCEDURES 5 6 Manual 0 2604 The kit also includes Installation Instructions Static Dissipative Bag Grounding Wrist Strap Static Handling Instructions Installation Procedure WARNING Disconnect primary power at the source before as sembling or disassembling power supply torch parts or torch and leads assemblies Opening Enclosure Turn OFF main input power to the Power Supply both at the Power Supply ON OFF switch and at the main power
69. W1A to wire 9 through fuse F2 to wire 10 and T1 Manual 0 2604 Only one of the two contactors should have voltage applied If the red LED indicator D18 on the volt age selection board is lit MC2 should be energized If D18 is not lit MC1 should be energized a Checkthe voltage across the coil on the contactor for approximately 120 VAC If voltage is present replace the contactor If it is not perform the 120 VAC test refer to Section 4 05 A to check for a proper voltage supply from the voltage selection board If correct continue to step 2 to isolate the problem in the return path b With one meter lead on the supply side of the con tactor coil wire for MC1 or wire 4 for MC2 measure to wires 8 9 and 10 to determine where the return circuit is broken On the return path F2 and SW1 A can be measured for continuity En able Relay K1 on the Switching Control PC Board will normally be open when power is OFF Refer to Section 4 05 B for Enable Circuit Checks Diode Check There are fourteen diodes in the main heatsink area including six large 150 amp input rectifier diodes D1 6 and eight small 70 amp diodes snubbing diodes D7 10 and freewheeling diodes D11 14 To measure the resistance of each diode use one of the following 9 Anohmmeter set on the Rx1 or Rx10 scale Digital meter set to the diode function Measure the resistance of each diode in both direc tions The readings should differ by at l
70. WEST LEBANON NH 03784 7682 87 CORPORATION 298 571 INFORMATION PROPRIETARY TO THERMAL DYNAMICS ETE CD CORPORATION NOT FOR RELEASE OR DISTRIBUTION 28 25 97 av NOTE DRAWN REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE IN D DEMERS OHMS LAW 5 CAPACITORS ARE IN MICROFARADSIUF I Tas or 1 MERLIN 6000 EMC SLAVE SCHEMATIC 42X954 N 6 7 8 g 18 01727 Manual 0 2604 19 APPENDIX APPENDIX 14 SYSTEM SCHEMATIC Rev F T NEG 1 DIODE HEATSINK uu METAG BRACKETS D V 1841 1841 i e A Di w2 ci7 1 1 RI2 1991 INPUT 11 121 851 183 1 SUPPRESSION PCB C15 17 18 CB DRIVER PCB 5 N ci6 18 20 22 Di ooo N N N N 14 35 555 R4 5 8 Y I POS 1 DIODE amp MAIN HEATS INK E 1991 C32 m
71. Y GROUND 28 SLAVE UNIT CHASSIS GROUND 31 DEMAND TO LOGIC 15 y ALL EVEN B 34 ARE GND 221 DRAG SENSE PILOT 41 8 143 J1 20 145 dies 31 4 LOGIC 31 8 148 im o 25 LED 1471 J6 VOLTAGE SELECTION PCB LOGIC 37 12 SWITCHING CONTROL a SHUNT 312 3 MAIN TRANSFORMER IT j 45 PARALLEL CABLE TS 315 36 48 CONTROL TRANSFORMER 172 315 35 326 27 DRIVER PCB 138 MAIN HEATSINK 439 FAN MOTOR 447 FAN MOTOR CAPACITOR IC32 455 SWITCHING CONTROL REVISIONS REV REVISIONS PATE THERMAL DYNAMICS pare 2 F assy WEST LEBANON NH 03784 ec seen sas 5225 CORPORATION AB Ec 8143 Has EE INFORMATION PROPRIETARY TO THERMAL DYNAMICS gt CORPORATION NOT FOR RELEASE OR DISTRIBUTION 98 25 97 11729 Li AC eco 101330 HAS a4 UNLESS OTHERWISE SPECF RESISTORS ARE M OHMS 1 49 5X CAPACITORS ARE MICROFARADSIUF MERLIN 6880 g EMC SLAVE SCHEMATIC D DEMERS APP ie 42X964 l Art A 04884 Manual 0 2604 23 APPENDIX APPENDIX 16 SYSTEM SCHEMATIC Unit Rev or later N p
72. Y IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal products shall be as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster Series shall be as follows A maximum of four 4 years from date of sale to an authorized distributor and a maximum of three 3 years from date of sale by such distributor to the Purchaser and with the further limitations on such three 3 year period see chart below The limited warranty period for Cougar and DRAG GUN shall be as follows A maximum of two 2 years from date of sale to an authorized distributor and a maximum of one 1 year from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below Parts XL Plus amp Parts Parts PAK Units Power Supplies CutMaster Series Cougar Drag Gun All Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits
73. act per normal procedures Manual 0 2604 2 03 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities Technician should be prepared to recommend arrangements of components which will provide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Technical Services Department at West Lebanon NH for assistance 1 603 298 5711 This manual may include references to the Power Supplyor Printed Circuit Board PCB Assembly revision letter s Depending on when manufactured the revision letters may besingle or double letters Locate of the revision letter s are as follows Power Supply Revisions There are old style and new style data tags The old style data tag has the revision letter s at the end of the serial number The new style data tag has the revision letter s in an area marked Rev Printed Circuit Board Revisions Revision letter s are located at the end of the PCB Assembly part number 2 1 INTRODUCTION INTRODUCTION 2 2 Manual 0 2604 SECTION 3 INTRODUCTION amp DESCRIPTION 3 01 Introduction 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 Technician with the
74. arately 9 1054 9 4383 9 1300 8 3260 9 2936 8 1025 9 2937 8 1324 9 5333 9 6798 9 6797 9 6659 9 6660 Manual 0 2604 di P d 2 2 J2 Part of 7 3360 Kit lv Si 724850 Kit Driver GBT Wire Harness PC Board Suppressor MS PC Board lt E i IGBT gt E Shunt Amp i Thermal lt uc Art A 06796 NOTE Kit 7 3360 includes several parts If any of these parts fail all must be replaced at the same time along with additional parts in the kit Failure to replace all parts together may lead to parts failure Manual 0 2604 6 9 PARTS LISTS 6 09 Main Heatsink Assembly Replacement Parts Item Qty AN amp WN n2 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PRP M Description Reference Catalog Main Heatsink 9 1404 Capacitor 550 mfd 400VDC 9 1303 Bracket Capacitor Heatsink 8 4521 Support Air Foil 8 2176 Capacitor Clamp 9 4212 Support Heatsink Assembly 9 6663 Thermstrate Transistor 9 1406 Transistor IGBT Refer to Section 6 08 Item 2 Capacitor 10 mfd 400V Poly Hi Current 9 1305 Bracket Capacitor Mounting 8 6314 70 Amp STR Diode Replacement Kit Includes 8 1168 Diode 70A 600V STR Fast Thermal Interface Pad 7
75. arter box Repair as required If START LED does not stay ON for 3 sec onds then Q1 may be faulty Refer to Sec tion 4 05 H Switching Control Check H Weak or Sputtering Pilot 1 Incorrect pilot resistor setting in Master Power Sup ply a Must be adjusted according to the input line voltage Refer to Master Power Service Manual Section 4 05 M Pilot Resistor Adjustment 2 Low Open Circuit Voltage OCV a Improper connection of transformer voltage select buss bars check for correct configura tion b Faulty Voltage Selection PCB The Merlin has three input voltage ranges 200 230 380 460 500 575 VAC If the incoming voltage is in the lower half of any range an LED D18 on the Volt age Selection PCB should be if it s ON refer to 4 05 A Voltage Selection PCB Check 4 6 I Main arc starts but current is 1 2 what is expected Main contactor W1 or W2 goes off 1 Fault condition causes output greater than 175 amps a Current Control signal DEMAND greater than 10 vdc Measure for 10 vdc on the Switching Control PC Board from TP1 ground to Front Panel CURRENT Control J10 15 or to the Remote Current Control J7 18 see NOTE NOTE Measure the voltage while attempting to cut as the voltage may be correct prior to cutting If voltage exceeds 10 vdc may be momentarily perform checks at Section 4 05 K Steps 2 and 3 b Shorted Q1 or faulty Switching Control PC Board Refer to Sectio
76. ble aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superin tendent of Documents U S Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRA VAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American Na tional Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI 7411 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE SOUDAGE disponible aupr s de l American Na tional Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies LES SY
77. cable to plasma cutting equipment and associated accessories CENELEC EN50199 EMC Product Standard for Arc Welding Equipment For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed stand off guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX CE Date January 27 2004 1 7 GENERAL INFORMATION 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 Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below
78. cator 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 pro ceed with the disassembly REPLACEMENT PROCEDURES 5 04 External Parts Replacement NOTE Refer to Section 6 03 External Power Supply Re placement Parts for parts list and overall detail drawing A Left Right Side Panel Replacement The Left and Right Side Panels are replaced in the same manner The Left Side Panel of the Supply is the panel on the left side of the unit as viewed from the front of the unit Screws 10 Places 1 Removethe four screws that secure the rear of the Side Panel to the Power Supply A 01528 2 Loosen the two screws securing the bottom of the Side Panel to the base of the Power Supply These two screws are in slotted holes in the Side Panel 3 Toremove the Side Panel from the Power Supply pull up and out on the Side Panel 4 Reinstall the replacement Side Panel by revers ing the above procedure 5 2 Manual 0 2604 B Top Panel Replacement 1 Remove the Left and Right Side Panels per para graph B above On the top of the unit remove the Coolant Tank Cap from the Coolant Tank Remove the four screws securing the Top Panel to the front of the unit Remove the two screws securing the Top Panel to the rear of the unit Install the replacement Top Panel by reversing the above procedure C Work Cable
79. ccepts input voltages of 380 415V 50 or 60 Hz three phase The unit converts AC input power to DC power for the main cutting arc The negative output is connected to the torch electrode through the negative torch lead and the positive output connects to the work piece through the work cable B Main Cutting Arc The Power Supply accepts 50 or 60 Hz three phase line input The power supply converts AC input power to DC power for the main cutting arc The negative output is connected to the torch electrode through the negative torch lead The positive outputis connected to the work piece via the work cable and clamp connection C Thermal Interlocks The system has built in thermal 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 Thermal overload sensors are located in the transformer and main heatsink in the power supply If one of these components is overheated the appropriate switch will open up causing the temperature light to turn from green to red and shutting off power to the main contactor When the overheated component cools down the switch will close again and allow operation of the system Manual 0 2604 SECTION 4 TROUBLESHOOTING 4 01 Introduction This Section provides service troubleshooting for the Power Supply allowing the Technician to isolate any faulty Sub assemblies Refer to Section 5 Repa
80. cessary Refer to Section 4 05 C Blown Fuse F1 or F2 4 Faulty ON OFF switch SW1 a Disconnect primary power Check each sec tion for continuity Replace switch if necessary 5 Faulty Voltage Selection PC Board a Refer to 4 05 A Voltage Selection PC Board Check Replace Voltage Selection PC Board if necessary 6 Faulty motor contactor 1 or MC2 a Refer to Section 4 05 D Motor Control Contac tor Check MC1 or MC2 Replace contactor if necessary Manual 0 2604 C Fuse blows at disconnect when primary power is turned ON 1 Voltage selection busbars connected incorrectly 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 transformer Fuse blows at disconnect when main contactor W1 or W2 closes 1 Shorted input diode D1 D6 a Referto Section 4 05 E Diode Check Replace diode s as required 2 Switching transistor Q1 shorted to heatsink a Replace Q1 check heatsink for possible dam age Refer to Section 4 05 H Switching Con trol Check O1 3 Shorted input capacitor C7 C12 a Replace capacitor if necessary 4 Shorted diode D11 D14 a Check for proper 3 phase power at input ter minal board check diodes Refer to Section 4 05 E Diode Check 5 Faulty Voltage Selection PC Board a IFW1and W2 come on simultaneously replace Voltage Selecti
81. current control pot setting and generates logic level PWM signals The shunt and Shunt Amp PC Board are located between the input bridge positive and work lead to measure the output cutting current The PWM signals are sent to the Driver PC Board where they are converted into the current and voltage levels needed to drive the switching transistor TROUBLESHOOTING NOTE The Switching Control PCB in the Merlin 6000 Master Power Supply may be used in the Merlin 6000 Slave Power Supply and the Merlin 6000GST Master Power Supply In the Master Power Supply the Switching Control PCB does the following e Senses if the Remote Control RC6010 is installed then routes the current control signal from the re mote instead of the Merlin Master Power Supply front panel control Sends the Current Control Signal to the Slave PowerSupply through the Isolation PCB and Par allel Cable connection All signals to and from the Slave Power Supply pass through the Isola tion PCB and Parallel Cable Combines the Output Signal from the Slave Power Supply with the Shunt Amp signal The result creates a Display Signal that is sent to the Remote Control current display e Configures the Remote Control for 300A instead of 150A when a Slave Power Supply is used Sends a torch voltage signal to the Standoff Con trol if used e Supplies POT HI and POT LOW signals for set ting MIN and MAX output to both the Remote Control and Master Pow
82. d ON the SLAVE IS ON signal is present Signalis active low less than 2 vdc from the Slave Power Supply Logic PCB J1 20 to J15 17 Thesignalthen goes through the Parallel cable to the Master Power Supply Isolation PCB Refer to Section 4 05 L Isolation and Parallel cable The Master Power Supply Logic PCB receives the low SLAVE IS ON signal at J4 4 Master Power Supply Logic PCB then sends out an active high 5 vdc on J1 20 Remote Control uses 5 vdc logic Theactive high 5 vdcsignal is then sent to the Master Power Supply connector J15 17 and out the remote interface cable If there is no Slave Power Supply or it is not turned ON J15 17 should be low Signal then goes to the Remote Control con nector J37 14 which sets the Remote Control display to 300A full scale If there is no Slave Power Supply or it is not turned ON the Re mote Control display is set to 150A full scale TROUBLESHOOTING The Current Control potentiometer voltage of 3 3 to 10 vdc gives a display of 50 to 150A or 100 to 300A if the Slave supply is ON The voltage comes from the Mas ter Power Supply Switching Control PCB at J7 2 It then is routed out through the Master Power Supply connector J15 3 The voltage then goes through the remote interface cable and on to the Remote Control connector J37 1 This causes the current to be dis played from 50 to 150A or 100 to 300A if the Slave supply is ON In the preview mode not cutting the
83. disconnect Waitatleasttwo minutes to allow the input capacitors to discharge Remove the top and side panels of the Power Supply To remove the top panel of the Power Supply requires theremoval of several screws Carefully remove all the screws before attempting to remove the panels Driver PC Board Assembly Installation Locate the old Driver PC Board Assembly on the inside left side behind the front panel as viewed from the front of the unit A 01083 Driver PC Board Location Note and label the two wiring connectors that connect to the Driver PC Board Disconnectthe two wiring connectors from the Driver PC Board Manual 0 2604 4 5 7 Press in the securing tab knob on the PC Board Guide to release the PC Board from the PC Board Guides There is a securing tab on both the upper and lower PC Board Guides Upper PC Board Guide Securing Tab gt Driver Board Lower Board Guide Securing Tab 01084 Board Guide Securing Tab Carefully pull the PC Board from the guides and re move from the unit Install the replacement Driver PC Board Assembly re versing the above steps IGBT Q1 Installation Locate the old Switching Transistor IGBT Assembly on the inside center left between the four large blue capacitors as viewed from the front of the unit There are two different types of Switching Transistor IGBT The types can be identified by the top of the transist
84. display signal at J7 2 should equal the control poten tiometer wiper voltage at J7 18 checked step 3 above If voltage is incorrect then the Switching Con trol PCB is faulty When cutting each Power Supply Master and Slave monitors the actual output amps with their own Shunt Amp PCB Each Power Supply Shunt Amp PCB out put is 5 45 vdc for 150A and is sent to the Switching Control PCB at J9 5 in each Power Supply Each Switching Control PCB converts the voltage to 10 vdc for 150A The resulting signal is set through the system as fol lows e Inthe Slave Power Supply the voltage is sent out the Switching Control PCB at J7 2 as OUT PUT SIGNAL TO MASTER This signal is then sent to the J15 3 connector and out through the Parallel Cable to the Mas ter Power Supply connector J15 3 Refer to Section 4 05 L Isolation PCB and Parallel Cable Master Power Supply Switching Control PCB receives the OUTPUT SIGNAL TO MASTER signal at J7 11 Signal is then averaged with the Master Power Sup ply output signal e The average signal is then sent out to remote display on J7 2 as DISPLAY SIGNAL TO RE MOTE e This signal is then sent out the Master Power Supply connector J15 3 to the Remote Control The following is an example of how the averaging circuit functions Master Power Supply outputs 10 vdc 150A and the Slave Power Supply outputs 6 67 vdc 100A The average is 10 6 67 2 8 33 vdc With the display
85. e that the Logic PCB goes through Receives the START signal from the CNC cutting machine controller from either the remote control standoff control direct from the controller via the remote connector or through TB2 the simple in terface terminal strip Energizes the main contactor W1 or W2 as de termined by the Voltage Selection PCB When the Arc Starter Box senses OCV greater than 250V between the torch s plus and minus it starts the capacitor discharge CD arc starting circuit to fire the spark gap producing the high voltage spark which starts the DC pilot arc Once a constant DC pilot is established the torch voltage drops below 250V and shuts off the CD circuit When the torch is close to the work the cutting arc transfers to the work The resulting current inthe work lead is sensed by theShunt Amp then the Switching Control PCB sends the CSR signal to the Logic PCB which opens the pilot contactor shutting off the pilot and generating an OK TO MOVE signal The OK TO MOVE signal can be either contact closure or 24 VAC through contacts selected by SW5 on the Logic set for contacts if RC6010 or SC11 is used The OK TO MOVE signal is sent to the remote control standoff control or direct to the cutting machine controller It also controls the Arc Hour and Starts Counter Meters and the op tional High Flow Water Shield At the end of the cut when the START signal is removed and the Logic PCB starts a 1 2
86. east a factor of ten If the readings do not differ both high or both low disconnect one end of the diode and recheck If the diode reading is not correct with one end dis connected then replace the diode Check all diodes before turning on power to the system If a diode fails check the potential causes of diode failure to make sure the replacement diode will not also fail when it is installed 1 Isolate and check each diode separately to deter mine which individual diode has failed 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 Manual 0 2604 3 Diodes can overheat if air flow over the heatsink is not adequate or if the diode is not properly fas tened to the heatsink Check that all small diodes 07 14 are torqued to 20 25 in Ibs 2 3 2 8 Nm and all large diodes D1 6 are torqued to 100 125 in lbs 11 3 14 1 Nm Apply a light film of elec trically conductive heatsink compound between the diode and heatsink Make sure air passages in and out of the unit are not obstructed 4 Diodes that are faulty at the time of manufacture are difficult to diagnose These diodes generally fail within the firs
87. emove J9 J10 and J50 from the Switching Control Also remove J70 from the Signal Isolation PCB TROUBLESHOOTING Check for 15 vdc from TP1 to TP2 Ifvoltage is incorrect then the PCB may be faulty proceed to next step Ifvoltage is correct then reinstall the connec tors one at a time to isolate the problem In the case of a ribbon cable the cable itself may be shorted C Blown Fuse F1 or F2 1 Ashorted or frozen motor will cause F1 to fail A shorted or open fan motor starting capacitor C32 may also cause F1 to fail 2 Fuse F2 fuses the 120 VAC circuit or MC2 and T2 are energized when power is first applied If shorted any one of these components would cause F2 to fail W1 or W2 and PCR energize after the torch switch or remote start switch is ac tivated The resistance for each of these compo nents is as follows Resistance ohms Check the resistance of each component or dis connect all the components and reconnect one at a time to determine which component causes the fault D Motor Control Contactor Check MC1 or 4 8 MC2 NOTE Refer to Appendix 5 for 120 VAC Circuit Diagram The 120 VAC is supplied to the Motor Control Con tactor MC1 and MC2 coils from the Voltage Selec tion PC Board which selects the proper tap on the Main Transformer T1 The return path travels from wire 110 through K1 on the Switching Control PC Board to wire 8 through the ON OFF switch S
88. endix 5 for 120 VAC Circuit Diagram 1 Check the voltage input from F2 wire 10 to J6 9 for 100 120 VAC Check the input from F2 to J6 10 for 120 140 VAC 2 Ifthe voltage input is present check the red LED indicator D18 on the voltage selection board If the indicator is lit measure voltage output be tween F2 wire 10 and J6 7 If the indicator is not lit measure between F2 and J6 12 The volt age output at either point should measure 110 130 VAC 3 If both or neither J6 7 or J6 12 have high voltage present replace the voltage selection board Check voltage between 6 14 and wire 10 on fuse F2 for 110 130 VAC This supplies 120 VAC to the rest of the unit B Enable Circuit Tests Coil voltage of 120 VAC is supplied to the Motor Contac tors MC1 and MC2 and the Main Contactors W1 and W2 through the Voltage Selection PCB refer to Section 4 05 A and Appendix 5 The return path is through the Switching Control PCB Enable Relay K1 the ON OFF Switch SW1 A and the 5A fuse F2 Shutting off the Enable removes power from the contac tors fan motor and the DC output ENABLE signal to the Slave Power Supply also comes from TB2 in the Master Power Supply The signal goes through the Isolation PCB to the Parallel Connector J54 Signal then goes through the Parallel Cable to J15 on the Slave Power Supply Refer to Section 4 05 L Isolation PCB and Parallel Interface Check Enable Relay K1 circuit per the f
89. er If the front panel PILOT led is ON indicating drive to the PCR contactor but there are no sparks at the spark gap in the arc starter box first confirm that there is open circuit voltage OCV of 280 350 vdc between work lead and torch negative power lead Then measure from the negative power lead to the red pilot wire 7 If it is low zero to 50v the torch is probably shorted pilot resistors will get very hot If it is between 100 and 200v PCR con tactor is probably not closing If it measures the same as the OCV the arc starter box may be defective For a shorted torch remove the consumable parts and check for damage remove the head from the mounting tube and check for arcing The short may also be internal to the head and it may or may not be measurable with an ohmmeter Sometimes the only way to be sure is replace the head If the front panel PILOT indicator is OFF check the CSR indicator D5 on the Logic PC Board It should be OFF If it is ON the Switching Control PC Board may be falsely indicating main arc transfer Check for zero volts on the Switching Control PC Board at J9 5 If it does not measure zero the Shunt Amp which should have no output is de fective Otherwise the Switching Control PC Board is faulty If the Logic PC Board CSR indicator is OFF and PILOT indicator is OFF the Logic PC Board is faulty TROUBLESHOOTING 4 14 If PILOT indicator is ON and PCR is not closing check for 120 VAC between wire 11
90. er Supply front panel cur rent controls Sends current sensing CSR signal when output is greater than 12A to Logic PCB e Sends over current shutdown signal when cur rent is greater than 175A to Logic PCB Turning OFF the ENABLE from the Remote Con trol switch or a switch connected to TB2 will shut off coolant flow and DC power to allow changing torch parts A relay on the Switching Control PCB removes power from one side of the motor con tactor MC and main contactor W coils when the ENABLE switch is OFF A DIP switch SW1 configures the Switching Control PCB for no current ramping Merlin 6000 or current ramping Merlin 6000GST NOTE For a Merlin 6000 System both Master and Slave Power Supplies should have both sections of SW1 turned OFF 4 2 Manual 0 2604 Logic PC Board PCB Functions The Logic PC Board used in the Slave Power Supply is the same part as used in the Master Power Supply Some func tions of the PC Board that are used in the Master Power Supply are not used in the Slave Power Supply The func tions of the Logic PC Board in the Slave Power Supply are as follows Monitors the temperature interlocks Drives the front panel Status LED s Contains circuits to determineif a Slave Power Sup ply is connected and turned ON If Slave Power Supply is turned ON signals the Switching Control PCB and Remote Control to be configured for 300A operation The following is the sequenc
91. es Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m B vs D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons Date January 27 2004 ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protec
92. hmme ter Refer to Section 4 05 H Switching Con trol Check Faulty Shunt or Switching PCB will prevent current control same results as with shorted Q1 may also cause Q1 to fail Refer to Section 4 05 I Switching Control Checks NoCurrentSensing Signal CSR getting to the Logic PC Board Loss of CSR will remove the START signal The cause could be a faulty Switching PC Board current sensing circuit or a faulty Logic PC Board Installing a jumper from TP8 see Note to TP1 on the Logic PC Board should prevent the shutdown NOTE Logic PC Boards with Reo D or later have a test point TP8 connected to the anode of D62 TROUBLESHOOTING Ifshutdown continues the Logic PC Board is faulty If output current is set for over 250A and the PILOT contactor stays ON check for a logic low near zero volts at J3 11 the CSR input the Logic PC Board is faulty Ifnot low then the Switching PC Board Shunt PC Board or ribbon cables are faulty J Pilot Circuit Check The pilot is ignited by a high voltage spark generated in the Arc Starter Box The Arc Starter Box requires a 24 VAC supply which should always be present and a torch tip to electrode voltage greater than 250 vdc When the PCR contactor closes power supply open circuit voltage 280 350 volts is connected across the torch plus tip and minus electrode Once the pilot starts the voltage drops to under 250 vdc shutting off the arc start
93. ide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Aho Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace e Noise levels should be measured to be sure the deci bels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION 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 These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses i
94. ing the Access Panel to the LED PC Board standoffs Install the replacement Access Panel by reversing the above procedure 5 06 Front Panel Chassis Parts Replacement NOTE Refer to Section 6 05 Front Panel Chassis Replace ment Parts for parts list and overall detail draw ing A Bias PC Board Replacement 1 2 53 Remove the Right Side Panel per Section 5 04 A Disconnect all the wiring connections to the Bias PC Board Assembly Remove the Bias PC Board Assembly from four PC Board Standoffs Install the replacement Bias PC Board Assembly by reversing the above procedure REPLACEMENT PROCEDURES B Transformer T2 Assembly Replacement The Transformer T2 Assembly is mounted to the rear of the Horizontal Chassis Panel and has 25 2 VCT Center Tap output 1 Remove the Left Side Panel per Section 5 04 A 2 Disconnect all the wiring connections to the Trans former Assembly 3 Remove the four screws which secure the Trans former Assembly to the Horizontal Chassis Panel 4 Carefully remove the Transformer Assembly from the unit 5 Install the replacement Transformer Assembly by reversing the above procedure Internal Fuse F3 Replacement The Fuse F3 is located inside the Power Supply be hind the RightSide Panel The Fuse is mounted next to the Bias PC Board on the rear of the Horizontal Chassis Panel 1 Remove the Right Side Panel per Section 5 04 A 2 Locatethe Fuse m
95. ion 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 09 Main Heatsink Assembly Replacement Parts NOTE Parts listed without item numbers are not illus trated but may be ordered by the catalog numbers shown B Returns If a product must be returned for service contact your authorized distributor Materials returned without proper authorization will not be accepted C Product Improvements Improvements to the product since release is denoted by a revision letter s located on the data tag of the unit There are old style and new style data tags that may be encounted The old style data tag has the revision letter s at the end of the serial number The new style data tag has the revision letter s in an area marked The parts lists may include references to the revision letter s for parts that are different between revisions 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the de scription column of the Parts List Also include the model and serial number of the machine as shown on the data tag attached to the unit Address all inquiries to your authorized distributor Manual 0 2604 6 1 PART
96. irs amp Replacement Procedures for parts replacement instructions Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other Subassemblies of this unit Evidence of unauthorized repairs will void the fac tory warranty NOTE The troubleshooting contained in this manual is for the CE Merlin 6000 Slave Power Supply only Troubleshooting other parts of the system is cov in the separate manuals for that product 4 02 Periodic Inspection amp Procedures NOTE Refer to Appendix 4 for a recommended mainte nance schedule for non liquid cooled plasma cut ting systems This subsection describes inspection procedures which should be performed at periodic intervals as required The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating en vironment To clean the unit first make sure that the power is dis connected Remove the side panels and blow out any accumulated dirt and dust with compressed air The unit should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used 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 03 System Theory The CE Merlin 6000 Slave Power Supply is used with ei ther the CE Merlin 6000 or CE Merlin 6000GST Master
97. lel Cable Maximizer 300 Spare Parts Kit 25 ft 7 6 m Work Cable and Ring Lug Optional Air Line Filter Assembly or High Pres sure Regulators for Master Power Supply 3 1 INTRODUCTION amp DESCRIPTION 3 03 Specifications amp Design Features The following apply to the Slave Power Supply only 1 Controls ON OFF Switch 2 Control Indicators AC TEMP DC LED Indicators 3 Input Power NOTE Refer to Appendix 1 for recommended input wir ing size current ratings and circuit protection re quirements Amperage depends on input voltage Refer to Ap pendix 1 4 Output Power Slave Power Supply 50 to 150 amps Total output of Master Slave Power Supplies Continuously adjustable by potentiometer from 100 to 300 amps Minimum of 50 amps if Slave Power Supply is Turned OFF 5 Duty Cycle see NOTE NOTE The duty cycle will be reduced if the primary in put voltage AC is low or the DC voltage is higher than shown in the chart Power Supply Duty Cycle Ambient 104 F 40 seria Duty Cycle 10096 DC Voltage 140 vdc INTRODUCTION amp DESCRIPTION 3 2 6 PowerSupply Dimensions Enclosure Only Width 24 12 in 0 61 m Height 38 38 in 0 98 m Depth 34 25 in 0 87 m Fully Assembled Width 28 50in 0 72 m Height 43 38 in 1 10 m Depth 43 75 in 1 11 m 7 Weightof Power Supply Only 575 1 5 260 8 kg 3 04 Theory Of Operation A Input and Output Power The Power Supply a
98. llowing procedure 1 Remove the Left and Right Panels per Section 5 04 A 2 Locate the Thermostat Assembly to be replaced and place a clean rag under the copper support This will prevent debris from getting into the transformer coil 3 Remove the tie wrap securing the glass sleeving over the Thermostat Assembly 4 Slidethe glass sleeving back over the wiring har ness see NOTE to expose the Thermostat Assem bly connections NOTE To make it easier to slide the glass sleeving back far enough it may be necessary to remove a second tie wrap on the wiring harness 5 Disconnect the wiring connections at the Thermo stat Assembly 6 The Thermostat Assembly has Loctite on the threads and requires heat to break the seal At the copper support carefully use a propane torch to heat the base and exposed threads of the Ther mostat Assembly for 30 to 60 seconds REPLACEMENT PROCEDURES 7 Carefully use a wrench to remove the Thermostat Assembly If resistance is felt apply more heat see NOTE NOTE Using excessive force will cause the Thermostat As sembly mounting stud to shear off 8 Clean the Thermostat Assembly contact surface area of the copper support 9 Install the replacement Thermostat Assembly by reversing the above procedure and noting the fol lowing e Carefully bend the tabs on the replacement Thermostat Assembly 90 the same as the re moved part Apply Loctite 290 or equivalent to the
99. lot resistors R16 R21 and R22 which are on a bracket in front of the fan Manual 0 2604 4 17 Pilot Resistor Clamp a mG 2 A URL Pilot Resistor Wire 99 C A 7 2 E gt Wire Go i m 7 Q gt SN N SS ax d R21 9 2 EE 02597 Figure 4 4 Location Of Pilot Resistors Viewed From The Front Of Power Supply 3 Check the busbar configuration on the input ter minal board to determine which range the power transformer is set for 4 Measure the level of the AC line voltage being supplied to the Power Supply 5 To determine the recommended pilot resistor set ting use the following table as follows a Find the voltage that is nearest what was mea sured above b Notetheohms value for the voltage Example If the measured voltage is 360 then the pilot resistor value is 6 ohms NOTE Voltages that are from 410 to 420V required val ues from 8 5 or 9 to 4 5 ohms If the voltage is near one of these points it is best to set for the lower ohms value TROUBLESHOOTING The reason is because within each range the Power Supply will automatically select a high or low tap on the transformer secondary This is based on the input AC line voltage at the time the Power Supply is turned ON If the line voltage is near one of these points the voltage might measure for example 410
100. ment both ways means the Q1 is shorted and must be replaced TROUBLESHOOTING If correct measure from the gate terminal to emitter termi nal Normal reading is 2 2 ohms digital meter on ohms not diode scale a short zero ohms or an open indicates a defective Q1 NOTE If the Switching Control Q1 has failed the Driver PC Board must also be replaced Refer to Section 6 for replacement parts On all units Units with Logic Control 19x1247 or 19x1360 rev AE or earlier If DC voltage is not detected within 75 ms at 1 24 on the Logic PC Board the PWM Enable signal on 10 9 is removed the START and W ON LEDs turn OFF and the Main Contactor opens Units with Logic Control 19x1360 reo AF or later If DC voltage is not detected within 75 ms at 1 24 on the Logic PC Board the PWM Enable signal on 10 9 is removed and the START and PWM ON LEDs are turned OFF Disabling protection circuits for troubleshooting Connecting TP4 to TP1 ground on the Logic PC Board allows the PWM Enable signal to stay ON for 3 seconds For Logic PCBs with TP7 rev AD or later connecting both TP7 and TP4 to TP1 ground allows the PWM Enable signal to stay on indefinitely 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 a
101. n 4 05 H Switching Con trol Check O1 J Main arc transfers but does not pierce through the plate or pierce is too slow 1 Current is correct from Master Power Supply a Make sure Slave Power Supply is turned ON Parallel Cable is connected and the Slave Power Supply Work Lead is connected b Current Control circuit is faulty Refer to Sec tion 4 05 K Current Control Display and CSD Checks Standoff Control Not Working Correctly Refer to Troubleshooting in the Standoff Control In struction Manual L Remote Control Not Working Correctly Refer to Troubleshooting in the Remote Control In struction Manual Manual 0 2604 4 05 Test Procedures The following tests are suggested for specific problems listed in the troubleshooting guide G Several of these tests involve voltage measurements that must be made with power on Use extreme care when making these tests Tests requiring volt age measurements are marked with the warning symbol Disconnect primary power to the system for all other tests pum M T A Voltage Selection PC Board Check The CE Merlin transformer uses the input voltage range 380 460 VAC selected by buss bars Within this range there are transformer taps for the upper and lower halves of the range The dividing line between the upper and lower halves for this range is as follows 380 460 VAC approximately 409 VAC The
102. n good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the work piece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Docu ments U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 Date January 27 2004 1
103. nd secondary supply and pressure flow 4 Purge plasma gas line to remove any moisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Blow or vacuum dust and dirt out of the entire machine mmm CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit Six Months or Every 720 Cutting Hours 1 Check the in line air filter s clean or replace as required 2 Check cables and hoses for leaks or cracks replace if necessary 3 Check all contactor points for severe arcing or pits replace if necessary APPENDIX A 4 Manual 0 2604 APPENDIX 5 MERLIN 6000 SLAVE POWER SUPPLY 120 VAC CIRCUIT DIAGRAM F2 SW1 A 8 NEON IND1 250 hm w VOLTAGE SELECTION PC BOARD SWITCHING CONTROL PC BOARD Energized by Enable Switch K4 HV LV LOGIC PC BOARD K5 LV K2 24 02039 Manual 0 2604 A 5 APPENDIX APPENDIX 6 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM For Merlin 6000 System NOTE Refer to Appendix 7 for complete data on the Cables and Hoses A CNC F B OR N CAC J37 J29 RC 6010 OR B CNC 187
104. nd 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 fail ure The Switching Control PC Board sends pulses 15 V to the Driver PC Board on 8 1 and J8 3 The width of these pulses controls the on time of O1 The pulses are best observed with an oscilloscope but an AC voltmeter should read about 6 to 7 VAC from J8 2 to both 8 1 8 3 If 0 VAC is measured at both J8 1 and J8 3 with the enables J10 9 and 10 23 and shunt amp J9 5 input low replace the Switching Control PC Board A G Both base and emitter are at 320 vdc potential Use extreme caution when testing Driver PC Board out put TROUBLESHOOTING 4 12 Ifswitching pulses are present at J8 1 and J8 3 check the Driver PC Board output between J27 3 and J27 2 The Driver PC Board output J27 3 to J27 20 should mea sure about 1 VAC If voltage measures 0 to 4 vdc lead on J27 3 replace Driver PC Board If switching pulses are not present start signal OFF 4 vdc is normal 1 PWM Enable Signal Circuit When complaint is No DC or no output from the Slave Power Supply what to do There are a number fault sensors in the Power Supply which can prevent the Power Supply output from coming ON or cause it to shut OFF once it is ON The output section is turned ON by the PWM Enable signal from the Logic PC
105. nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pasle chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combus tibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ceproduit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie
106. noting the following a Wipe the surface clean where the replacement diode is to be installed NOTE The thermal interface pads must be properly aligned when replacing the diode b Position the thermal interface pad between the diode and contact surface where the diode will be installed wmm CAUTION Diodes can overheat if not properly installed c Install the replacement diode and torque the diode to 20 25 in Ibs 2 3 2 8 Nm d Re solder the wire lead to the replacement di ode e Apply a layer of RIV over the top of the Di ode Assembly to encapsulate the lead and top of the diode f Close up the Power Supply Manual 0 2604 5 11 Relay Replacement PSR and O The two Relay Assemblies are replaced in the same manner The PSR Relay is 110 vdc and the O Relay is 120VAC Relay 1 Remove the Right Side Panel per Section 5 04 A 2 Move the Relay Hold Down Spring to the side of the Relay Assembly 3 Pullthe Relay Assembly from the Relay Socket 4 Install the replacement Relay Assembly by revers ing the above procedure 150 Amp REV Diode Replacement The Diode Replacement Kit Cat 8 6152 is a direct parts replacement for the failed Diode Assembly in the Power Supply The following parts are supplied with each replace ment assembly 150 Amp 800V Rev Diode Assembly 1 each 1 06 inch diameter Thermal Interface Pad 1 each 1 Turn OFF main input power to the Power Sup
107. ollowing NOTE This procedure applies to both the Master and Slave Power Supplies 4 7 TROUBLESHOOTING Merlin 3000 6000 RC6010 or 6000GST Switching Control PCB 37 17 J15 5 J50 12 V1 J1 5 J1 4 J37 27 15 33 J50 10 ENABLE TB2 1 2 037 26 J15 32 50 111 A To AMP VOLT TB2 2 Display Enable 01137 Figure 4 3 Enable Circuit Diagram 1 Check for zero AC volts from F2 wire 10 to J7 22 and from F2 wire 10 to J7 24 Ifvoltageis correct the Enable Relay is closed The fault is in the contactor refer to Section 4 05 D Motor Control Contactor Check or the voltage supply refer to Section 4 05 A Volt age Selection PCB Checks Ifvoltage approximately 120 VAC is present at J7 24 the circuit is open between J7 24 and F2 Check Fuse F2 or ON OFF Switch for open condition e fthereis about 120 VAC at J7 22 then Enable Relay K1 is not closed proceed to next step Check for the 15 vdc relay power supply V1 on the Switching Control PCB Measure between TP1 and TP2 on the Switching Control PCB Should be about 15 vdc at TP2 If voltage is not correct power may not be get ting to the PCB or there may be a short either on or off the PCB Checkfor 14 to 18 VAC incoming power by mea suring from TP1 to J7 12 and J7 15 If voltage is not correct refer to Section 4 05 A 28 VAC tests To check for shorts r
108. on PC Board 6 Faulty Main Contactor W1 or W2 a Checkboth contactors for welded contacts and replace contactor s if necessary E TEMP indicator on red 1 Faulty Fan power Fan Fan Capacitor Fuse or Con tactor a Isolatethe faulty component as follows and re place component s as necessary Check for approximately 230 VAC between wire 13 MC1 or MC2 J39 2 and wire 12 F1 fuse J39 5 Ifnot present check for blown F1 refer to sec tion 4 05 C or defective MC contactor refer to section 4 05 D e If 230 VAC is present Fan or Fan capacitor C32 is defective Manual 0 2604 2 Faulty thermal sensor TS1 to TS5 a Refer to Section 4 05 F Thermal Sensing Circuit Check Replace sensor s if necessary 3 Faulty Logic PC Board a Refer to Section 4 05 F Thermal Sensing Circuit Check Replace Logic PC Board if necessary 4 Faulty LED Current Control PC Board a Refer to Section 4 05 F Thermal Sensing Circuit Check Replace LED Current Control PC Board if necessary Depending on the Logic Control PCB installed refer 45 to one of the following symptoms For Logic Control PCB 19x1247 or 19x1360 rev AE or Earlier After Pre Flow DC indicator OFF Logic Control PCB START LED and Main Contactor do not come ON or only momentarily ON less than 1 2 second No Pilot Arc For Logic Control PCB 19x1360 rev AF or Later After Pre Flow DC indicator OFF Logic Control PCB LEDs PWM ON and
109. ontrol Earth Ground 3 Phase Input Work Cable Workpiece Earth Ground Work Cable A 01512 NOTE Work Cable s must connect direct to workpiece DO NOT connect Work Cable s to earth ground and then to workpiece APPENDIX A 2 Manual 0 2604 APPENDIX 3 PARALLEL CABLE Master Power Slave Power Supply J54 Cable Supply J15 DEMAND P 4 3 3 10 VDC 2 2 u 7 32 ENABLE 11 lt gt 33 Teo e 24 START STOP k 4 6 gt 25 E 14 6 gt 17 SLAVE IS ON gt L 12 lt gt 15 8 e 3 i SLAVE OUTPUT 0 10 VDC Signal 9 lt gt 4 s 10 5 317 Isolation PC Board Power 5 e gt 30 Supply 13 Shield Drai 19 77 35 This Is Slave 36 26 nme Remote Installed 27 Manual 0 2604 9 APPENDIX 4 ROUTINE MAINTENANCE SCHEDULE This recommended schedule applies to alltypes of non 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 Cutting Hours 1 Check torch consumable parts replace if damaged or worn 2 Inspect torch for any cracks or exposed wires replace if necessary 3 Check plasma a
110. opre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions et GAZ sant 1 3 La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de GENERAL INFORMATION Eloignez toute fum e et gaz de votre zone de respira tion Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome
111. or casing This kit replaces both types Style With 3 Terminals Style With 2 Terminals Art A 06055 Switching Transistor IGBT Styles Remove the two screws securing the wires to the Switch ing Transistor IGBT Assembly terminals Remove and discard the wire harness Remove the screw that secures the Capacitor Mount ing Bracket to the Switching Transistor IGBT Assem bly REPLACEMENT PROCEDURES b 10 11 Remove the screw that secures the Transistor Coil Bracket to the Switching Transistor IGBT Assembly Remove the screw and washer securing the PTC Resis tor Assembly to the Main Heatsink Move the PTC Resistor Assembly out of the way to prevent it from becoming damaged i TA PTC Resistor Assembly Art A 01089 PTC Resistor Assembly Location Remove the four screws securing the Switching Tran sistor IGBT module to the Main Heatsink Be careful not to damage the surface of the heatsink Pry between the Main Heatsink and the faulty Switch ing Transistor IGBT Assembly until it slides easily Remove the faulty Switching Transistor IGBT Assem bly from the unit by sliding it towards the center of the Main Heatsink Ifthe transistor thermal pad was not removed with the transistor remove it now Useisoproply alcohol to clean the residue of the old tran sistor thermal pad from the transistor mounting area REPLACEMENT PROCEDURES 12 Install the replacement Thermal pad the IGBT Assem
112. ounted next to the Bias PC Board on the Horizontal Chassis Panel 3 Remove the damaged Fuse from the snap type fuse holder 4 Reinstall the replacement Fuse 1A 250V by re versing the above procedure Fuse Holder Internal Replacement 1 Remove the Left Side Panel per Section 5 04 A 2 Remove the Fuse from the holder 3 Disconnect the two wires connected to the Fuse Holder 4 Remove the two small screws securing the Fuse Holder to the chassis 5 Install the replacement Fuse Holder by reversing the above procedure REPLACEMENT PROCEDURES 5 07 Rear Panel Parts Replacement 54 NOTE Refer to Section 6 06 Rear Panel Parts Replace ment for parts list and overall detail drawing Fan Replacement 1 Remove the Left Side Panel per Section 5 04 A 2 Locatethe Fan Assembly wiring connector inside the Rear Panel 3 Carefully disconnect the wiring connector from the wiring harness 4 Notethe pin location of each wire to the connector 5 Using a pin extraction tool remove the wiring from the connector 6 On the Rear Panel remove the strain relief secur ing the Fan Assembly wiring to the Rear Panel 7 Locate and remove the four bolts and lock nuts securing the Fan Assembly to the Rear Panel As sembly 8 Carefully pull the Fan Assembly from the Rear Panel Assembly feeding the wiring through the hole 9 Install the replacement Fan Assembly by revers ing the above procedure PCR Contactor Re
113. p 2 OFF FOR MERLIN 6008 18 WIRE RIBBON CABLE 34 WIRE RIBBON CABLE er SWI 1 amp 2 ON MERLIN 600055 PIN z 1 CABLE IN PLACE INTERLOCK EE GND WITH CABLE CONNECTED pr LES 5 SHUNT AMP OUTPUT B 14 UNFILTERED 9 ENABLE 9 ISVDC Len ALE OTHER GND 21 OVERCURRENT SHUTDOWN 23 PWM ENABLEZ NOTE 25 DRAGING COMMON ON D 1 EARTH OR UTILITY GROUND 29 SLAVE UNIT 7 CHASSIS GROUND 31 DEMAND TO LOGIC 5 ALL EVEN 8 34 ARE GND 2 k 1W7 DRAG 5 SENSE PILOT gt J 15 215 15 J1 20 145 15 17 A J1 4 LOGIC jut 146 15 LED 5 5 J a 1 4 1471 s 5 15 VOLTAGE SELECTION LOGIC 17 18 SWITCHING CONTROL Jn SHUNT AMP FCB 912 13 MAIN TRANSFORMER ITI maw mel J5 PARALLEL CABLE TS 215 36 J19 CONTROL TRANSFORMER 1721 STE J5 35 126 27 DRIVER J38 MAIN HEATSINK PTC 139 FAN MOTOR J47 FAN MOTOR CAPACITOR 32 J58 SWITCHING CONTROL PCB REVISIONS REVISIONS THERMAL DYNAMICS rane z E EE CORPORAT ION WEST LEBANON MH 03784 r aa 1553 298 5711 EC 8143 9 INFORMATION PROPRIETARY TO THERMAL DYNAMICS DER CORPORATION NOT FOR RELEASE OF DISTRIBUTION ECO 191330 NOTE REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE MN OHMS 1 4W BX CAPACITORS ARE N LECRDRAMADSIUR ECO 101778 1 or 1 me MERLIN
114. placement 1 Remove the Right Side Panel per Section 5 04 A 2 Note the orientation of all the wires and then dis connect the input and output wiring from the Three Phase Contactor Assembly 3 Removethe two locking nuts securing the Three Phase Contactor to the Rear Panel of the unit 4 Install the replacement Three Phase Contactor As sembly by reversing the above procedure Voltage Selection PC Board Replacement 1 Remove the Right Side Panel per Section 5 04 A 2 Disconnect all the wiring connections to the Volt age Selection PC Board Assembly 3 Remove the Voltage Selection PC Board from the four PC Board Standoffs 4 Install the replacement Voltage Selection PC Board Assembly by reversing the above procedure Manual 0 2604 5 08 Base Assembly Parts Replacement NOTE Refer to Section 6 07 Base Assembly Replacement Parts for parts list and overall detail drawing A DC Inductor L2 Assembly Replacement G The removal of this Assembly requires the use of a mechanical lift 1 Remove the Left and Right Side Panels per Sec tion 5 04 2 Disconnect all the wiring at the DC Inductor As sembly 3 Remove the six mounting bolts securing the DC Inductor Assembly to the Base 4 Place a mechanical lift next to the left side of the Power Supply 5 Carefully slide the DC Inductor Assembly out the left side of the unit and onto the mechanical lift 6 Install thereplacement DC Inductor
115. ply both at the Power Supply ON OFF switch and at the main power disconnect 2 Wait at least two minutes to allow the input ca pacitors to discharge 3 Open the Power Supply to gain access to the faulty Diode Assembly 4 Locate the old Diode Assembly inside the Power Supply 5 Remove the nut and washer securing the old di ode assembly to the mounting surface 6 Remove the nut securing the diode wire lead to the PC Board 7 Make sure the replacement diode is a direct re placement for the old one 8 Install the replacement diode by reversing the above procedure and noting the following a Wipe the surface clean where the replacement diode is to be installed NOTE The thermal interface pads must be properly aligned when replacing the diode REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES b Position the thermal interface pad between the diode and contact surface where the diode will beinstalled wmm CAUTION Diodes can overheat if not properly installed c Install the diode Torque the nut securing the diode to 100 125 in Ibs 11 3 14 1 Nm d Reinstall the nut and washer securing the re placement diode wire lead to the PC Board D 150 Amp STR Diode Replacement The Diode Replacement Kit Cat 8 6153 is a direct parts replacement for the failed Diode Assembly in the Power Supply The following parts are supplied with each replace ment assembly 150 Amp 800V Str Diode Assembly 1
116. pply Lift the end of the PCB closer to the rear of the Power Supply and slide the PCB rear ward to release it from the forward screw S Rear of Power Art A 03850 Shunt Amp PCB Removal If necessary carefully clean the PCB mounting surfaces on the shunt Wipe the surfaces clean with a lint free rag ma CAUTION Do not use conductive material such as steel wool to clean the mounting surfaces Position the replacement Shunt Amp PCB on the Shunt Secure with the hardware loosened previously Tighten securely Do not overtighten Fasten the Shunt to the main heatsink by tightening the bolt loosened previously Tighten securely Do not overtighten Align the ribbon cable connector with the receptacle onthe Shunt Amp PCB Press the connector fully into the receptacle Close the two locking tabs on the recep tacle Check for a secure connection Reinstall the power supply outer panels REPLACEMENT PROCEDURES B Auxiliary Transformer T2 Assembly Replacement 1 2 Remove the Left Side Panel per Section 5 04 A Disconnect the wiring connector from the wiring harness at the Auxiliary Transformer Assembly Remove the two mounting screws securing the Auxiliary Transformer Assembly to the Upper Chassis Gauge Assembly Remove the Auxiliary Transformer Assembly from the unit Install the replacement Auxiliary Transformer As sembly by reversing the above procedure C Fuse F1 and F2 Replacement 1
117. r F or later on the data tag SlavePower Supplies that have been retrofitted with Pilot Resistors Slave Power Supplies as noted above and all Master Power Supplies contain adjustable pilot resistor circuits For out put current below 250A only the pilot circuit in the Mas ter Power Supply is activated For output current above 250A the Master and Slave Power Supply pilot circuits are activated Slave and Master Supply pilot resistors are initially set at the factory and may need to be adjusted to the customer s input power see Notes NOTES The instructions in this Sub Section apply to the Slave Power Supply only To adjust the Master Power Supply pilot resistors refer to the Manual supplied with the Master Power Supply The pilot current has to be high enough that the pilot will not sputter or go out but not too high to cause excessive wear of the torch consumables The amount of pilot cur rent is determined by the value of the pilot resistors and the open circuit voltage which varies with the input line voltage Both the Slave and Master Power Supplies should be adjusted the same Wire 99 tap sets the pilot current level To set the pilot current level use the fol lowing procedure 1 Remove the left and right side panels of the Mas ter Power Supply NOTE The switches located on the Logic PC Board and the Switching PC Board must be set the same as in the Master Power Supply 2 Locate and identify the pi
118. replacement Switching Control PC Board Install the replacement Switching Control PC Board by reversing the above procedure 5 10 Main Heatsink Assembly Parts Replacement NOTE Refer to Section 6 09 Main Heatsink Assembly Re placement Parts for parts list and overall detail drawing A 70 Amp STR Diode Replacement The Diode Replacement Kit Cat 8 1168 is a direct parts replacement for the failed Diode Assembly in the Power Supply The following parts are supplied with each replace ment assembly 5 10 70 Amp 600V Str Diode Assembly 1 each 0 75 inch diameter Thermal Interface Pad 1 each Tube of RTV 1 each Turn OFF main input power to the Power Supply both at the Power Supply ON OFF switch and at the main power disconnect Wait at least two minutes to allow the input ca pacitors to discharge Open the Power Supply to gain access to the faulty Diode Assembly Manual 0 2604 4 Locate the old Diode Assembly inside the Power Supply 5 Unsolder the wire lead from the old Diode As sembly 6 Remove the old Diode Assembly from the unit Make sure the replacement diode is a direct re placement for the old one NOTE To avoid damage to a replacement diode from over heating during installation a proper heatsink ex ample alligator clip must be used to disperse heat when soldering the wire lead to the diode 7 Install the replacement diode by reversing the above procedure and
119. roubleshooting refer to Operating Manual 0 2603 Read both the Operating and Service Manual thoroughly A complete understanding of the capabilities and func tions of the equipment will assure obtaining the perfor mance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s require ments as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than selec tion of standard options Accessories or Factory approved updates are to be made to this equipment C Customer Operator Responsibilities It is the customer operator s responsibility to maintain the provided equipment and peripheral Accessories in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or malicious damage D Repair Restrictions The electronics consists of Printed Circuit Board Assem blies which must be carefully handled and must be re placed as units No replacement of printed circuit sol der mounted components is allowed except as noted in this manual Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned int
120. set for 300A full scale 10 vdc equals 300A then 8 33 vdc will equal approximately 250A Normally both the Master and Slave Power Sup plies should have the same output except if there is a fault both supplies TROUBLESHOOTING 4 16 L Isolation PCB and Parallel Cable Checks The Slave Power Supply is controlled from the Master Power Supply There are three digital ON or OFF signals and two analog voltages of varying levels signals that must be passed between the two units These signals have to be electrically isolated between the two units The Isola tion PCB in the Master Power Supply accomplishes this using both digital and analog optoisolator integrated cir cuits IC NOTE For a simplified diagram refer to Appendix 12 Parallel Interface Diagram The circuits on each side of the isolation barrier require their own power supply On the Master Power Supply side unregulated approximately 20 vdc from J7 14 of the Master Power Supply Switching Control PCB goes to J70 3 of the Isolation PCB to power a regulator for V1 15 vdc On the Slave Power Supply side voltage from a 20 ma current source on the Slave Power Supply Switch ing Control PCB is applied through the Parallel Cable J15 30 to J54 5 to a zener diode for V2 15 vdc The two supplies as well as the circuits they operate are com pletely isolated from each other Two digital signals ENABLE and START TO SLAVE and one analog signal DEMAND TO SLAVE 3
121. t Control Board 1 28 VAC ALL PC BOARD INPUTS CENTER ACTIVE LOW EXCEPT J1 24 AND J1 21 REFERENCES J1 CONNECTOR O REFERENCES J3 CONNECTOR A 03296 APPENDIX A 14 Manual 0 2604 APPENDIX 11 CURRENT CONTROL AND DISPLAY DIAGRAM Remote Control Cable Remote Control RC6010 Master Power Supply Switching Control PCB Output AMPS Remote Pot High Adjustment 237 5 iy J15 20 86 50 8 10 VDC ca m 3 3 10 VDC 337 21 i 415 1 32 17 175 Demand Signal CSD eo 29 10 0 1 1 Remote Pot Low to PWM Circuits i 7 J37 25 es J15 22 97 J50 6 3 3 VDC TES ce ag LED and Current 35 TODO x Control PCB E J5 17 lt 410 17 Pot High 10 VDC E J5 15 410 15 I 1 K lt gt J5 13 lt SIL MEUS E Rese ee Pot Low 3 3 VDC J37 11 71 15 26 36 7 20 Remote Installed 097 191 37 7 1 15015 27 37 SE 9 2 DISPLAY ke 15 3 our 150 300A 372 1 J15 4 35 lt 123 gt Averaging J Y Circuit J11 5K S dum 1 411 6 lt plas me gt Amp T J7 10 J7 11 J50 3 J50 4 1 2 0 9 NZ EE J70 8 270 6 70 10 70 12 Analog Analog w
122. t few hours of operation Be fore deciding that this was the case be sure to check out other possibilities F Thermal Sensing Circuit Check 4 9 1 Thermal sensors TS1 TS2 TS4 and TS5 are con nected in series to J1 9 on the Logic PC Board TS2 is a PTC resistor whose resistance varies with temperature from about 100 ohms at room tem perature 68 F 20 C to 3 3K at 140 F 60 C switch point 751 154 and 155 switches nor mally closed 0 ohms that open at over tempera ture TS1 TS4 and TS5 are part of the Main Trans former Assembly TS2 is on the Heatsink Check the voltage from J1 9 to test point TP1 or J1 8 on the Logic PC Board for less than 7 5 vdc If the voltage is greater than 7 5 vdc the unit is overheated or a temperature sensor is faulty 2 Iftheunitstill operates but the TEMP indicator is red the problem may be on the LED PC board If the voltage is less than 7 5 vdc check the voltage from J3 4 to test point TP1 ground If the volt age is greater than 4 vdc and the TEMP indica tor is lit red replace the LED PC board If the voltage at J3 4 is less than 4V replace the Logic PC Board TROUBLESHOOTING G Power Supply Start Circuit The following describes the flow of the START signal through the system The START signal enters the Master Power Sup ply at J15 24 sig and J15 25 return This is in parallel with TB2 3 and TB2 4 which can be used instead of J15 From 15 or
123. the top of the casing Switching Transistor Style With 3 Terminals Style With 2 Terminals Art A 06055 On a X1 or X10 scale or with a digital meter set for diode measure between C collector terminal wire 83 and E emitter terminal wire 84 Reverse the meter leads and measure again It is normal to measure an open high reading one way and a lower reading the other A low or zero measurement both ways means the Q1 is shorted and must be replaced If correct measure from the B base terminal wire 82 to E emitter terminal wire 84 Normal reading is from about 50 to 150 ohms digital meter on ohms not diode scale a short zero ohms or an open indicates a defective Q1 NOTE If the Switching Control Q1 has failed the Driver PC Board must also be replaced Refer to Section 6 for replacement parts Manual 0 2604 4 11 H 2 IGBT On units with O1 without Suppressor PC Board Q1 without IGBT Suppressor PC Board Wire 82 Wire 84 ET mi 5 Art A 06762 On units with O1 with Suppressor PC Board Q in Units with IGBT Suppressor PC Board Gate Terminal Suppressor PC Board Art A 06761 On a X1 or X10 scale or with a digital meter set for diode measure between gate terminal and emitter E termi nal Reverse the meter leads and measure again It is normal to measure an open high reading one way and a lower reading the other Alow or zero measure
124. tion Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC Z49 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie Pour prot ger votre ou e contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 Date January 27 2004 1 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponi
125. trol Dis play Circuit Diagram 1 Drag Circuit The Power Supply unit has a circuit to monitor the torch tip voltage The tip voltage is normally between 50 to 200 vdc piloting or cutting Less than 20 vdc indicates the tip may be double arcing or touch ing the work If that occurs the tip drag circuit re duces the current to 40 to 50A to reduce torch part wear Each power supply Master and Slave moni tors this voltage independently via the pilot lead to the ArcStarter Box Symptoms of a problem are Only 40A to 50A output in a single Power Sup ply system Only 190A to 200A output in a dual Power Sup ply system One power supply output is cor rect and the other power supply in drag cut Only 80A to 100A ina dual Power Supply sys tem Both Power Supplies in drag cut There are other problems that can cause similar symp toms To check for drag cut do the following a Check for 20 to 200 vdc on the Logic PCB in each Power Supply from TP1 ground to wire 7 faston W7 Wire 7 at W7 goes to the red pilot lead under where the gas and coolant hoses attach The wire then goes to the Arc Starter Box and on to the torch tip If voltage is incorrect then check for an open from that Power Supply to the ArcStarter Box and then to the torch tip fvoltage is correct then check for less than 2 vdc from TP1 to TP5 If voltage is correct then that Power Supply is in drag mode and the Logic

merlin 6000 slave power supply

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