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Thermal Comfort 3000 User's Manual

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1. A 00981 NEG DIODE HEATSINK METAL BRACKETS NET gene 84 841 L 12 Di 05 y ZN 66 83 R3 ci ES us 7 18 R12 28 d 84 Ti 88 i T 871 MOV2 ut INPUT af C 4T C11 12 Ep i FILTER tb i 38 PGB es MOV3 31 B4 227 2 327 3 227 1 SUPPRESSION RI PCB C15 17 ha DRIVER PCB 219 21 L E N m c16 o o ww m 20 22 D1 g g ggg y 3 gt a0 R4 6 TIMES 71 73 r3 29 7 Send 7 68 52 D4 06 y A 72 9 11 997 POS FT DIODE amp MAIN HEATSINK 13 139 2 C32 J12 8 1 MC 86 MC1 J47 1 BL R18 J7 8 7 5 1 AINA US jag jisfa B xc J12 5 2 MC2 87 MC2 jista t ta J8 2 TIP i HE me ZEN 12 4 T2 1 Nep SENSE 3B VET SWITCHING 5 TT Hs CONTROL PCB Fi 12 122 5 J12 1 an A jis h2 jas
2. COMPONENTS LOCATION mr 1 1UF 1 82 7 458VDC 11 12 1 UF 83 C13 14 8 15UF IKV A4 C15 17 18 21 2 2NF B4 1 18 20 22 4 7NF B5 23 BB A C24 4 7 NF A7 C25 4 7 NF 6KV 7 c28 37BVAC BB c28 2 2NF BB 4 7NF BB c31 198 PF 15KV 7 2 BUF 4BBVAC 01 3 5 150A REV 2 02 4 6 158A B V STR 82 ARC 7 70A 2BBNS STR B5 STARTER 011 14 70 6BBV 2BBNS STR 4 BOX F1 FUSE 25 VAC MOTOR C2 F2 FUSE 25 VAC CONTROL C2 FS FLOW SWITCH 0 75 GAL MIN E4 IND RED 125VAC NEON INDICATOR C1 Li 4 TURN SUPPRESSION COIL 84 L2 MAIN INDUCTOR 2 SECTIONS B L3 HF INDUCTOR 7 2 MOTOR CONTROL CONTACTOR 25 2 POLE C2 C3 PUMP MOTOR 23 VAC 50 58 HZ C2 SHUNT M2 FAN MOTOR 23 VAC 50 60 HZ C3 LI MOV1 2 3 420 V RMS 2 JOULES 82 10 WIRE 1J11 SHUNT AMP PCR PILOT CONTACTOR 4BA 3 POLE 8687 rre e PI COOLANT CONDUCTIVITV PROBE E7 REMOTE POT 3 132 J15 1 Ps1 PLASMA PRESS SW 35 PSI E3 CURRENT SIG J7 17 33 315 2 PS2 SECONDARY PRESS SW 35 PSI 4 SHUNT SIG 27 2 34 PSR PILOT SENSING RELAY 11 VOC BB TO REMOTE 1 S 17 35 4 REMOTE ChOLED
3. MERL IN ji RC 1 7 PSR TB1 8 OK PS gt 5 0104 KW INSTALLED B 7 OK TO MOVE J2 14 JIS 18 J37 30 YES L j OK PS 12 15 Ji5 11 J37 31 E 1 1 1 J5 15 RIBBO REMOTE K CABLE pow CABLE 17 15 2 ti sc 10 OK PS OFF OK To Move Boe m 2 1 9 OK P akoy e PIERCE 0102 24 DELAY LOGIC PCB 0 3 seconds 24 VAC Source 15 11 J7 11 VS J6 15 des sec i N OK OUT Rippon OK 5 537 128 14 J9 15 J6 14 CABLE SIG E1 J6 13 2 229 12 J8 14 gt RC 6010 01081 Standoff Control SC11 Merlin 3000 6000 OK PS OK OUT or 6000GST D82 D37 x i T cartes TB2 9 7 7 K12 006 J15 10 J42 12 PS 142 14 Pierce Delay K12 Energized prior to 0 3 Seconds and during pierce delay 24 Source 1 gt J11 7 112 16 E J42 14 Qu A OK 1 1 1 1 2 10 J11 6 J8 24 J40 14 E1 lt L J11 5 J8 22 A 01082 J40 12 x J11 8 APPENDIX 78 Manual 0 2533 EEGT 0 lENUEN 64 XIGNAddV Plasma Gas Hose Assembly Gas Connections Rear Panel To Regulator Rear Panel Plasma Gas Plasma Gas Solenoid Regulator Front Panel Secondary Gas heck Val Solenoid Regulator a en Ai Secondarv Gas Front Panel Secondary Gas Water Hose Assembly T Fit
4. 68 APPENDIX Ill TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS 69 APPENDIX IV INTERFACE CABLES FOR REMOTE CONTROL RC6010 AND STANDOFF SQ TT Ft Pere to Rte ete a 70 APPENDIX V CNC INTERFACE Lara 71 APPENDIX VI 120 VAC CIRCUIT DIAGRAM 72 APPENDIX VII LADDER DIAGRAM 15 VDC nnns 73 APPENDIX VIII SIGNAL FLOW BLOCK DIAGRAM iii 74 APPENDIX IX START CIRCUIT 75 APPENDIX X CURRENT CONTROL DISPLAY CIRCUIT DIAGRAM eme 76 APPENDIX CSD CORNER SLOWDOWN CIRCUIT 77 APPENDIX XII OK TO MOVE CIRCUIT DIAGRAM nennen nnne nnns 78 APPENDIX XIII HOSE BLOCK 8 79 APPENDIX XIV SYSTEM SCHEMATIC iii 80 APPENDIX XV RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS 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 wmm CAUTION A procedure which if not properly followed may cause damage to the equipment G
5. 380 AMP 550V B4 INSTALLED SIG J7 18 37 Hess RI OHM 83 R2 3 OHM A4 J58 86 115 28 POT HE J50 7 871 R4 6 8 10 1 OHM B4 115 21 R5 7 9 11 5 OHM BB POT LOW 150 6 97 115 22 R12 3k OHM 1BBW 158 5 387 JIB 23 R13 OHM AB TORCH J50 2 188 1 R14 22K OHM 1 1 W BB C VOLTS J50 1 181 8945 29 R15 1K OHM 1 1W BB 515 G J15 28 R16 4 8 OHM 1KW PILOT BB 118 33 R17 OHM 8 5W BB ENABLE deu it 1089 J15 32 R18 188 OHM BB E rur Rat 4 8 DUM 1KW PILOT 861 Q182 4 JUMPER 1 ENABLE IF REMOTE 24 LS 182 2 4 NOT USED swt ON OFF DPST ROCKER SW DPST C2 09020 7 5 2 RUN SET PURGE SPOT ON OFF ON 05 F Psa swa SECONDARY MODE SW DP3T 068 2 po 118 ea 73779 782 SOL t PLASMA GAS SOLENOID 115VAC DB 4317 1 4 J181 246 14 j38 1 4BV J15 34 SOL2 SECONDARY GAS SOLENOID 115VAC 06 SOL2 2311 5011 SECONDARY J15 6 SOL3 SECONDARY WATER SOLENOID 115VAC 06 PLASMA GAS 18 8 SHUNT 250A 1 2 87 SOL3 338 3 31 2 215 7 SECONDARY 821 J15 8 MAIN TRANSFORMER 3 PHASE m WATER 115 37 T2 115VAC PRI 25 2VCT SEC C4 318 3 usps T3 118VAC PRI 25 2V 1A SEC F7 115 1518 751 754 TS5 T TEMP SW 120 DEG C E2 D 50 58 Di JUMPER TS2 80 DEG MAIN HEATSINK
6. jis COOLANT CONDUCTIVITV PROBE J46 SECONDARY WATER SOLENOIO 5013 J2 22 J2 24 12 11 117 PLASMA GAS SOLENOID 5011 147 FAN MOTOR CAPACITOR C32 L FLT k 518 SECONDARY GAS SOLENOID S0L2 J48 HIGH FLOW WATER SHIELD HFWS 57 58 24 12 319 CONTROL TRANSFORMER T2 J48 24V TRANSFORMER 1A 320 PUMP MOTOR 158 SWITCHING CONTROL PCB J16 3 J16 1 Jap eed 125 FLOW SWITCH J51 TO OPTIONAL GAS CONTROL HARNESS 185 428 27 DRIVER PCB 152 OPTIONAL HOUR STARTS COUNTER 128 STANDOFF CONTROL SC5 SC6 P 187 24811 CODLANT 1189 OATE CONDUCTIVITY 524 DETIONAL rev REVISIONS By Date Rev REVISIONS THERMAL DYNAMICS mosmi pane 2 r PROBE HOUR METER 5 18 CORPORATION WEST LEBANON NH 83784 PSSTNO 7 7 RELEASE DAT 7 SUPERSEDES 0 1 MEGOHM CM 86 doctus A SEAE N A OPTIONAL INFORMATION PROPRIETARY TO THERMAL DYNAMICS DATE SUPERSEDED 1526 1 OPTION CORPORATION NOT FOR RELEASE OR DISTRIBUTION 4 15796 lt 15828 COUNTER NOTE DRAWN REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE IN DA m OHWS 4W 5X CAPACITORS ARE IN MICROFARADS UF 83 HFWS vine 11 R MERLIN 3000 SYSTEM 42X925 7 8 g A 00981 Manual 0 2533 81 APPENDIX APPENDIX XV RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of liquid cooled plasma cutting systems Some systems will not have all t
7. CNC RC 6810 ISOLATOR J28 3 28 3 Es l 81 START F J28 4 49 4 D103 TET START START STOP x 1673 WITHN NO a 10 16 4 1 START MOMENTARY VES L J29 1 J9 1 STOP ENABLE ON uie amp STATION J289 2 JIS 2 J E SELECT RIBBON ACTIVE CABLE IZ 1 4 J6 8 5 10 STOF ge START MOMENT ARY 079 T L J28 5 J9 5 o AP gt J2856 J9S 6 lt HEIGHT 0 FOUND OR FIND J6 5 lt gt HT OFF 26 6 PLASMA DN 17 17 sate CABLE 15 17 LOGIC PCB 11 18 TB2 3 J15 24 J37 8 4 U1 18 J15 25 237 10 1 TB2 4 4 REMOTE CABLE A 01079 ESQ 3080 o mE i RC ta Standoff Control SC11 START PLASMA D79 ON FIND HT K10 OFF START J40 3 J8 17 C lt AP FIND 44044 08 18 HT nr gt A START OPTO J8 10 J42 3 J11 3 Isolator gt J11 4 START ET m J8 11 Manual 0 2533 75 gt 01080 Merlin 3000 J15 24 cii Merlin 6000 J15 25 Merlin 6000687 APPENDIX APPENDIX X CURRENT CONTROL DISPLAY CIRCUIT DIAGRAM CURRE
8. vELLOW GREEN STRIPE 9 48 RTN 2 am 37 X GREENZYELLOW STRIPE 48 VDC SUPPLY Bu 18 BLANK FOR KEY SHIELD DRAIN WIRE 19 77 IN SC11 REMOTE CABLE lt SC 11 MERLIN 3000 J41 3 i mi 7 2 105 8 48 VDC SUPPLY POWER J41 4 RED J15 8 48 SUPPLY SUPPL Y J41 1 WHITE J15 7 48 VDC RTN ME 141 2 GREEN J15 8 48 VDC RTN m J42 12 ORANGE J15 10 OK TO MOVE J42 14 BLUE JTE 1 1 OK TO MOVE J42 3 YELLOW J15 24 START STOP SIGNALS 2 BROW J15 25 START STOP RTN J42 5 VIOLET o J15 28 TORCH VOLTS SIG L J42 8 GRAY J15 29 TORCH VOLTS SIG Tr J42 13 SHIELD DRAIN J15 18 7 7 7 lt CJ Q LLI A 00983 Manual 0 2533 APPENDIX V CNC INTERFACE Manual 0 2533 m E L BBBEJ Be ji N CABLE E x S d gt 2 Ha NI USE WITH RC8810 REMOTE 382 S Baz ff TU JG IX CUTTING CNC CABLE RC zii 5l MACHINE por REMOTE EN EJ du ST
9. 5 Install the replacement Hose Assembly by revers ing the above procedure Plasma Gas Hose PLASMA GAS to T Fitting Assembly Replacement The Plasma Gas Hose Assembly goes from the front panel PLASMA GAS connector to the T Fitting on the Plasma Pressure Gauge Assembly Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the front panel PLASMA GAS connector REPLACEMENT PROCEDURES 48 3 Disconnect the Other end of the Hose Assembly from the T Fitting at the Plasma Pressure Gauge Assembly 4 Remove the Hose Assembly from the unit 5 Install the replacement Hose Assembly by revers ing the above procedure Coolant Supply Hose Coolant Filter to Pump Assembly Replacement The CoolantSupply Hose Assembly goes from the rear panel Coolant Filter Assembly to the Pump Assem bly Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 07 Base Assembly Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the Coolant Filter Assembly on the rear panel 3 Disconnect the other end of the Hose Assembly from the Pump Assembly 4 Remove the Hose Assembly from the unit 5 Install the replac
10. N 7 138 5 IND 1 25 241 118 125V 35 54 ENABLE RELAY NEO N F2 ON OFF SWI A J12 4 ca 258 tei 118 122MAC PE TURN 118 37 22 a gt TORCH VOLTAGE 5 1 DIVIDED BY 23 L 27 0270 1028 D MC2 wt e 212 8 v i 17 12 47 2715 2715 Lita AN 21 22 TE J12 12 B p3 else 1181 14 J6 9 m J6 12 3 ien m 15 J6 e JB 7 4 884 it it VOLTAGE 26 SELECTION ty Ija 21 J135 18 J6 17 Y 25 18 Sw 2 RUN 63 H qs ited Ew il 1434 6 22 PURGE VOLT SEL PCB MONITORS INPUT VOLTAGE AND CLOSES EITHER LV OR HY CONTACTS 62 WHEN POWER IS TURNED ON TO SELECT PROPER TAPS ON T1 SECONDARY Joia 2 J13 3 18 J6 24 st 12 J1 101 1124 23 T 26 5 23 J2 9 24 ROUE lik 5132 19 je 2a JB 14 24 J2 5 128VAC Il Hu 28 J5 21 513 T 292 1431 20 J6 18 26 18 26 ACD Le A A 281 18 18 111 COMM a 2 59 58 J 8 fa 95 E 64 1382 7338 3 68 Ji 5 J12 16 E E J12 15 TA PS1 PLASMA l m TS2 MAIN HEATSINK 55 53 J1 TSI T54 T55 T PILOT TAD TH 5 3 o GAS 52 SECONDARY M RES SECONDARY 9 OXYGEN 55 52 52 31 7 ERE FESS E WATER FS1 52 251 5 J25 1 J25 2 54 Ji 5 COOLANT r o hl o a FLOW OK PRIMARY CONNECTIONS COOLANT FLOW 56 rT 5 INPUT BUS BAR VOLTAGE CONNECTIONS SYST
11. From Switching Control TORCH VOLTAGE 23 CSR from Current Control Board M 1 28 VAC ALL PC BOARD INPUTS CENTER TAP ACTIVE LOW EXCEPT J1 24 AND J1 21 A 01013 73 APPENDIX APPENDIX VIII SIGNAL FLOW BLOCK DIAGRAM 6010 SIGNAI F W BLO RAM SIGNALS WITH S RC SIGNALS WITH SC 1 Y SIGNALS WITH R 6 NL Y STANDOFF ONT START FIND HEIGHT START STANDO SABLE HEIGHT ESD ENG INHIBIT CONTR Il USED WI CSD MERLIN OK TO MOVE TO fl JK TO M MOVE ELAY gt TORCH LTS DISPLAY VOLTS SIG WER SUPPLY 48 VD START gt 5 START G rer OK TO MOVE MOVE TORCH VOLTS SIG POWER PLY 48 VD STANDOFF INHIBIT 4 CSD AIN l M Ss JEMAND CSD 24 D AMP DISPLAY iro PLAY SIGNAL A 01139 APPENDIX 74 Manual 0 2533 APPENDIX IX START CIRCUIT DIARGRAM RC 6810 SC 1 MERLIN 3000 START CIRCUIT
12. 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 disponible aupr s du Superintendent of Docu ments U S Government Printing Office Washing ton D C 20402 2 Norme ANSI Z49 1 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 Date 6 22 99 4 Norme ANSI 787 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 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 ET DE SOUDAGE disponible aupr s de l American National 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 PRODUIT
13. 3 8 NPT Reducer Pump Procon Type 2507XH Plate Pump Mounting Resistor Air Cooled 4 5 Ohm Power Rib Support Pilot Resistor Mounting Thermostat Open 212 F Close 192 F Temp Switch Top Clamp Temp Switch Bottom Clamp Hose Assembly Pump Inlet to Filter Hose Assembly Pump Outlet To Bulkhead 58 Catalog 8 5145 8 5578 8 5579 9 1243 9 5539 8 6143 8 6145 8 6670 9 1244 8 3263 9 2391 9 3496 9 4018 9 4019 8 6146 8 1251 8 0353 8 1328 8 3264 9 3959 8 3265 8 3315 8 3316 8 3317 8 4507 8 4508 Manual 0 2533 A 00894 Manual 0 2533 59 PARTS LISTS 6 08 Upper Chassis Replacement Parts Item Qty 1 PARTS LISTS P NNR RP 4 en PNP RP RPP WOH Description Panel Upper Chassis Gauge Power Driver PC Board Assembly Includes Thermstrate Transistor Refer to Section 6 09 Item 7 Transistor 300A 550V Darlington Refer to Section 6 09 Item 8 Current Driver PC Board Assembly PC Board Guide With 16mm Screw Auxiliary Transformer Assembly Capacitor 300mfd 400VDC Capacitor Mounting Clamp 1 3 4 Diameter Gauge 0 100 psi BAR 2 Diameter Gauge 0 160 psi BAR 2 Diameter 1 8 NPT Female Tee Pressure Switch 35 psi Adapter Bulkhead 3 8 NPT Inert B Adapter Bulkhead 3 8 NPT Inert B L H Body Bulkhead 1 8 NPT Body Bulkhead
14. Board should come ON with OK To Move If not check continuity between TB2 9 and J37 30 also TB2 10 and J37 31 The Remote Control RC6010 OK relay is initially energized The relay turns OFF to send the OK To Move sig nal through the relay normally closed contact As soon as indicator D104 turns ON or after the PIERCE DELAY if the Standoff Control SC10 is also used indicator D102 should go OFF indicat ing the OK relay is off If no Standoff Control SC10 is used and indicator D102 does not go OFF the Remote Control PC Board is defective If the Standoff Control SC10 is used set the torch to proper cutting height manually and disconnect the Standoff Control SC10 by removing the ribbon cable from J5 or J7 and try again If indicator D102 goes OFF now the Standoff Control PC Board is faulty or the ribbon cable is open pin 11 or 15 If indicator D102 does not go OFF with the Standoff Control SC10 disconnected the Remote Control RC6010 is defective 3 If indicator D102 goes OFF as it should and the E1 jumper is connected to J6 14 contacts measure for contact closure at J6 13 to 16 or if E1 jumper is Manual 0 2533 31 in J6 15 24 VAC measure for 24 VAC at J6 13 to J6 16 If OK the problem is in the CNC cable con nections to the cutting machine or the controller 4 For the Standoff Control SC11 refer to Section 5 Customer Operator Service in the Standoff Con trol Instruction Manual Pilot Resistor
15. FL 33126 3 NIOSH SAFETY AND HEALTH IN ARC WELD ING AND GAS WELDING AND CUTTING obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OC CUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 5 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broad way New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Insti tute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Date 6 22 99 oo 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 Asso ciation Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Pro tection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obt
16. If the Switching Control Q1 has failed the Driver PC Board must also be replaced Refer to Section 6 08 Item 2 for replacement parts SERVICE TROUBLESHOOTING The PWM compares shunt amp output on J9 5 with the current control signal 3 3 10 VDC from the re mote 7 18 or the panel control J10 15 A faulty shunt amp could cause the output normally 0 VDC with no cutting arc to go higher shutting off the PWM and thus producing no DC If the shunt amp ribbon connector is disconnected or pin 1 is open approxi mately 12 VDC is applied to J9 5 shutting down the PWM in the same manner as a shunt amp failure The Switching Control PC Board sends pulses 15 V to the Driver PC Board on J8 1 and J8 3 The width of these pulses controls the on time of Q1 The pulses are best observed with an oscilloscope but an AC voltmeter should read about 6 to 7 VAC from J8 2 to both J8 1 and J8 3 If 0 VAC is measured at both J8 1 and J8 3 with the enables J10 9 and J10 23 and shunt amp J9 5 input low replace the Switching Control PC Board Ao G Both base and emitter are at 320 VDC potential Use extreme caution when testing Driver PC Board output If switching pulses are present at J8 1 and J8 3 check the Driver PC Board output between J27 3 Q1 base and J27 2 Q1 emitter The Driver PC Board output J27 3 O1 base to J27 2 O1 emitter should measure about 1 VAC If volt age measures 0 to 4 VDC lead on J27 3 repla
17. Logic PC Board Power Supply Start Circuit NOTE Refer to Appendix IX for Start Circuit Diagram The start signal enters the Merlin at J15 24 sig and 715 25 return or if no remote is used it could be wired to TB2 3 amp 4 From there it goes directly to the Logic PC Board For troublshooting remove any remote con nections from either J15 or TB2 Connect a jumper from TB2 1 to TB2 2 to enable the Merlin The RUN D1 and READY D2 leds on the Logic PC Board should be on If The front panel TEMP led is green and the COOLANT PRESSURE led is on but READY is not on the Logic PC Board is defective If READY is on and RUN isn t check that RUN SET PURGE is set to run Measure for less than 1 VDC on the Logic PC Board J1 13 to J1 12 If correct the Logic PC Board is defective If greater than 1 VDC the RUN SET PURGE switch or wire connections to it are defective If RUN and READY are on connect a jumper from TB2 3 to TB2 4 Logic PC Board START led D3 should come on and gases start flowing If not check for less than 1 VDC at J1 19 to J1 18 If correct Logic PC Board is defective If greater that 1 V wiring from TB2 to J1 is defective After the gases flow for the selected preflow time the W ON led should light and both the main contactor W1 or W2 and PCR contactor should come on If W ON does not light even momentarly the Logic PC Board is defective If W ON is on for a moment then off but neither W1 or W2 comes on eve
18. REPLACEMENT PROCEDURES 5 01 Introduction This Section describes parts replacement procedures and all repairs which may be performed on the Merlin 3000 Power Supply Under no circumstances are field repairs to be attemped 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 wmm 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 A WARNINGS 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 B Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Manual 0 2533 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach t
19. Relay Hold Down Spring to the side of the Relay Assembly 3 Pull the Relay Assembly from the Relay Socket 4 Install the replacement Relay Assembly by revers ing the above procedure C 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 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 Open 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 diode assembly to the mounting surface REPLACEMENT PROCEDURES 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 b Position the thermal interface pad between the diode and contact surface where the diode w
20. Start Circuit If no pilot refer to Section 4 05 K for Power Supply Start Cir cuit SERVICE TROUBLESHOOTING M DC indicator off after pre flow Main contactor comes on momentarily No pilot arc No main arc transfer 1 Switching transistor Q1 not turning on a Refer to Section 4 05 M Switching Control Check O1 N No pilot arc DC indicator on Pilot indicator OFF PCR not energized 1 Faulty Logic PC Board Switching Control PC Board or Shunt Amp PC Board a Refer to Section 4 05 N Pilot Circuit Check O No pilot arc PILOT indicator on PCR energized 1 Faulty Arc Start Box a Refer to Section 4 05 N Pilot Circuit Check 2 Shorted torch a Refer to Section 4 05 N Pilot Circuit Check P Weak or sputtering pilot 1 Faulty torch consumable parts a Replace consumables as needed 2 Plasma gas pressure too high a Adjust pressure 3 Low OCV normal 290 350 caused by improper con nection of voltage selection bus bars a Check input voltage connections 4 Low OCV caused by faulty Voltage Selection PC Board a If three phase input voltage is within the lower half of range refer to Operating Manual Sec tion 3 07 Input Voltage Selection D18 on Volt age Selection PC Board should be off If D18 is on replace the Voltage Selection PC Board 5 Input voltage low a Adjust pilot resistor for less resistance Refer to Section 4 05 R Pilot Resistor Adjustment No pilot PILOT indicator on Strong
21. TEMP E2 5 SW3 A ERE Men J5 PLUG TS3 PILOT RES TEMP SW 1 DEG C ET J51 2 SESOMDAR OXYGEN wi W2 MAIN W CONTACTOR 75A 3 POLE C3 A1 89 75 TER 051 J15 18 22 223 1217 118 AW J51 4 START LED J2 21 38 mis kan REMOTE 2 1 WIRE RIBBON CABLE 34 WIRE RIBBON CABLE PS PILOT PLASMA 2117 421 PIN 1 CABLE IN PLACE INTERLOCK DLE AN E EA 5E J1 16 43 GND WITH CABLE CONNECTED sia OD J18 15 B SHUNT AMP OUTPUT 3 GAS PRESSURE LED LOGIC PCB PURGE J1 21 44 515 16 Loe gus 4 TEMPERATURE LED 11 28 45 y 5 DC LED STATE 46 ee Se ALL OTHER 6 14 0 UNFILTERED 11 18 471 i D HE SEED gt J15 25 8 ENABLE Y L Ortez summ NOTE COMMON 11 CSR Q TB2 4 L EARTH OR UTILITY GROUND 13 LOW PANEL lt 15 WIPER 1 contro Ki TB2 9 OK TO AT CHASSIS GROUND 17 HIGH POT OK TO MOVE Taz 1 MOVE 21 OVERCURRENT SHUTDOWN 22 14 48 J15 23 ENABLE2 s J2 16 41 M5 14 J1 4 LOGIC PCB 25 TIP DRAGING B P 14 GHAND TORCH 14 26 VOLTAGE SELECTION Pca ALL EVEN 8 34 ARE GND 5 5 49 114 3 37 10 SWITCHING CONTROL PCB Ji 15 48 1744 J11 SHUNT AMP PCB ki J2 18 17 108 4 J12 13 MAIN TRANSFORMER 1 238 31 BIAS PCB 48VDC Q His 214 TORCH SIG ARC START BIAS J38 MAIN HEATSINK PTC gt 22 418 5 5 214 13 115 REMDTE CONTROL 339 FAN MOTOR a
22. VAC is not present remove 14 control connec tor at the torch bulkhead and measure for 24 VAC be tween pins 5 and 8 of the receptacle The 24 VAC comes from T3 is fused by F3 1A 250v and passes through the filter FL1 to J14 If voltage is not present at J14 the most likely fault is the fuse T3 and FL1 are other possibilities If F3 is blown replace it and leave J14 disconnected If it doesn t blow then recon nect J14 If fuse blows again then the Arc Starter PC Board is defective or there is a short in the torch leads between J14 and the Arc Starter PC Board O Current Control Display and CSD checks 1 Tip Drag Circuit The Merlin 3000 has a circuit that monitors the torch tip voltage to reduce cutting current to 40 50 amps reducing consumable parts wear if the tip voltage is less than 20 volts indicating double arcing or the tip contacting the work Wire 7 from the torch bulkhead connection connects to the Logic PC Board at terminal W7 If the voltage there is less than 20 VDC the Logic PC Board puts a low on J3 25 can measure at TP5 on the Logic PC Board causing the Switching Control PC Board J10 25 to reduce the current When piloting or cutting the tip voltage at W7 should be greater than 20 volts if so and Logic TP5 is low the Logic PC Board is defective 2 Front Panel Current Control If the Remote Control RC6010 is being used the front panel control is inactive go to next step The front panel c
23. Voltage Selection PC Board determines whether the voltage is in the lower or higher part of the selected input voltage range If the input voltage is within the upper part of the range the board energizes K1 K4 and K5 relays labeled HV on the system schematic If the input voltage is within the lower part of the range the board energizes the K2 and K3 relays labeled LV on the schematic If HV is selected the red LED indicator D18 on the voltage selection board will be lit The relays do not energize until SW1 B one pole of the ON OFF switch is closed because the DC voltage to the coils passes through it 28 VAC Test 1 Check the AC input from J6 24 to both J6 20 and J6 22 for 12 18 VAC Manual 0 2533 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 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 6 16 check SW1 B and all wiring and connections 120 VAC Test NOTE Refer to Appendix VI for 120 VAC Circuit Dia gram 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 If the voltage input is present check th
24. a te ees 2 1 04 Note Attention et Avertissement 3 1 05 Precautions De Securite Importantes sse 3 1 06 Documents De Reference ss 5 1 07 Declaration of Conformity ssssseeessseesesssrressrnsssrrssrnrstnnssstnsssrrnnsrnnssennnennnnt 7 1 08 Statement of Warranty iii 8 SECTION 2 INTRODUCTION ot edet 9 2 01 Scope Of Manual 9 2 02 General Service Philosophy ss 9 2 03 Service Responsibilities eene 9 SECTION 3 INTRODUCTION amp DESCRIPTION nnn nnne rnit 11 3 01 Scope of Manual ue 11 3 02 General Description 11 3 03 Specifications amp Design Features 11 3 04 Theory Of Operation nanna anna 12 3 05 Options And Accessories 4400 13 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS seen 15 4 01 imet Ut HEURES EE 15 4 02 Periodic Inspection amp Procedures 15 4 03 System Theory iii 16 4 04 Troubleshooting Guide us 18 4 05 m Fe ena re t Re tet 23 SECTION 5 REPAIRS 8 REPLACEMENT PROCEDURES sisi 33 5 01 Introduction er Re mere 33 5 02 Anti Static Handling 33 5 03 Parts Replacement General Information 33 5 04 External Parts Replacement 34 5 05 Access Panel Parts
25. blow out any accumulated dirt and dust with compressed air especially from the radiator The unit should also be wiped clean If necessary solvents that are recom mended 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 Coolant Filter Assembly Rear Panel The rear panel filter screen should be cleaned peri odically Remove the filter screen by unscrewing the filter holder from the Coolant Filter Assembly Clean the filter screen by rinsing with hot soapy water Re move soap residue by rinsing with clean hot water Be sure that all the soap has been removed and the screen is dry of water before re installing in the Cool ant Filter Assembly Coolant Filter Assembly Filter Screen i Figure 4 1 Coolant Filter Assembly Rear Panel A 01018 Filter Holder D Internal Filter Assembly The internal filter screen should be cleaned periodi cally To gain access to the Internal Filter Assembly remove the Left Side Panel viewed from the front of unit of the Power Supply Remove the filter screen by unscrewing the filter holder from the Internal Fil ter Assembly Clean the filter screen by rinsing with SERVICE TROUBLESHOOTING hotsoapy water Remove soap residue by rinsing with clean hot water Be sure that all the soap has been removed and the screen is dry of water befo
26. contact closure between J29 7 and 8 J6 7 and 8 of the Remote Control RC 6010 sends an active low signal to the Standoff Control 5 10 via J5 21 which turns OFF the Standoff Control THC ACTIVE indicator turns ON the three decimals in the VOLTS display and prevents the Standoff Control SC10 from changing torch height NOTE Refer to Appendix XI for Corner Slowdown CSD Circuit Diagram At the same time the CSD relay in the Remote Control RC6010 closes switching current control from the OUTPUT AMPS control to the CSD con trol and turning on the three decimals in the AMPS display Turning ON switch SW1 1 a dip switch on the Remote Control PC Board inside the Re mote Control RC6010 will reverse the logic so a closure is required at the CSD input for normal operation and an open for CSD SERVICE TROUBLESHOOTING For the Standoff Control SC11 used without the Remote Control RC6010 the CNC input for CSD is through J40 10 and J40 11 or J11 1 and J11 2 of the Standoff Control SC11 For the Power Sup ply corner current reduction is only available when using the Remote Control RC6010 The CSD relay output at J42 is not used with the Power Supply If the problem is the CSD on all the time or none of the time disconnect the CSD input from the cutting machine set Remote Control RC6010 in ternal switch SW1 1 OFF and jumper the CSD in put pins at either J6 or J29 J42 or J11 for Standoff Control SC11 If CS
27. indicating the current control pot setting SERVICE TROUBLESHOOTING The display signal at J7 2 should be equal to the control pot wiper voltage at J7 18 measured in Step 3 above If this is not correct the Switching Control PC Board is defective After arc transfer the display signal switches to represent actual cutting current as monitored by theShunt Amp and Switching Control PC Boards At the same time OK To Move is sent to the re mote shutting off the left hand decimal refer to Section 4 05 O OK To Move Tests The output of the Shunt Amp at J9 5 of the Switching Control PC Board is 5 45 volts for 150 Amps The display signal at J7 2 should be 10 volts If the shunt volt age is correct and the display signal is not then the Switching PC Board is defective If the remote display and the shunt amp voltage atJ9 5 is correct but the cutting current is low mea sured with separate ampmeter then the Shunt Amp may be faulty but first check step 1 of this section 5 Corner Slowdown CSD Corner Slowdown CSD a CNC signal is also referred to as standoff inhibit or corner current reduction The CNC signal comes from the cut ting machine controller to inhibit the standoff con trol when cutting speed reduction is desired Spped reduction may be needed for cutting around corners where high speeds would ad versely affect the standoff regulation It also can be used to reduce cutting current when the cut speed is lowered A
28. location of the pointer on the knob 2 Loosen the screw securing the Current Knob to the potentiometer shaft 3 Remove the old knob 4 Place the replacement Current Knob on to the po tentiometer shaft with the location of the pointer the same as noted in step 1 5 Tighten the screw to secure the knob to the poten tiometer shaft B ON OFF Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the ON OFF Switch 2 Disconnect all the wiring to the ON OFF Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement ON OFF Switch by revers ing the above procedure C RUN SET PURGE Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the RUN SET PURGE Switch 2 Disconnect all the wiring to the RUN SET PURGE Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement RUN SET PURGE Switch by reversing the above procedure Manual 0 2533 D LED Current Control PC Board Assembly Replacement 1 Remove the Current Knob per paragraph A above 2 Unlatch the Access Panel to gain access to the LED Current Control PC Board 3 Remove the four screws and washers securing the LED Current Control PC Board to the Access Panel 4 Disconnect the connector at J5 of the LED Current Control PC Board 5 Install the replacement LED Current Contro
29. mended procedures 3 Disconnect the wiring connector of the Flow Switch Assembly from the wiring harness at J25 4 Disconnect the hose connected to the bottom of the Flow Switch Assembly in the unit 5 Secure the end of the hose to prevent coolant from draining out of the Coolant Tank 6 Remove the four nuts washers and long screws that secure the Coolant Tank to the rear panel 7 Note the orientation of the old Flow Switch As sembly on the Coolant Tank 8 Move the Coolant Tank forward enough to allow removal of the old Flow Switch Assembly see note NOTE When removing the Flow Switch Assembly leave the brass fitting in the Coolant Tank 9 Remove the brass hose fitting in the end of the old Flow Switch Assembly and install into the replace ment Flow Switch Assembly 10 Install the replacement Flow Switch Assembly as noted in Step 7 by reversing the above procedure 11 Refill the Coolant Tank with the coolant removed or add fresh Thermal Arc Torch Coolant IL Conductivity Sensor Assembly Replacement 1 Remove the Top Panel per Section 5 04 B 2 Drain enough of the coolant from the Coolant Tank per Section 4 02 F to lower the coolant level be low the Conductivity Sensor Assembly hole lo cated on the end of the Coolant Tank Manual 0 2533 mm CAUTION Handle and dispose of the used coolant per recom mended procedures W Remove the two wires from the Conductivity Sen sor Assembl
30. replacement Hose Assembly by revers ing the above procedure Coolant Return Hose RETURN Connector to Radiator Assembly Replacement The Coolant Return Hose Assembly goes from the RE TURN Connector to the inlet side of the Radiator Re place the Hose Assembly using the following proce dure NOTE Refer to Subsection 6 05 Front Panel Cahassis Replacement Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the rear of the front panel RETURN connector 3 Locate the other end of the Hose Assembly at the inlet of the Radiator 4 Disconnect the Hose Assembly from the Radiator 5 Remove the Hose Assembly from the unit 6 Install the replacement Hose Assembly by revers ing the above procedure Coolant Supply Hose Pump to Pressure Gauge Assembly Replacement The Coolant Supply Hose Assembly goes from the Pump to a T Fitting at the Pressure Gauge Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the T Fitting at the rear of the front panel Pressure Gauge As sembly 3 Disconnect the other end of the Hose Assembly from the Pump Assembly 4 Remove the Hose Assembly from the unit 5 Install the replacement Hose Assembly by r
31. shielded torch and control leads F Interlocks The system has several built in interlocks to provide safe and efficient operation When an interlock shuts down the system the torch switch or control device must be used to restart the system 1 Parts In Place PIP Interlock The Power Supply has a built in parts in place inter lock that prevents accidental torch starting when torch parts are not properly installed A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly If not satisfied the switch interrupts power to the tip and electrode 2 Gas Pressure Interlock Pressure switches act as an interlock for the gas sup plies If supply pressure falls below minimum require ments the pressure switches will open shutting off the power to the contactors and the GAS indicator will go out When adequate supply pressure is avail able the pressure switches close allowing power to be resumed for cutting 3 Thermal Interlock Thermal overload sensors are located in the Main Transformer Main Heatsink Assembly and Pilot Re sistor in the power supply If one of these compo nents 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 sys tem G Plasma Torches Plasma torches are simi
32. 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 80XL 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 Series amp Parts Parts PAK Units Power Supplies CutMaster 80XL Cougar Drag Gun 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 Other Circuits 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 Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty
33. the cap from the fuse holder 3 Pull the faulty Fuse from the fuse holder 4 Install the replacement Fuse by reversing the above procedure Plasma or Secondary Regulator Assembly Replacement NOTE Both the Plasma and Secondary Regulator Assem blies are replaced in the same manner 1 Remove the Top Panel per Section 5 04 B 2 Carefully remove the input and output gas Hose Assemblies to the Regulator Assembly 3 On the Upper Ghassis Gauge Assembly remove the securing nut for the Regulator Assembly 4 Slide the Regulator Assembly out of rear of the Upper Ghassis Gauge Assembly 5 Remove the fittings from the old Regulator Assem bly 6 Reinstall the replacement Regulator Assembly by reversing the above procedure Control Logic PC Board Assembly Replacement 1 Open the front panel access panel cover at the front of the Power Supply 2 Fasten the access cover open with string or rubber band 3 Note where each connector is located on the old Control Logic PC Board REPLACEMENT PROCEDURES 44 4 Disconnect the three connectors from the old Con trol Logic PC Board 5 Note the orientation of the old Control Logic PC Board 6 Remove the old Control Logic PC Board 7 On the new Control Logic PC Board set the switches SW1 through SW5 the same as the old Control Logic PC Board 8 Install the replacement Control Logic PC Board by reversing the above procedure Switching Control PC Boar
34. to 20 25 in Ibs 2 3 2 8 Nm and alllarge diodes D1 6 are torqued to 34 in Ibs 3 8 Nm Apply a light film of electrically con ductive 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 first few hours of operation Before deciding that this was the case be sure to check out other possibilities F Thermal Sensing Circuit Check 1 Thermal sensors TS1 TS2 TS3 TS4 and TS5 are connected 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 TS1 TS3 TS4 and TS5 are switches nor mally closed 0 ohms that open at over tempera ture TS1 TS4 and 155 are part of the Main Trans former Assembly TS2 is on the Heatsink and TS3 is on the Pilot Resistor 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 If the unit still 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 voltage is greater than 4 VDC and the TEMP indicator is lit
35. transistor Q1 shorted to heatsink a Replace Q1 check heat sink for possible dam age Refer to Section 4 05 M Switching Con trol Check 01 Shorted input capacitor C7 C12 a Replace capacitor if necessary Shorted diode D11 D14 a Check for proper 3 phase power at input termi nal board check diodes Refer to Section 4 05 E Diode Check Faulty Voltage Selection PC Board a If W1and W2 come on simultaneously replace Voltage Selection PC Board Faulty main contactor W1 or W2 a Check both contactors for welded contacts and replace contactor s if necessary G TEMP indicator on red 1 Unit overheated a Clean radiator and check for obstruction b Excessive piloting allow unit to cool 2 Faulty thermal sensor TS1 TS2 or TS3 a Refer to Section 4 05 F Thermal Sensing Circuit 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 SERVICE TROUBLESHOOTING 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 H No GAS indicator Motor and Pump operating Other LED indicators normal Both gases flow 1 Front panel RUN SET PURGE switch set to PURGE or PURGE selected at Remote Control a Normal operation purges plasma line only sec ondary pressure switch is not satisfied Ga
36. 1 Remove the two Coolant Hose connections to the Coolant Filter Assembly 2 Remove the two elbow fitting on each side of the Coolant Filter Assembly and remove the damaged assembly from the bracket 3 Clean the old thread sealer from the threads of the elbow fittings 4 Apply a thin coating of liquid teflon thread sealer to the threads of the elbow fittings 5 Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings 6 Reconnect the two Coolant Hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly left side as viewed from the back REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES G Coolant Tank Replacement 1 Remove the Left Right and Top Side Panels per Section 5 04 B 2 Drain the coolant from the Coolant Tank per Sec tion 4 02 F CAUTION Handle and dispose of the used coolant per recom mended procedures 3 Remove the two wires from the Conductivity Sen sor located on the end of the Coolant Tank near the center 4 Unplug the wiring connection at the Flow Switch Assembly located on the end of the Coolant Tank near the top return hole 5 Remove the hose connected to the bottom of the Flow Switch Assembly 6 Remove the hose connected to the 90 Adapter Fit ting near the bottom side outlet hole of the Cool ant Tank 7 Remov
37. 1 8 NPT LH Receptacle Square Flanged 14 Circuit CPC Rev Sex Fuse Holder For 1 4 x 1 Fuse 5 Amp Fuse MTH5 250V Fuse Holder Buss HPS 10 Amp Fuse Spill Tray 1 8 NPT Female Elbow 4 JIC 1 8 NPT STR Adapter Orifice Water Flow Metering 1 4x 1 8 NPT Reducer Air Regulator 1 4 NPT Coupling PC Board Support 1 4 NPT Street Elbow Assembly Logic PC Board 1 8 NPT STR Tee Connector Bulkhead Lead Torch Lead 9 16 x 1 8 Jam Nut Connector Inductor Lead 4 JIC 1 8 x 90 Adapter Assembly Switching Control PC Board 3 8 x 1 4 NPT Reducer 6 JIC x 3 8 NPT STR Adapter 8 x 3 8 NPT STR Adapter 3 8 NPT Female Tee 3 8 NPT Close Nipple Valve Check 3 8 NPT Female Brass 60 Catalog 9 1302 7 3360 9 1406 8 6154 9 4381 9 1054 9 4383 9 1300 8 3260 8 4313 8 4330 8 0312 9 1044 8 6147 8 6148 8 4509 8 4510 9 3293 9 2936 8 1025 9 2937 9 3641 8 6149 9 4175 8 0257 8 2177 9 2023 8 3223 9 3885 9 5333 9 2184 9 5968 8 0352 8 6150 8 4511 8 2149 9 1400 8 0262 9 5970 8 1422 8 0348 8 1251 9 2385 9 2384 9 1402 Manual 0 2533 Item Qty Description Catalog f 43 1 Check Valve Male 1 4 NPT 5 PSI 8 4512 44 1 Hose Assembly Secondary Water Gauge To T Fitting 8 4513 45 1 Hose Assembly Secondary Gas Water to Bulkhead 8 4514 46 1 Hose Assembly Secondary Gas Inlet to Regulator 8 4515 47 1 Hose Assembly Bulkhead to Coolant Pressure Gauge 8 4516 48 1 Hose Assembly Secondary Wate
38. 11 RED 24 CLOSE TO START GREEN SOURCE 24VDC 18 MA OPEN TO STOP T 25 1 N na N E BLACK Ea WHITE de SOURCE 24VDC 18 MA ALSO SEE TB2 LI x i SHIELD v D 74 m U a ul LL A 00982 APPENDIX VI 120 VAC CIRCUIT DIAGRAM SWITCHING Ki CONTROL PCB J28 TO OPTIONAL STANDOFF CONTROL Lo 3 10 rU 24 110 ore 50014 8012 SOL3 1 p el lee _ _ 9e 5 pao 4 Ka K 50 sweA 23 75 15 eue ceps 1 L __ VOLTAGE SELECTION 04 HE 5 LOGIC PCB pc POM de qur qe J APPENDIX 72 Manual 0 2533 APPENDIX VII LADDER DIAGRAM 15 VDC GAS CONTROL CIRCUIT SECONDARY PRE FLOW amp POST FLOW CIRCUIT SWITCH RECOGNITION START INDICATOR CONTACTOR CONTACTOR CONTROL CONTACTOR DISABLE Only after main con tactor initially closes VOLTAGE 60VDC To disable this circuit for troubleshooting short test points together VOLTAGE gt 60VDC HF AND PILOT CONTACTOR L REFERENCES J1 CONNECTOR Manual 0 2533 BENSE BRIDGE SENSE BRIDGE O REFERENCES J3 CONNECTOR SW2 RUN SET PURGE START STOP CNC START STOP Hand FS1 194 195 TS1 152 eel oel ood GAS PS1 OXYGEN OVER CURRENT SHUTDOWN
39. ART PER 1 SOURCE 24VDC zz Ez rom MOMENTARY La 2 DM 228105 Bil Go MS SHIELD f 1 2 We l SO START STOP i HEB ceu 3 SOURCE 24VDC We P3 s CLOSE TO START GREEN 1 2 a MA 2 OPEN TO STOP DATE QE 1 2 qe 22 S gt ro 1 BLACK les u z STOP l 5 SOURCE 24VDC Cla j Slo MOMENT ARY ii MA MS SHIELD dh 20 ex 5 7 M E SOURCE 24VDC Eo 238 STATION WHITE 1 p AAR m SELECT DE SHIELOM il x M 8 a 21 2 BLACK i CORNER SLOWDOWN mi m Tu QDHBEE Se TD gt GREEN 11 10 MA CORNER CURRENT La 11 1 REDUCTION SHIELD y AVA ie 24 ES z CONTACT SOURCE afs BLACK 3E OK TO MOVE WHITE M START MOTION pere 0 SHIELDS 2A 125VAC Z 4 2 VDE MA SEE RC 8010 MAX ale MANUAL FOR BLACK ORANGE amp SIS in STATION SELECT BLACK BROWN T d AND CSD OPTIONS PAIRS NOT USED zr lt CONNECT SHIELDS TO GND AT CUTTING MACHINE END QE POWER SUPPLY CNC CABLE 71 USED W O REMOTE CONTROL CABLE PT H r CUTTING MACHINE 4 r MERLIN 3000 e 115 24 SOURCE 3 ORANGE OK TO MOVE BLUE 18 START MOTION bie ee E ME e esi Fg 2A 125VAC 250 MA MAX F pg 28vDC START STOP
40. Adjustment The amount of pilot current is controlled by the value of the pilot resistors R16 and R21 Too much current causes excessive tip wear and too little causes a sput tering pilot that wears the electrode The factory set ting is correct for most cases but with low input line voltage and with some combinations of gas and tips the current may be too low to maintain a steady no sputtering pilot To adjust the resistors use the following procedure 1 Remove the left side panel as viewed from the front of the unit 2 Locate and identify the pilot resistors which are on a bracket in front of the fan Pilot Resistors A R16 and R21 A 01219 Location Of Pilot Resistors 3 Locate wire 96 which is connected between the two resistors The wire is attached to each pilot resistor with a clamp 4 Using a screwdriver loosen both clamps 5 Move each clamp down the pilot resistors toward the inside of the unit approximately 1 2 inch 12 7 mm 6 Test the pilot if it still sputters move the clamps another 1 2 inch 12 7 mm SERVICE TROUBLESHOOTING CAUTION Move the clamps only what is necessary for a steady pilot Too much adjustment can cause increased parts wear DO NOT move each clamp more than a total of 2 inches 50 8 mm If a steady pilot cannot be achieved with the adjust ment then something else is wrong SERVICE TROUBLESHOOTING 32 Manual 0 2533 SECTION 5 REPAIRS amp
41. 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 information 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 an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors 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 Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding cir cuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp GENERAL INFORMATION Install and maintain equipment according to NEC code refer to item 9 in S
42. B Disconnect all the wiring at the DC Inductor As sembly Remove the six mounting bolts securing the DC Inductor Assembly to the Base Place a mechanical lift next to the left side of the Power Supply Carefully slide the DC Inductor Assembly out the left side of the unit and onto the mechanical lift Install the replacement DC Inductor Assembly by reversing the above procedure 29KVA Transformer T1 Assembly Replacement A WARNING The removal of this Assembly requires the use of a mechanical lift Remove the Left and Right Panels per Section 5 04 B Disconnect all the wireing at the Transformer As sembly Remove the six bolts star washers and flat wash ers securing the Transformer Assembly to the Base Place a mechanical lift next to the left side of the Power Supply Carefully slide the Transformer Assembly out the left side of the unit and onto the mechanical lift REPLACEMENT PROCEDURES 6 Install the replacement Transformer Assembly by reversing the above procedure 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 per Section 5 04 B 2 Label all the wiring connected to the Main Contac tor Assembly 3 Disconnect the wires from the Main Contactor As sembly terminals 4 Remove th
43. Bulkhead Adapter Fitting 3 Disconnect the gas Hose Assembly from the fitting at the end of the Bulkhead Adapter Fitting 4 Remove the fittings from the end of the Bulkhead Adapter Fitting 5 Remove the first nut from the Bulkhead Adapter Fitting 6 Remove the second nut securing the Bulkhead Adapter to the Upper Chassis Gauge Assembly m Pull the Bulkhead Adapter Fitting from the Upper Chassis Gauge Assembly 8 Install the replacement Bulkhead Adapter by re versing the above procedure Plasma or Secondary Gas Input Fitting Replacement NOTE Both the Plasma and Secondary Gas fittings are replaced in the same manner 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the Torch connection to the fitting be ing replaced at the Upper Chassis Gauge Assem bly REPLACEMENT PROCEDURES 3 Disconnect the gas Hose Assembly from the fitting at the end of the Gas Input Fitting 4 Remove the fitting screwed into the end of the Gas Input Fitting O1 Remove the first nut from the Gas Input Fitting 6 Remove the second nut securing the Gas Input Fit ting to the Upper Chassis Gauge Assembly N Pull the fitting from the Upper Chassis Gauge As sembly 7 Reinstall the replacement Plasma or Secondary Gas Input Fitting Assembly by reversing the above pro cedure Fuse F1 and F2 Replacement 1 Open the hinged cover at the Front Panel torch leads connection area 2 Locate and remove
44. Control PC Board The Switching Control PC Board compares the shunt amp output with the 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 signals are sent to the driver PC board where they are converted into the current and voltage levels needed to drive the switching transis tor TheSwitching Control PC Board senses if the Remote Control RC6010 is installed to route the current con trol signal from the remote instead of the Merlin front panel control TheSwitching Control PC Board routes theShunt Amp signal to the remote s current display sends a torch voltage signal to the standoff control and supplies POT HI and POT LOW signals to set min and max output to both remote and front panel current controls CSR output greater than 25A and over current shutdown current greater than 175A are sent to the Logic PC Board A relay on Switching Control PC Board controled by the Remote Control RC6010 ENABLE switch or the ENABLE input on TB2 removes power from one side of the motor MC and main W contactors coils when the enable switch is off shutting off the coolant flow and DC power to allow changing torch parts Logic PC Board Functions The Logic PC Board controls the timing and sequenc ing of the system It monitors the pressure tempera ture and flow interlocks and co
45. D is on display indicates three decimals when the jumper is connected and off when the jumper is not connected the prob lem is with the cutting machine or the CNC cable If jumping the CSD does not work the Remote Control RC6010 or Standoff Control SC11 is faulty If while using the Remote Control RC6010 and Standoff Control SC10 together CSD works in the Remote Control RC6010 but not the Stand off Control SC10 check for a low less than 3 VDC on the ribbon cable at J5 21 If not low with CSD on the Remote Control RC6010 is faulty If J5 21 is low either the Standoff Control SC10 is faulty or the ribbon cable is open P 48 Volt Bias Test 1 Remove the remote cable from the Remote Control RC6010 or the Standoff Control SC11 Tempo rally jumper TB2 1 to TB2 2 for enable For the Remote Control RC 6010 measure for 48 5 VDC from J37 16 35 and 37 to J37 15 34 and 36 If correct Remote Control RC6010 is faulty For the Standoff Control SC11 measure J41 3 and 4 to J41 1 and 2 If correct Standoff Control SC11 is faulty 2 If the 48 VDC is not correct go the Power Supply and measure for 48 5 VDC at J31 1 to 2 of the Bias PC Board If correct check for open in the Power Supply harness to J15 or the remote cable If 48 VDC is not correct remove J31 from the Bias PC Board as and measure again on the Bias PC Board If correct check for a short in the wiring harn
46. Diode Replacement Kit Includes Diode 150 Amp 800V REV Thermal Interface Pad 1 06 Dia 150 Amp STR Diode Replacement Kit Includes Diode 150 Amp 800V STR Thermal Interface Pad 1 06 Dia Assembly PTC Resistor Relay Hold Down Spring Bracket Transistor Coil Harness Assembly Transistor Standoff 3 8 Hex Nylon Washer Fiber Shoulder Shunt 250A 100 mV Shunt Amp PC Board Assembly 62 Catalog 9 1404 9 1303 8 4521 8 2176 9 4212 9 1304 9 1406 8 6154 9 1305 8 6314 8 1168 9 1408 9 1409 8 6316 9 1410 8 6315 9 1405 8 4522 8 6677 9 2731 9 5256 8 6675 8 6674 8 6155 8 6153 8 6152 8 4523 9 4297 8 6676 8 6313 8 5147 8 6678 9 4392 9 4391 Manual 0 2533 eoc 36 A en A 00971 PARTS LISTS 63 Manual 0 2533 6 10 Power Supply Options And Accessories Item Qty 1 dO WN 8 9 10 11 12 13 14 15 16 17 1 RP WR RR RR RR RP 1 Description Remote Control RC6010 Standoff Control SC10 Gas Control GC3000 Air Line Filter Assembly Replacement First Stage Filter Element Replacement Second Stage Filter Element Gas Regulators Nitrogen Regulator CO2 Regulator Argon Hydrogen Regulator Oxygen Regulator Water Regulator Remote Pendant Control Assembly Switch for Remote Pendant Cord Grip for Remote Pendant Handle Only for Remote Pendant 14 pin Plug for Remote Pendant Pin for Remote Pendant Plug C
47. EM VOLTAGES L1 1 L1 3 3 4 J15 200 208 12 6 12 6 8 8 220 230 H D FRI VOLTS LED amp CURRENT CONTROL PCB UO 20 03 13 09 200 200 2207230 PANEL CONTROL POT amp STATUS LEDS L1 3 415 500 460 575 388 415 184 3 468 2 0 e SEC VOLTS LOGIC PCB DIP SWITCH FUNCTIONS LISIA 258 VA 298 VAC SWI 182 ON FOR NO AUTO RESTART O L1 5 1 2 A1 A1 288 230 SW2 182 ON FOR DELAYED AUTO RESTART 500 575 L2 10 6 7 B BI 195 225 PREFLOW POSTELI sO 7O L3 15 11 12 B B2 245 288 EPER DSTRED 1 115 TIME 5 3 TIME 5w4 228 239 468 MES PE Tale Tel 0 01 14 16 2 ale 5 ali L1Q KO B 0 02 16 19 4 jali a c ca 01 01 28 32 7 20 lila 20 a 02 02 33 38 jali 4 1 t H IE E E 26 26 GND E E 130 13 1 IS ON amp 0 IS OFF I8 Go ELEM d BE SW 5 OK TO MOVE UP CONTACTS DOWN 24VAC D APPENDIX 80 Manual 0 2533
48. IHERMAL DYNAMICS A THERMADYNE Company MERLIN 3000 Plasma Cutting Power Supply Service Manual October 6 1999 Manual No 0 2533 Read and understand this entire Service Manual and your WARNING employer s safety practices before installing operating or servicing the equipment While the information contained in this Service Manual repre WARNING sents our best judgement Thermal Dynamics Corporation assumes no liability for its use MERLIN 3000 Plasma Cutting Power Supply Service Manual Number 0 2533 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1996 by Thermal Dynamics Corporation rights reserved Reproduction of this work in whole or in part without written permission 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 the MERLIN 3000 Plasma Cutting Power Supply Service Manual whether such error results from negligence accident or any other cause Printed in the United States of America October 6 1999 SECTION 1 GENERAL INFORMATION erii ba ertet ed Ee et ee pone teen 1 1 01 Notes Cautions and Warnings 1 1 02 Important Safety Precautions sse 1 1 09 a ee de
49. IX 82 Manual 0 2533
50. LASMA 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 GENERAL INFORMATION To protect your eyes always wear a welding hel metor 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 in 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 Documents U S Government Printing Office Wash ington D C 20402 2 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami
51. MANDATIONS DE PRA TIQUES SURES POUR LA PREPARATION ALA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTEC TION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 6 Date 6 22 99 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address Industrial Park 2 West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Direc tive 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 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 ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ a
52. NT CONTROL DISPLAY CIRCUITS MEHE D RC 6210 MERLIN POT HI 215 20 J Z55 SWITCHING CONTROL deu J37 21 J15 1 PCB TC 1 SWITCHING DUTPUT a g denm CONTROL AMPS CSD A CB J37 20 J15 2 J7 17 JIS L2 J298 25 qeu s 5 I T POT LOW J37 11 J15 26 J7 28 ze REMOTE INSTALLE J37 12 015 27 47 19 tee al ek 4 J15 3 J7 2 DISPLAY m ds TO 158A 1 _ 1037 2 115 4 APPENDIX 76 Manual 0 2533 APPENDIX XI CSD CORNER SLOWDOWN CIRCUIT CSD CIRCUITS CSD J29 10 J8 9 CSD cg AP 229 11 48 178 lt RC 6011 16 1 re Las J J ka D m ISOLATOR RIBBON J8 9 33559544 16 2 E CABLE d 4 CSD i4g 1g 9 79 G AP wl J8 7 J40 9 CSD 18 20 Z l lt 14 11 NTROI J11 2 ISOLATOR STANDOFF CONTROL SC 18 01140 USED INLY WITH STANDOFF ONTRO SC 11 Manual 0 2533 77 APPENDIX APPENDIX XII OK TO MOVE CIRCUIT DIAGRAM Merlin 3000 or Merlin 6000 or Merlin 6000GST with Remote Control RC6010 Standoff Control SC10 OK To Move Circuit
53. RVICE TROUBLESHOOTING 24 the Switching Control PC Board to wire 8 through the ON OFF switch SW1A to wire 9 through fuse F2 to wire 10 and T1 Only one of the MC 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 1 Check the 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 test paragraph A above to check for a proper voltage supply from the volt age selection board If correct continue to step 2 to isolate the problem in the return path 2 With one meter lead on the supply side of the con tactor coil wire 3 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 SW1 A and E Stop can be measured for conti nuity 1 the switching control board will nor mally be open when power is off 3 When the remote control cable is installed a jumper between 15 26 and J15 27 pulls J7 20 on switching control board to 0 V board connector J7 19 When the jumper is not in place remote cable is not plugged in J7 20 measures 15 VDC and K1 should energize bypassing the E stop func tion If not replace the switching control board Diode Check There are fourteen diodes in the main heatsink area
54. Replacement sss 35 5 06 Front Panel Chassis Parts Replacement 35 5 07 Rear Panel Parts Replacement 36 5 08 Base Assembly Parts 39 5 09 Upper Chassis Parts Replacement 40 5 10 Main Heatsink Assembly Parts Replacement 45 5 11 Hose Assembly Replacements 47 TABLE OF CONTENTS TABLE OF CONTENTS continued SECTION 6 PARTS a contia tui A a 51 6 01 IntrOdUCllOn niei e HE t rd e 51 6 02 Ordering Information 51 6 03 External Power Supply Replacement Parts 52 6 04 Access Panel Replacement Parts 53 6 05 Front Panel Chassis Replacement Parts 54 6 06 Rear Panel Replacement Parts 56 6 07 Base Assembly Replacement 58 6 08 Upper Chassis Replacement Parts 60 6 09 Main Heatsink Assembly Replacement Parts 62 6 10 Power Supply Options And Accessories 64 APPENDIX I INPUT WIRING eerte 67 APPENDIX Il SEQUENCE OF OPERATION BLOCK DIAGRAM
55. S 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 Pro tection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 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 GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES 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 MOW 1R3 13 ivret 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 GENERAL INFORMATION 14 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM
56. SEMENT 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 DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT 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 propre 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 NENNEN et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respi ration Gardez votre t te hors de la plume de
57. SR signal to the Logic PC Board which opens the pilot contactor shutting off the pilot anf generating an OK To Move signal OK To Move can be either contact closure or 24VAC through con tacts selected by switch SW5 on the Logic PCB OK To Move is sent to the remote control the standoff control or directly to the cutting machine controller It controls the optional High Flow Water Shield and the Arc Hour Starts Counter LED Current Control PC Board The LED and current control PC board contains the sequence status LED indicators and the front panel current control pot Remote Control The Remote Control allows remotely controlling the cutting current setting reduced current for corner slowdown and enabling gas purge and set functions An ENABLE switch shuts down the power supply and coolant pump for changing torch consumables The Digital Amperage display allows accurate setting and monitoring of the cutting current Connections to the cutting machine controller CNC are electrically iso lated to minimize interference Both a rear panel con SERVICE TROUBLESHOOTING nector and an internal terminal strip are provided for CNC connections The remote includes internal con nections to interface to the SC10 standoff control so the single remote cable works for both A Merlin 3000 system may include the following No Remote Control RC6010 Remote Control Only RC6010 Remote Control Only RC6010 With Standoff Con
58. URGE gt ci 29 4 gt ORANGE RED 5 gt gt 17 PURGE RTN S aet LEES 5 RED GREEN STHIPE 37 48VDC RTN gt jes GREEN ZRED STRIPE gt 34 48VDC SUPPLY SEN 5 up Zol 7 x RED BROWN STRIPE _ gt mg ON LED 2 5 E T BROWN RED STRIPE 20 sz 9 gt 20 RED GRAY STRIPE 2 DEMAND RTN 58 32 21 gt STRIPE 1 DEMAND 4 22 BLACK Z BLUE STRIPE 15 SET RTN te 23 BLUEZBLACK STRIPE gt 14 SET 24 BLACK ORANGE STRIPE o 23 POT LOW RTN 2 25 gt DORANGE BLACK STRIPE gt 22 POT LOW i 4 26 BLACK GREEN STRIPE 32 ENABLE RTN k 27 gt GREEN BLACK STRIPE gt 33 ENABLE 28 BLACK BROWN STRIPE o 34 E STOP RTN gt 29 BROWN BKACK STRIPE 35 E STOP NOT USED fa 30 BLACK GRAY STRIPE o 10 OK TO MOVE gt 7 31 GRAY BLACK STRIPE gt 11 OK TO MOVE 7 32 X YELLOW BLUE STRIPE 28 TORCH VOLTS SIG ee 33 BLUE 7YvELLOW sTRIPE 29 TORCH VOLTS SIG YELLOW ORANGE STRIPE gt 7 48 VDC RTN alls 35 gt ORANGE YELLOW STRIPE gt 48 VDC SUPPLY ui 36
59. able Clamp for Remote Pendant Remote Pendant Adapter The following are not shown PARTS LISTS 1 1 1 1 ee M Plasma Gas Supply Line 10 ft 3 0 m Secondary Gas Supply Line 10 ft 3 0 m High Pressure Air Regulator High Flow Water Shield 220V Version 460V Version Remote Control Cable 25 ft 7 6 m 50 ft 15 2 75 ft 22 8m 100 ft 30 4m Remote Control RC6010 CNC Interface Cable 5 ft 1 5 m 10 ft 3 0 m 15 ft 4 5 m 20 ft 6 m Standoff Control Lifter Motor Control Cable 10 ft 3 0 m 15 ft 4 5 m 20 ft 6 m Power Supply CNC Interface Cable 25 ft 7 6 m 50 ft 15 2 75 ft 22 8m 100 ft 30 4m Torch Coolant Standard 25 75 Mix for Ambient Temperatures to 10 F 12 C Super 50 50 Mix for Ambient Temperatures to 34 F 36 C 64 Catalog 3 6106 3 6110 7 3411 7 3139 9 1021 9 1022 9 2722 9 2759 9 3053 9 4379 8 6118 7 3114 9 4229 9 4228 8 1662 9 3294 8 4524 9 3295 9 4393 9 2146 9 2147 9 3022 7 2984 1 7 2984 2 9 5961 9 5962 9 5963 9 5964 9 4483 9 4484 9 4485 9 4486 9 4535 9 4536 9 4537 8 3380 8 3381 8 3382 8 3383 7 2850 7 2959 Manual 0 2533 A 01218 Manual 0 2533 65 PARTS LISTS PARTS LISTS 66 Manual 0 2533 APPENDIX I INPUT WIRING REQUIREMENTS Freq 3 Ph 3 Ph Fuse Amps Wire AWG Wire Canada sw a soso o ml pee 8 LX pu 50 60 50 60 Line Voltages wit
60. ag 8 3312 15 1 Coolant Tank 8 4275 16 2 Bracket Tank Support 8 4506 17 1 Cap Coolant Tank 8 5142 18 3 4 JIC 1 8 NPT x 90 Adapter 8 0262 19 1 Check Valve 1 8 NPT Female 8 1787 20 4 1 8 NPT Close Nipple 8 0354 21 2 Assembly Solenoid Valve Connection 8 1196 22 1 Fitting Adapter 3 8 NPT 9 16 18 O Ring 9 1412 23 1 Assembly Flow Switch 9 5969 24 1 Spec O Ring Hose Adapter 8 0319 25 1 Assembly Conductivity Sensor 8 6203 26 1 Support Filter 8 6202 27 1 Coolant Filter 8 4276 28 3 1 4 1 8 NPT Reducing Bulkhead 9 4078 29 1 Strain Relief For 10 Stranded Wire 8 4249 30 1 Twist Loc Base 9 3290 31 1 3 4 Inch Snap Button Hole 8 0232 32 1 Valve Solenoid 5 32 Orifice 1 4 NPT 8 4323 PARTS LISTS 56 Manual 0 2533 A 01216 Manual 0 2533 57 PARTS LISTS 6 07 Base Assembly Replacement Parts Item Qty o amp CQ 2 PRR RRP e RRR Be DoF WN OO WAN FFP WN PARTS LISTS PrP FP RP NN FP RP NN RP RP RP PN RP RP RON nm NY mr 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 Squeeze Connect Westinghouse 1 2 HP Motor 1PH 50HZ 110 220V 5 8 Coupling Body Coupling Spider Body Coupling 7 16 Diameter Bore 8 JIC x 3 8 NPT Straight Adapter 1 2 x
61. age chlor s Eliminez toute source de telle fum e A CHOC 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 lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail 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 par ties du circuit de soudage 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 GENERAL INFORMATION INCENDIE 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 mat
62. ainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Ca nadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRA PHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 REC OMMENDED SAFE PRACTICES FOR THE PREPA RATION FOR WELDING AND CUTTING OF CON TAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRA TORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note 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 wmm ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question Date 6 22 99 S
63. arts Item Qty o OFF WN NNN PPR RP RP RP RP WAN FF WN r PARTS LISTS Description Front Panel With Overlay Front Panel Overlay Cord Grip Torch Leads Panel Boot Radiator 6 JIC x 3 8 NPT Male Union Coolant Filter Support Inner Coolant Filter Support Lower Coolant Filter 8 to 3 8 Straight Adapter Panel Access Divider Horizontal Chassis Panel Assembly Torch Leads Shield 2 1 4 Resistor 8 ohm Resistor Mounting Bracket Kit Assembly Bias Supply PC Board Fuse 1A 250V Fuse Block 1 4 x 1 1 4 Fuse EMI Filter P C Board Support Transformer Assembly Hose Assembly Internal Filter to Tank Hose Assembly Bulkhead to Radiator 54 Catalog 8 6304 Manual 0 2533 PARTS LISTS 55 Manual 0 2533 6 06 Rear Panel Replacement Parts Item Qty Description Catalog 1 1 Rear Panel 8 4505 2 1 Fan 16 Axial 8 6312 3 2 Contactor 25 amp 2 pole 120V Coil 8 5143 4 1 3 PH Contactor 8 1373 5 1 4 mfd Capacitor 9 3210 6 2 Capacitor Mounting Bracket 8 6308 7 1 330k Ohms Resistor Assembly 9 5545 8 1 Voltage Selection PC Board 8 5144 9 4 P C Board Supoort 9 5333 10 1 Bracket Heatsink Support 8 5576 11 1 Hose Assembly Tank to Coolant Filter 8 4274 12 3 8 3 8 NPT x 90 Adapter 8 0346 13 1 Basket Coolant Tank 8 4273 14 1 Deionizer B
64. as supply 5 Faulty solenoid valve SOLI plasma gas SOL2 secondary gas 5013 secondary water SOLA through SOL9 Optional Gas Select a Check solenoid for sticking or clogging Check coil resistance per the following SOL1 and SOL3 should be approximately 400 ohms SOL2 should be approximately 100 ohms SOLA through SOL should be approximately 300 ohms 6 Faulty switch SW3 A or Gas Control GC3000 Sec ondary Select Switch a Check SW3 A for continuity wire 75 to 88 for secondary gas 75 to 89 for secondary wa ter 7 Faulty Logic PC Board a Refer to Section 4 05 H Gas Solenoid Circuits Replace Logic PC Board if necessary 8 Input gas pressure set too high preventing solenoids from operating a Remove input gas line and retry b Regulate input gas pressure between 90 to 110 psi 6 2 to 7 6 bar J COOLANT indicator off 1 Little or no pressure shown on gauge a Check coolant level b Check motor rotation and rpm c Check and replace pump if necessary 2 Clogged internal or external coolant filters a Check internal and external coolant filters Clean or replace if necessary Flush the old cool ant from the system see note below Manual 0 2533 21 NOTE With a clogged internal coolant filter or Torch and leads the Coolant Pressure Gauge will be normal but the Pressure LED indicates flow will be OFF 3 Clogged torch or leads a Check torch and leads and replace if n
65. ation is cor rect when installed The 80 PSI mark should be at the twelve o clock position Coolant Pressure Gauge Replacement 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the Coolant Hose Assembly from the fitting at the Pressure Gauge 3 Remove the fitting s from the Pressure Gauge 4 Remove the nut and clamp Securing the Pressure Gauge Assembly to the Upper Chassis Gauge Assembly 5 Slide the Pressure Gauge out of the Upper Chas sis Gauge Assembly 6 Reinstall the replacement Pressure Gauge Assem bly by reversing the above procedure NOTE Besure that the Pressure Gauge orientation is cor rect when installed The 80 PSI mark should be at the twelve o clock position Manual 0 2533 43 E Pressure Switch Replacement NOTE Both the Plasma and Secondary Pressure Switches are replaced in the same manner 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the two wires connected to the Pres sure Switch Assembly 3 Remove the assembly from the T fitting 4 Install the replacement Pressure Switch Assembly by reversing the above procedure and noting the following Apply pipe thread sealant to the fitting before reassembling Coolant Supply and Return Bulkhead Adapter Fitting Replacement NOTE Both the Coolant Supply and Return Bulkhead Fittings are replaced in the same manner 14 Remove the Top Panel per Section 5 04 B m Remove the Torch connection to the
66. 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 19 5 If it does not measure zero the Shunt Amp which should have no output is defective 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 If PILOT indicator is ON and PCR is not closing check for 120 VAC between wire 110 and J2 1 on the Logic PC Board NOTE Refer to Appendix VI for 120 VAC Circuit Dia gram If not present replace the Logic PC Board If 120 VAC is present check to see if it is at the PCR coil If volt age is present the contactor is faulty A WARNING High Voltage is present For the Arc Starter Box confirm that the OCV mea sured at the torch bulkhead is also preset at E1 and E2 on the Arc Starter PC Board if not the torch leads ex tension may be open Check for 24 VAC from J1 1 to J1 3 on the Arc Starter PC Board see note NOTE Later versions of the Arc Starter Box have a 24 VAC indicator on the Arc Starter PC Board The indicator 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 de fective Manual 0 2533 If 24
67. ble and Clamp Air Line Filter Assembly or High Pressure Regula tors NOTE Refer to Section 3 05 for complete list of Power Sup ply Options and Accessories 3 03 Specifications amp Design Features The following apply to the Power Supply only 1 Controls ON OFF Switch Output Current Control RUN SET PURGE Switch Secondary Gas Regulator Plasma Gas Regulator Secondary Mode Switch 2 Control Indicators LED Indicators AC TEMP GAS PILOT COOLANT PRES and COOLANT COND Gauges Secondary Plasma and Coolant Pressure Gauges 3 Input Power 200 220 230 50 or 60 Hz 98 89 85 380 415 460 50 or 60 Hz 51 47 42 500 575 50 or 60 Hz 40 34 NOTE Refer to Appendix I for recommended input wir ing size current ratings and circuit protection re quirements Amps depends on input voltage Refer to Appendix I 4 Output Power Continuously adjustable by potentiometer from 50 to 150 amps 11 INTRODUCTION amp DESCRIPTION 5 Duty Cycle 3 04 Theory Of Operation 100 A Plasma Arc Cutting and Gouging Plasma is gas which is heated to an extremely high tem Auto Restart Pre Flow Delay Recycle perature and ionized so that it becomes electrically con ductive The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece The metal Enable Start Stop OK to Move Pilot Sensing Relay to be cut is melted by the intense heat of the arc and then 7 CNC S
68. bly from the unit 5 Install the replacement Transformer Assembly by reversing the above procedure E Internal Fuse F3 Replacement The Fuse F3 is located inside the Power Supply be hind the Right Side 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 B 2 Locate the Fuse mounted 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 F Fuse Holder Internal Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Fuse from the holder 3 Disconnect the two wires connected to the Fuse Holder 3 Remove the two small screws securing the Fuse Holder to the chassis 4 Install the replacement Fuse Holder by reversing the above procedure 5 07 Rear Panel Parts Replacement NOTE Refer to Section 6 06 Rear Panel Parts Replace ment for parts list and overall detail drawing Fan Replacement 36 1 Remove the Left Side Panel per Section 5 04 B 2 Locate the Fan Assembly wiring connector inside the Rear Panel 3 Carefully disconnect the wiring connector from the wiring harness 4 Note the pin location of each wire to the connector 5 Using a pin extraction tool remove the wiring from the connector 6 Rear Panel remove th
69. ce Driver PC Board If switching pulses are not present start signal OFF 4 VDC is normal Driver PC Board should be replaced Pilot Circuit Check The pilot is ignited by a high frequency spark gener ated in the Arc Starter Box The Arc Starter Box re quires a 24 VAC supply which should always be present and a torch tip to electrode voltage greater than 220 vdc When the PCR contactor closes power supply open circuit voltage 280 350 volts is con nected across the torch plus tip and minus elec trode Once the pilot starts the voltage drops to un der 220v shutting off the arc starter 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 torch NEG and the work lead then measure the voltage at the torch bulkhead marked NEG and POS If itis low zero to 50v the torch is probably SERVICE TROUBLESHOOTING 28 shorted pilot resistors will get very hot If it is be tween 100 and 200v PCR contactor is probably not closing If it measures the same as the OCV the arc starter box may be defective Fora shorted torch remove the consumable parts and check for damage remove the head from the mount ing tube and check for arcing The short may also be internal to the head and it may or may not be measur able with an ohmmeter Sometimes the only way to
70. cuits are selected directly by relays on the Voltage Selection PC Board The fan and pump motors are supplied by the Motor Control Contactors MC1 and MC2 MC is for the high voltage tap and MC2 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 Manual 0 2533 C Switch Mode Power Supply Operation Primary three phase power is rectified by the three phase bridge diodes D1 D6 The resulting negative DC voltage approximately 320 VDC is applied to the switching transistor O1 The switching transis tor controls the output current by pulse width modu lation 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 Components D7 10 R2 3 C13 14 L1 and the Suppression PC Board are snubbers to limit voltage and current surges caused by switching O1 on and off D11 14 are free wheeling diodes When 1 is on current flows through O1 into the output network When 1 is off D11 14 provide a path for current to continue flowing supported by energy that was stored in the output network during the time Q1 was on The switching transistor output is a series of pulses which are filtered back into pure DC voltage by the output network The output net work consists primarily of the main inductor L2A and L2B resistor R13 and capacitor C23 Switching
71. d Assembly Replacement 1 Remove the Top and Right Side Panels per Section 5 04 B 2 Note the orientation of the old Switching Control PC Board 3 Remove the Switching Control PC Board from the rear of the Upper Chassis Gauge Panel far enough to disconnect the wiring connections 4 Note where each connector is located on the Switch ing Control PC Board 5 Disconnect the connectors from the Switching Con trol PC Board 6 Reconnect the original wiring connectors to the replacement Switching Control PC Board before installing the replacement Switching Control PC Board 7 Install the replacement Switching Control PC Board by reversing the above procedure Coolant Check Valve Replacement 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the Hose Assemblies from the fitting connection at the input end of the Check Valve 3 Carefully remove the Check Valve and fittings from the TORCH COOLANT SUPPLY fitting 4 Remove the Fittings from the old Check Valve NOTE The input of the replacement Check Valve should be pointing towards the rear of the unit when in stalled The output is designated by a symbol on the side of the part as shown in the following Fig ure Manual 0 2533 Check Valve Symbol Direction Of Flow A 00370 5 Install the replacement Check Valve by reversing the above procedure and noting the following Coat the threads of the Fittings with a
72. d the fitting Apply a thin coating of liquid teflon thread sealer to the threads of the fitting Radiator Replacement 1 Remove the Left and Right Side Panels per Section 5 04 B 2 On the right side of the radiator locate the Hose Assembly connected to the input of the Radiator at the top 3 Remove the Hose Assembly from the Radiator in put connection 4 Remove the Internal Coolant Filter per paragraph A above 5 On top and bottom of the Radiator remove the six screws and star washers that secure the Radia tor to the Front Panel 6 Carefully slide the Radiator out of the unit 7 Install the replacement Radiator by reversing the above procedure Bias PC Board Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect all the wiring connections to the Bias PC Board Assembly 3 Remove the Bias PC Board Assembly from four PC Board Standoffs 4 Install the replacement Bias PC Board Assembly by reversing the above procedure Transformer T2 Assembly Replacement The Tramsformer 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 B 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 REPLACEMENT PROCEDURES 4 Carefully remove the Transformer Assem
73. e Power Supply 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 To remove the Side Panel from the Power Supply pull up and out on the Side Panel Reinstall the replacement Side Panel by reversing the above procedure Top Panel Replacement 1 2 Remove the Handles per paragraph above 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 Work Cable Replacement 1 Remove the Left Side Panel per Section 5 04 B Manual 0 2533 2 Loosen the two screws of the Work Cable strain relief securing the Work Cable at the Front Panel 3 Remove the nut under the Horizontal Chassis Panel securing the Work Cable connection to the Shunt Assembly 4 Pull the Work Cable from the unit 5 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 CURRENT Knob Replacement 1 Turn the CURRENT adjustment fully counter clock wise and note the
74. e product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN 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 MAY 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 80XL 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
75. e red LED indicator D18 on the voltage selection board If the indicator is lit measure voltage output between F2 wire 10 and J6 7 If the indicator is not lit measure between F2 and J6 12 The voltage out put 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 J6 21 and wire 10 on fuse F2 for 110 130 VAC This supplies 120 VAC to the rest of the unit B Enable Circuit Tests 23 Relay K1 on the Switching Control PC Board along with SW1 A and F2 completes the 120VAC return path K1 is energized by the ENABLE switch on the RC6010 remote or if the remote is not used by a switch connected to TB1 1 amp 2 Check for K1 being energized by measuring AC volts from F2 wire 10 to J7 22 and J7 24 It should be 0 v If so refer to Section 4 05 D Motor Control Contactor Check MC1 or MC2 to check motor contactors If there is voltage about 120v at J7 24 circuit is open between J7 24 and F2 F2 or SW1 A open If there is no voltage at J7 24 but it is at J7 22 then 1 is not closed If K1 is not closing and the remote is being used tem porarily jumper TB2 1 to 2 If the fan and pump come on the problem is in the remote s enable circuit Check continuity from TB2 back to the remote ENABLE switch to find the problem If jumping TB2 did not SERVICE TROUBLESHOOTING work check continuity from TB2 wires 102 am
76. e strain relief securing the Fan Assembly wiring to the Rear Panel Manual 0 2533 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 reversing the above procedure Three Phase Contactor Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Note the orientation of all the wires and then dis connect the input and output wiring from the Three Phase Contactor Assembly 3 Remove the 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 B 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 Gas Solenoid Assembly Replacement NOTE The Plasma and Secondary Gas Solenoid Valve Assemblies are replaced in the same manner 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the Gas Supply at the Rear Panel con nection 3 Disconnect the internal Gas Hose Assembly con nected to the elbow fi
77. e the four nuts flat washers and lond screws that secure the Coolant Tank to the Rear Panel 8 The parts on the Coolant Tank must be removed and installed on the replacement per the follow ing a Note the orientation of the Flow Switch Assem bly to the Coolant Tank b Remove the Flow Switch Assembly from the Coolant Tank and install it on the replacement Coolant Tank the same as noted in Step a c Remove the Conductivity Sensor Assembly from the Coolant Tank and install it on the re placement Coolant Tank d Note the orientation of the 90 Adapter Fitting in the outlet hole on the bottom of the Coolant Tank e Remove the 90 Adapter Fitting from the Cool ant Tank and installit on the replacement Cool ant Tank the same as noted in Step d 9 Reinstall the replacement Coolant Tank by revers ing the above procedure 10 Remove the Coolant Tank Cap and Deionizer Bas ket from the faulty Coolant Tank 11 Fill the replacement Coolant Tank with the cool ant removed or fresh Thermal Arc Torch Coolant 38 12 Place the Deionizer Basket and Bag into the Cool ant Tank filler hole and install the Coolant Tank Cap Flow Switch Assembly Replacement 1 Remove the Top Panel per Section 5 04 B 2 Drain enough of the coolant from the Coolant Tank per Section 4 02 F to lower the coolant level be low the Flow Switch Assembly hole mmm CAUTION Handle and dispose of the used coolant per recom
78. e two screws and star washers securing the Main Contactor Assembly to the Base 5 Install the replacement Main Contactor Assembly by reversing the above procedure Motor M1 Assembly Replacement 1 Remove the Left and Right Side Panels per Section 5 04 B 2 Loosen the allen set screw securing the Coupling to the shaft of the Motor Assembly 3 Remove the two bolts and nuts securing the Pilot Resistors air cooled 4 5 ohms to the left Pilot Re sistor Mounting Support 4 Remove the two bolts securing the Pilot Resistor Mounting Support to the Base 5 Carefully suspend the free end of the Pilot Resis tors with string to prevent damage to the resis tors 6 Disconnect the Motor Assembly wiring 7 Remove the four bolts securing the Motor Assem bly to the Base 8 Remove the complete Motor Assembly out the left side of the unit 9 Install the replacement Motor Assembly by revers ing the above procedure Pump Assembly Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the two Hose Assemblies at the fittings on the Pump Assembly 3 Loosen the allen set screw securing the Coupling to the Pump Assembly shaft REPLACEMENT PROCEDURES 4 Note the orientation of the Pump Assembly to the Pump Mounting Plate 5 Remove the three nuts securing the Pump Assem bly to the Pump Mounting Plate 6 Remove the Pump Assembly from the unit 7 Install the replacement Pump Assembly by
79. ecessary Flush the old coolant from the system see note above 4 Faulty flow switch FS1 a Check and replace flow switch if necessary 5 Faulty Logic PC Board a Refer to Section 4 05 I Coolant Flow Sensor Circuit Check Replace Logic PC Board if nec essary 6 Faulty LED current control board a Refer to Section 4 05 1 Coolant Flow Sensor Cir cuit Check Replace Logic PC Board if neces sary Coolant conductivity indicator off 1 Ionized or contaminated coolant a Check coolant conductivity and deionizer car tridge Replace both if necessary 2 Faulty or contaminated conductivity probe a Clean conductivity probe and replace if neces sary 3 Faulty Logic PC Board a Refer to Section 4 05 Coolant Conductivity Circuit Replace Logic PC Board if necessary 4 Faulty LED Current Control PC Board a Refer to Section 4 05 Coolant Conductivity Circuit Replace LED Current Control PC Board if necessary Press cutting machine START and nothing hap pens or standoff finds height then nothing happens no gas flow or pilot 1 Start signal not getting to the Power Supply or Power Supply is defective a Determine if Remote Control or Power Supply is at fault Remove Remote Control or CNC cable from 15 or TB2 Jumper TB2 1 amp 2 to enable unit then jumper TB2 3 amp 4 for START If the pilot starts after preflow Remote Con trol or CNC is faulty Refer to Section 4 05 L Remote Control
80. el 40 for J41 for EXT PWR and J42 for plasma labeled PL A remote cable connects from the Power Supply J15 to both J41 and J42 carrying power and sig nals to Standoff Control Connector J40 ac cepts the same CNC cable as the Remote Control RC6010 and like the Remote Control it has an internal terminal strip 11 Connections J40 and J11 have only START STOP CSD and OK To SERVICE TROUBLESHOOTING Move signals which are optically isolated A re mote cable connects from the Power Supply to connector J41 supplying the Standoff Control power The cable connected to J42 supplies con trol signals between Power Supply and the Stand off Control Refer to the individual Instruction Manuals supplied with the equipment for more detailed information The Power Supply must have an enable switch connected to the terminal strip TB2 inside the Power Supply when the Standoff Control 5 11 is used NOTE Refer to Appendix VIII for a Signal Flow Block Diagram of the main functions Gas Control The Gas Control GC3000 consists of additional gas solenoids mounted on the Power Supply rear panel A remote switch box is used to select the desired Plasma and Secondary gases Up to four plasma and three secondary gases can be connected to the mani folds and selected by the Gas Control The secondary water input to the Power Supply may also be selected from the Gas Control 4 04 Troubleshooting Guide Troubleshooti
81. ement Hose Assembly by revers ing the above procedure Coolant Supply Hose Tank to Coolant Filter Assembly Replacement The Coolant Supply Hose Assembly goes from the Coolant Tank to the Coolant Filter Assembly mounted on the rear panel Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 06 Rear Panel Replacement Parts for part numbers and detail drawing 1 Drain the coolant from the Coolant Tank per Sec tion 4 02 F wmm CAUTIONS The coolant must be drained from the unit as the coolant will drain out the hose connection on the side of the Coolant Tank Handle and dispose of the used coolant per recom mended procedures 2 Disconnect the other end of the Hose Assembly from the Coolant Tank Manual 0 2533 3 Remove the Hose Assembly from the unit 4 Install the replacement Hose Assembly by revers ing the above procedure 5 Refill the Coolant Tank with Thermal Arc Torch Coolant before applying power IL Coolant Return Hose Internal Filter to Flow Switch Assembly Replacement The Coolant Return Hose Assembly goes from the top outlet of the Internal Filter Assembly to the Flow Switch Assembly located on the side of the Coolant Tank Replace the Hose Assembly using the follow ing procedure NOTE Refer to Subsection 6 05 Front Panel Chassis Re placement Parts for part numbers and detail draw ing 1 Remove the Left Side Panel per Section 5 04 2 D
82. er to Section 4 05 A Voltage Selection PC Board Check Coolant Flow Sensor Circuit Check The flow sensor FS1 for the coolant is calibrated for 0 25 gpm 1 1 lpm When adequate coolant flow sat isfies FS1 it closes connecting J1 5 on the Logic PC Board to J1 4 common Measure voltage between J1 5 and J1 4 or TP1 IfJ1 5 is greater than 1 volt FS1 or connections to FS1 are faulty If J1 5 measures close to 0 VDC check J3 2 If J3 2 measures less than 12 VDC and the coolant flow indicator is not lit replace the LED PC board If J3 2 measures greater than 12 VDC replace the Logic PC Board Coolant Conductivity Circuit The conductivity probe consists of two insulated pins that extend into the coolant reservoir The Logic PC Board sends out an AC voltage level on J2 24 that varies with the conductivity of the coolant 1 Disconnect one of the wires to the conductivity probe wire 57 or 58 The Logic PC Board will see infinite resistance and the coolant conductiv ity LED indicator should be lit If the coolant con ductivity indicator is lit replace the coolant Ifthe problem remains after coolant is changed replace the conductivity probe SERVICE TROUBLESHOOTING 2 If the coolant conductivity indicator is not lit with the probe disconnected measure between the Logic PC Board common TP1 and J3 1 If the voltage measures below 12 VDC replace the LED PC board If the voltage measures above 12 VDC replace the
83. ess of remote cable 3 If 48 VDC is still incorrect check for 115 VAC at J30 1 to J30 3 at the Bias PC Board If correct replace Bias PC Board Also check Fuse F1 3A 250v on the Bias PC Board Manual 0 2533 Q OK To Move Tests 1 TheShunt Amp sends a voltage levelto the Switch ing Control PC Board that corresponds to the work lead or cutting current When that current is greater than 25 amps a circuit on the Switching Control PC Board sends an active low signal called CSR to the Logic PC Board J3 11 that turns on K1 the OK To Move relay SW5 on the Logic PC Board selects whether the OK To Move output at J2 14 and 16 is a contact closure SW5 up or 24 vac SW5 down OK To Move from J2 14 and 16 connects to TB2 9 and 10 then on to J15 10 and 11 To troubleshoot while cutting measure at TB2 9 to TB2 10 for 0 volts both AC and DC indicating contact closure or if Logic PC Board switch SW5 is set for AC volts measure for 24 VAC NOTE Refer to Appendix XII for OK To Move Circuit Diagram If correct go to step 2 If not correct repeat the measurement at J2 14 to J2 16 If still incorrect mea sure Logic PC Board J3 11 to TP1 If less than 5 vdc replace the Logic PC Board otherwise the Switching Control PC Board is faulty or the rib bon cable open 2 If using the Remote Control RC6010 Logic PC Board switch SW5 must be up for contact closure indicator D104 OK PS on the Remote Control RC 6010 internal PC
84. etric screws supplied with the Switching Transistor are to be used for the transistor wire connections Small metric screws are to be torqued to 12 in lbs 1 4 Nm Larger metric screws are to be torqued to 26 in lbs 2 9 Nm Auxiliary Transformer T3 Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Disconnect the wiring connector from the wiring harness at the Auxiliary Transformer Assembly 3 Remove the two mounting screws securing the Auxiliary Transformer Assembly to the Upper Chassis Gauge Assembly 4 Remove the Auxiliary Transformer Assembly from the unit 5 Install the replacement Auxiliary Transformer As sembly by reversing the above procedure Manual 0 2533 C Pressure Gauge Replacement NOTE Both the Plasma and Secondary gauges are replaced in the same manner 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the wiring tho the desired Pressure Switch 3 Remove the Pressure Switch from the desired Pres sure Gauge Assembly 4 Disconnect the input gas Hose Assembly from the fitting at the Pressure Gauge 5 Remove the fitting s from the Pressure Gauge 6 Remove the nut and clamp Securing the Pressure Gauge Assembly to the Upper Chassis Gauge Assembly 7 Slide the Pressure Gauge out of the Upper Chas sis Gauge Assembly 8 Reinstall the replacement Pressure Gauge Assem bly by reversing the above procedure NOTE Besure that the Pressure Gauge orient
85. evers ing the above procedure Coolant Supply Hose Pump to Pressure Gauge Connection Assembly Replacement The Coolant Supply Hose Assembly goes from the Pressure Gauge T Fitting to the front panel Coolant Pressure Gauge connection Replace the Hose Assem bly using the following procedure REPLACEMENT PROCEDURES NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the T Fitting at the front panel Coolant Pressure Gauge connec tor 3 Disconnect the other end of the Hose Assembly from the Coolant Pressure Gauge 4 Remove the Hose Assembly from the unit 5 Install the replacement Hose Assembly by revers ing the above procedure Secondary Gas Hose T Fitting to SECONDARY GAS Connector Assembly Replacement The Secondary Gas Hose Assembly goes from the T Fitting to front panel SECONDARY GAS connector Replace the Hose Assembly using the following pro cedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the T Fitting on the Check Valve from the Secondary Gas Regu lator Assembly 3 Disconnect the other end of the Hose Assembly from the front panel SECONDARY GAS Connec tor 4 Remove the Hose Assembly from the unit
86. 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 GENERAL INFORMATION 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 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 pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoy
87. h 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 2533 67 APPENDIX APPENDIX Il SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION Close external disconnect switch RESULT Power to system ACTION Protect eyes and activate torch RESULT Gas indicator ON Gas pre flow Main contactor closes DC indicator ON Pilot contactor closes PILOT indicator ON Pilot arc established ACTION ACTION ACTION Enable ON at Remote RUN SET PURGE or TB2 switch to SET ON OFF switch to ON RESULT Gas solenoids open gases flow to set pressures GAS indicator ON RESULT AC indicator ON TEMP Indicator ON GAS indicator ON Fan and pump ON 40 second auto purge PILOT ARC Torch de activated by t
88. hat secures the Transistor Coil Bracket to the Switching Transistor Assem bly 16 Remove the screw and washer securing the PTC Resistor Assembly to the Main Heatsink Move the PTC Resistor Assembly out of the way to pre vent it from becoming damaged REPLACEMENT PROCEDURES PTC Resistor Assembly 01089 Main Heatsink 17 Remove the four screws securing the Switching Transistor module to the Main Heatsink 18 Pry between the Main Heatsink and the faulty Switching Transistor Assembly until it slides eas ily 19 Remove the faulty Switching Transistor Assem bly from the unit by sliding it towards the center of the Main Heatsink me CAUTION DO NOT damage Heatsink 20 If the transistor thermstrate was not removed with the transistor it must be removed 21 Clean the old transistor thermstrate from the tran sistor mounting area Verify that the Heatsink sur face under the transistor is smooth and free of de fects 22 Install the replacement Transistor Thermstrate and the Switching Transistor Assembly by reversing the above procedure and noting the following Place the replacement Transistor Thermstrate onto the Main Heatsink at the Switching Tran sistor mounting location Depending on the style of the replacement Switching Transistor connect the wires per one of the following Figures REPLACEMENT PROCEDURES 42 A 01087 Wire Connections O1 Without E Terminal The m
89. he copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure see instruction manual for the appropriate equipment and re move the failed PC board ON Carefullv open the ESD protective bag and remove the replacement PC board 7 Install the replacement PC board in the equipment and make all necessarv connections 8 Place the failed PC board in the ESD protective bag and seal for return shipping 9 Reassemble the equipment enclosure see instruc tion manual for the appropriate equipment 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment 5 03 Parts Replacement General Information The parts replacement procedures described in this manual except for Rear Panel Coolant Filter and exter nal 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 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 Turn OFF all gas inputs to the Power Supply at the
90. he parts listed and those checks need not be performed NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment Daily Operational Checks or Every Six Arc Hours 1 Check torch parts replace if damaged 2 Check plasma and secondary supply and pressure flow 3 Purge plasma gas line to remove any moisture build up 4 Check deionizer bag cartridge replace if color is predominantly yellow 5 Check coolant pressure 100 120 psi Weekly or Every 30 Arc Hours 1 Blow or vacuum dust and dirt out of the entire machine Six Months or Every 720 Arc Hours Remove and clean ir line filter screens Check cables and hoses for leaks or cracks replace if necessary Check all contactor points for severe arcing or pits replace if necessary WO N e Check all pillow blocks and bearings clean and lubricate if necessary 5 Check fan pump and pulley belts for wear or cracking replace if necessary Twelve Months or Every 1500 Arc Hours 1 Drain coolant fill with distilled water turn on main power switch and let machine run for approximately 30 minutes A WARNING DO NOT energize the Torch Drain distilled water and replace with Thermal Arc Coolant Use Standard Mix Coolant Catalog 7 2850 Super Mix Coolant Catalog 7 2959 for environments below 10 F 12 C 2 Check radiator fins clean and comb out if necessary 3 Repeat six month maintenance APPEND
91. i re qu il est impossible de retirer de la zone de travail 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 combustibles 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 RAYONS 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 ultra vio lets 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 lu nettes de protection ou une autre sorte de protec tion 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 protec tion en bon ta
92. ignals PSR Full CNC Available with Remote blown away by the flow of gas Plasma arc gouging uses process to remove material to a controlled depth 8 Coolant Pressure and width Internal Service adjustable With a simple change of torch parts the system can also be used for plasma arc gouging Plasma arc gouging is 130 psi 8 8 BAR at zero flow used to remove material to a controlled depth and width 9 Coolant Flow Rate The Power Supply accepts input voltages from 200 to 0 5 gpm 2 2 Ipm with 150 feet 45 7m of total torch 575V 50 or 60 Hz three phase Input voltages are set by an internal changeover in the unit The unit converts AC and torch leads at 70 F 21 C input power to DC power for the main cutting arc The NOTE negative output is connected to the torch electrode through the negative torch lead and the positive output The Yate Tend len CON connects to the workpiece through the work cable figuration ambient temperature amperage level etc C Pilot Arc 10 Cooling Capacity When the torch is activated there is a selectable 2 4 7 or 10 second gas pre flow followed by a uninterrupted DC d pilot arc established between the electrode and tip The NOTE pilot arc is initiated by a momentary high frequency pulse from Arc Starter Box The pilot creates a path for Maximum value based on free flow condition main arc to transfer to the work When the main a
93. ij 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 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 1 603 298 5711 or your local distributor if you have any questions Date 6 22 99 As AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to vour 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
94. ill be installed CAUTION Diodes can overheat if not properly installed c Install the diode Torque the nut securing the diode to 34 in Ibs 3 8 Nm d Reinstall the nut and washer securing the re placement diode wire lead to the PC Board D 150 Amp STR Diode Replacement 46 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 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 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 diode assembly to the mounting surface 6 Remove the nut securing the diode wire lead to the PC Board Manual 0 2533 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 b Position the therma
95. 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 An ohmeter 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 least 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 discon nected then replace the diode Check all diodes be fore 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 Manual 0 2533 2 High frequency protection for the input rectifier diodes D1 6 is provided by capacitors C1 C6 and MOV 1 3 which are located between each side of the diode heatsink on the input filter PC board Except for the shorts these components can not be checked with a volt ohm meter To be safe the complete input filter board should be replaced any time an input diode fails 3 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
96. ine symptom and isolate to defective assembly 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 4 Check the causes easiest listed first for the symptom 5 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 transfered between Printed Circiut Board Assemblies on Ribbon Cables If these cables become faulty they can then cause vari ous problems Do not forget about these cables when troubleshooting A No front panel LED indicators ON Fan and pump 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 section for continuity Replace switch if necessary Manual 0 2533 3 Faulty voltage selection board a Refer to Section 4 05 A Voltage Selection PC Board Check Replace Voltage Selection PC Board if necessary B AC indicator ON Fan and pump not operating 1 ENABLE signal not ON a Remote ENABLE or ENABLE at TB2 must be on Refer to Section 4 05 B Enable Circuit Test 2 Blown fuse F1 or F2 a Check and replace fuse if necessary Refer to Section 4 05 C Blown Fuse F1 or F2 3 Faulty ON OFF switch SW1 a Disco
97. isconnect the Hose Assembly from the outlet side of the Internal Filter Assembly 3 Locate the other end of the Hose Assembly at the lower part of the Flow Switch Assembly 4 Disconnect the Hose Assembly from the Flow Switch Assembly 5 Pull the Hose Assembly from the unit 6 Install the replacement Hose Assembly by revers ing the above procedure Secondary Water Gas Hose T Fitting to T Fitting Assembly Replacement The Secondary Water Gas Hose Assembly goes from the T Fitting at the Secondary Gas Check Valve to the T Fitting on the Secondary Gas Pressure Gauge As sembly Replace the Hose Assembly using the follow ing procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the T Fitting on the Check Valve from the Secondary Gas Regu lator Assembly 3 Disconnect the other end of the Hose Assembly from the T Fitting on the Secondary Gas Pressure Gauge Assembly 4 Remove the Hose Assembly from the unit Manual 0 2533 49 5 Install the replacement Hose Assembly by revers ing the above procedure Plasma Gas Hose Plasma Gas Solenoid to Plasma Gas Regulator Assembly Replacement The Plasma Gas Hose Assembly goes from the Plasma Gas Solenoid Assembly at the rear panel to the Plasma Gas Regulator at the front panel Replace the Hose Assembly using the f
98. ization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and com plete description of the part or assembly as listed in the description column of the Parts List Also include the model and serial number of the machine as shown on the plate attached to the front panel of the unit Address all inquiries to your authorized Thermal Dynamics dis tributor Manual 0 2533 51 PARTS LISTS 6 03 External Power Supply Replacement Parts List Item Qty Description Catalog Complete Merlin 3000 Power Supply With Running Gear and Work Cable 1 Without Gas Control GC3000 3 5100 1 With Gas Control GC3000 3 5101 1 1 Work Cable with Clamp 25 ft 7 6 m 9 4380 2 1 Panel Top 8 3300 3 1 Panel R H Side With Overlay 8 6301 4 1 Panel L H Side With Overlay 8 6303 5 1 Upper Gauge Panel Overlay 8 3304 6 2 Handle Merlin 8 2172 1 NE A 01220 PARTS LISTS 52 Manual 0 2533 6 04 Access Panel Replacement Parts Item Qty Description Catalog 1 Access Panel Assembly Includes 8 3257 1 1 Access Panel With Overlay 8 6302 2 1 Access Panel Overlay 8 3306 3 1 ON OFF Rocker Switch DPST 8 3258 4 1 Switch Rocker SPDT Center Off 8 3259 5 1 LED Current Control PC Board Assembly 9 5759 6 1 Knob Inner Concentric 9 4146 7 2 Fastener Receptacle 9 3995 8 2 DZUS Stud 9 4346 9 2 DZUS Retaining Ring 9 4347 2 522 yee A 00967 Manual 0 2533 53 PARTS LISTS 6 05 Front Panel Chassis Replacement P
99. l Power Supply Work Cable to Workpiece Manual 0 2533 69 APPENDIX APPENDIX IV INTERFACE CABLES FOR REMOTE CONTROL RC6010 AND STANDOFF CONTROL SC11 APPENDIX 70 lt a lo gt HC 601980 HC 6010 REMOTE CABLE MERLIN 3000 F s 8 e JE 1 o WHITE BLUE STRIPE 3 DISP lt o g D 2 aBLUE WHITE STRIPE 4 DISP gal 25 AE N LO 3 gt WHITE ORANGE STRIPE 12 START LED axle Ms 4 gt STRIPE 13 PS OFF Selo js 5 6 gt WHITE GREEN STRIPE 20 POT HIGH e 3GREEN WHITE STRIPE 21 POT HIGH RTN EE 7 gt STRIPE o HI LOW NOT USED ETE 2 z 8 s8 BROWN WHITE STRIPEr 31 HI LOW RTN z2 9 WHITE GRAY STRIPE gt 24 START STOP B gt GRAY WHITE STRIPE 25 START STOP RTN 25 25 o5 E e 1 REDZBLUE STRIPE o 26 REMOTE INSTALLED TE T hi 2 BLUEZRED STRIPE 27 REMOTE INSTALLED RTN U tu gz On RED ORANGE STRIPE 5 16 P
100. l PC Board by reversing the above procedure E Access Panel Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Remove the following components from the Ac cess Panel Current Knob per paragraph A above ON OFF Switch per paragraph B above RUN SET PURGE Switch per paragraph C above LED Current Control PC Board per paragraph D above 3 Remove the four screws securing the Access Panel to the LED Current Control PC Board standoffs 4 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 Internal Coolant Filter Replacement The Internal Coolant Filter Assembly is located inside behind the Left Side Panel viewed from the front of the unit The filter is attached to the Radiator inside of the Lower Front Panel 1 Remove the Left Side Panel from the Power Sup ply per Section 5 04 B 2 Locate the Internal Coolant Filter near the front of the unit 35 REPLACEMENT PROCEDURES 3 Remove the Coolant Hose from the Internal Cool ant Filter Assembly 4 Remove the Internal Coolant Filter from the fitting on the Radiator 5 Install the replacement Internal Coolant Filter As sembly by reversing the above procedure and not ing the following Clean the old thread sealer from the threads of the hose an
101. l 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 34 in Ibs 3 8 Nm d Reinstall the nut and washer securing the re placement diode wire lead to the PC Board 5 11 Hose Assembly Replacements This subsection describes the replacement of the various Hose Assemblies used in the Power Supply The replace ment part numbers and detail drawings are in Section 6 as noted in each Hose Assembly replacement instructions For a block diagram of the Power Supply Hose Assem blies refer to Appendix XV A Secondary Water Hose Check Valve to T Fitting Assembly Replacement The Secondary Water Hose Assembly goes from the Check Valve on the Secondary Water Solenoid Assem bly to the T Fitting on the Secondary Gas Pressure Gauge at the front panel Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the Check Valve on the Secondary Water Solenoid Assembly 3 Disconnect the other end of the Hose Assembly from the T Fitting on the Check Valve from the Secondary Gas Pressure Gauge at the front panel 4 Remove the Hose Assembly from the unit Manual 0 2533 47 5 Install the
102. lar in design to the common au tomotive spark plug They consist of negative and posi tive sections which are separated by a center insulator Inside the torch the pilot arc is initiated in the gap be tween the negatively charged electrode and the positively charged tip Once the pilot arc has ionized the plasma gas the superheated column of gas flows through the small orifice in the torch tip which is focused on the metal to be cut The Maximizer 300 Torch uses an internal closed loop cooling system Deionized coolant is distributed from a reservoir in the Power Supply through the coolant sup Manual 0 2533 ply lead At the torch the coolant is circulated around the torch tip and electrode where the extra cooling helps to prolong parts life Coolant then circles back to the power supply through the return lead The Maximizer 300 also can use secondary gases such as compressed air nitrogen N2 water and carbon dioxide CO 3 05 Options And Accessories These items can be used to customize a standard system for a particular application or to further enhance perfor mance Torch accessories are listed in the separate Torch Instruction Manual NOTE Refer to Section 6 Parts Lists for ordering infor mation A RC6010 Remote Control For mechanized systems this low profile unit provides full CNC capability and allows the operator to con trol most system functions from a remote location Computer Control Cable Kit
103. n momentarly do the following The Logic PC Board has a circuit to monitor the power supply output voltage If the circuit doesn t sense voltage in 75 ms if the contactor doesn t come on it shuts off the power to the contactor which makes it hard to troublshoot Connecting a jumper between TP4 and 1 on the Logic PC Board disables the volt age sensing circuit so W ON led stays on On the Logic PC Board K2 sends 120 VAC to the Volt age Selection PC Board refer to Appendix VI Relay K5 directs that voltage to either W1 or W2 depending on the level of incoming line voltage If high LED D38 on the Voltage Selection PC Board will be ON SERVICE TROUBLESHOOTING 26 and the 120 VAC should go to W2 otherewise it goes to W1 The first step is to measure for 120 VAC from Logic PC Board J2 9 to wire 110 PCR MC1 or MC2 coils If no voltage the Logic PC Board is faulty If about 120 VAC is present measure the voltage at the W contactor coil W2 if LED on Voltage Selection PC Board is ON or else W1 If about 120 VAC is present the contactor is faulty If no voltage check from wire 110 to J6 1 and J6 3 on the Voltage selec tion PC Board One of the two should have about 120VAC if not check J6 5 If it measures 120VAC re place the voltage selection PC Board If there is no voltage at J6 5 but was on J2 9 there is a faulty con nection wire 23 Remote Control Start Circuit NOTE Refer to Appendix IX for Start Circ
104. ng and Repair Troubleshooting and repairing the this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING 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 B Advanced Troubleshooting For basic troubleshooting and parts replacement procedures refer to Merlin 3000 Power Supply Op erating Manual 0 2532 18 Manual 0 2533 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 3000 Plasma Cut ting System 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 C 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 to possible circuit s 2 Determ
105. nnect primary power Check each section for continuity Replace switch if necessary 4 Faulty Voltage Selection PC Board a Refer to 4 05 A Voltage Selection PC Board Check Replace Voltage Selection PC Board if necessary 5 Faulty motor contactor MC1 or MC2 a Refer to Section 4 05 D Motor Control Contac tor Check MC1 or MC2 Replace contactor if necessary 6 Faulty ENABLE circuit a Refer to Section 4 05 B Enable Circuit Test No indicators are on for the RC6010 or SC10 remotes 1 No 48 VDC power to the remotes a 3 amp fuse blown on the Bias PCB replace b Defective Bias PCB Refer to Section 4 05 P 48 Volt Bias Test AMPS or VOLTS displays not on for RC6010 or SC10 1 Normal if ENABLE not on a Turn on ENABLE at RC6010 or TB2 if RC6010 not used b Defective ENABLE circuit Refer to Section 4 05 B Enable Circuit Test 2 Faulty Remote Device a Replace as needed SERVICE TROUBLESHOOTING E Fuse blown at disconnect when primary power is connected 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 E Fuse blown at disconnect when main contactor W1 or W2 closes 1 Shorted input diode D1 D6 a Refer to Section 4 05 E Diode Check Replace diode s as required Switching
106. nnect the two wiring connectors from the Driver PC Board 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 Driver PC Board P d Lower PC Board Guide Securing Tab A 01084 8 Carefully pull the PC Board from the guides and remove from the unit 9 Install the replacement Driver PC Board Assembly reversing the above procedure 10 Locate the old Switching Transistor O1 Assem bly on inside center left between the four large blue capacitors as viewed from the front of the unit Manual 0 2533 41 Transistor Coil Bracket Switching Transistor Large Blue Capacitors A 01085 11 There are two different styles of the Switching Transistor Q1 The style can be identified by look ing at the top of the transistor casing Style With E Terminal Style Without E Terminal 12 Note and label the wires connected to the Switch ing Transistor Assembly NOTE The older style transistor will have two wire con nections to the transistor module and the newer style will have only one wire connections 13 Remove the two screws securing the wires to the Switching Transistor Assembly terminals E and 14 Remove screw that secures Capacitor Mounting Bracket to the Switching Transistor As sembly 15 Remove the screw t
107. ntrols the gas flow in Manual 0 2533 run set and purge modes by turning on the plasma and secondary solenoids The Logic PC Board also controls pre flow and post flow durations which are selectable by DIP switches on the board The Logic PC Board drives the sequence status LED indicators and contains the circuit for measuring coolant con ductivity After receiving the CNC cutting machine controller START signal from either the remote control the standoff control direct from the controller via the re mote connector or TB2 the simple interface termi nal strip the Logic PC Board initiates gas preflow then energizes the main contactor W1 or W2 as deter mined by the Voltage Selection PC Board The Logic PC Board closes the pilot contactor and sends enable signals to the Switching Control PC Board to start the PWM and turn on the main switch ing circuits producing open circuit output voltage OCV When the ArcStarter Box senses OCV greater than 220 V between the Torch plus and minus it starts the CD capacitor discharge arc starting circuit to firethe 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 220 V and shuts off the CD circuit When the Torch is close to the work the cutting arc transfers to the work The resulting current in the work lead is sensed by the Shunt Amp and the Switching Control PC Board sends the C
108. o Sec tion 4 05 O Current Control Display and CSD Checks 3 Trying to pierce greater than 3 4 inch 19 mm plate a Unit rated only for piercing upto 3 4 inch 19 mm 4 Travel speed too high a Try a stationary pierce if piercing is correct then adjust travel speed Manual 0 2533 U Main arc transfers and pierces through the plate but cutting machine doesn t move 1 Incorrect or missing OK To Move signal a Many cutting machines require an AC voltage to activate the motion input Refer to Operat ing Manuals for setting OK To Move signal b Check for missing OK To Move signal Refer to Section 4 05 O OK To Move Tests V Standoff Control Not Working Correctly Refer to Troubleshooting in the Standoff Control In struction Manual W Remote Control Not Working Correctly Refer to Troubleshooting in the Remote Control In struction Manual 4 05 Test Procedures The following tests are suggested for specific problems listed in the troubleshooting guide WARNING 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 A Voltage Selection PC Board Check When wall power is first turned on the Voltage Se lection PC senses the low voltage AC present at J6 20 J6 22 and J6 24 center tap The
109. ollowing procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the Hose Assembly from the Plasma Gas Solenoid Assembly at the rear panel 3 Disconnect the other end of the Hose Assembly from the Plasma Gas Regulator Assembly at the front panel 4 Remove the Hose Assembly from the unit 5 Install the replacement Hose Assembly by revers ing the above procedure REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES 50 Manual 0 2533 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provides a breakdown of all basic replace able parts The parts lists are arranged as follows Section 6 03 External Power Supply Replacement Parts List Section 6 04 Access Panel Replacement Parts Section 6 05 Front Panel Chassis 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 Section 6 10 Power Supply Options And Accessories NOTE Parts listed without item numbers are not illus trated but may be ordered by the catalog numbers shown B Returns If a Thermal Dynamics product must be returned for service contact your Thermal Dynamics distributor Ma terials returned to Thermal Dynamics without proper author
110. op and disconnect the ribbon cable at J5 or J7 Then if the Power Supply will start the prob Manual 0 2533 lem is in the Standoff Control SC10 or the ribbon cable Refer to Section 5 Customer Operator Service in the Standoff Control Instruction Manual If the Standoff Control SC10 isn t used or the Power Supply didn tstart with the ribbon cable disconnected there are two approaches you can take Either dis connect the remote and see if the Power Supply will start without it or check if the start signal is getting to the Remote Control RC6010 To check the Power Supply remove the remote connector at J15 and con nect a jumper TB2 1 to TB2 2 for ENABLE then jump TB2 3 to TB2 4 for start If it starts the problem is in the remote or CNC connections If not refer to Sec tion 4 05 K Power Supply Start Circuit To check for start to the Remote Control RC6010 open the Remote Control cover and see if indicator 0103 comes ON If so problem is in Remote control RC6010 or the remote cable If indicator D103 is OFF remove J29 or the CNC start connections to J6 and jumper 29 3 to 4 or J6 3 to 4 Don t jumper to the screw heads on J6 as they don t always make electri cal contact If it starts indicator D103 ON with the jumper the problem is in the CNC connections If not replace the Remote Control RC6010 Switching Control Check Q1 To produce DC output the main switch O1 must be turned on and off rapidly Powe
111. orch switch ACTION RUN SET PURGE switch to RUN RESULT Gas flow stops Power circuit ready GAS indicator OFF ACTION Torch removed from work RESULT Main arc stops Pilot arc auto restart PILOT indicator ON ACTION Torch moved to within 1 8 3 8 inch of work RESULT Main arc transfer PILOT indicator OFF released or remote device e Pilot arc OFF RESULT Main arc stops Main contactor opens DC indicator OFF Pilot and PILOT indicator OFF ACTION ON OFF switch to NOTE If torch is activated during post flow OFF the pilot arc will immediately restart If within range of work main arc will transfer ACTION Open external RESULT disconnect AC indicator OFF e TEMP Indicator OFF Fan and pump OFF After post flow Gas solenoids close gas flow stops GAS indicator OFF RESULT No power to system A 01016 APPENDIX 68 Manual 0 2533 APPENDIX Ill TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS System With Remote Control RC6010 Standoff Control SC10 And Gas Control GC3000 J53 GC3000 Gas Control Option SC 10 Standoff Torch Lifter Control Assembly RC6010 Remote Control Earth 3 Phase Ground Input J37 Torch Lifter Assembly Power Supply Earth Ground 3 Phase Input A 01261 Cable Description Letter Designation Power Supply to Remote Control Standoff Control to Torch Lifter Assembly Remote Control to CNC Control Power Supply to Gas Contro
112. ower disconnect 2 Wait at least two minutes to allow the input ca pacitors to discharge 3 Open Power Supply to gain access to the faulty Diode Assembly 4 Locate the old Diode Assembly inside the Power Supply Unsolder the wire lead from the old Diode Assem bly O1 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 dispurse heat when soldering the wire lead to the diode 7 Install thereplacement 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 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 45 REPLACEMENT PROCEDURES d Re solder the wire lead to the replacement di ode e Apply a layer of RTV over the top of the Diode Assembly to encapsulate the lead and top of the diode f Close up the Power Supply B Relay Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Move the
113. p 108 to 150 10 amp 11 If correct replace the Switching Control PC Board Merlin 3000 6000 or 6000GST Switching Control PCB m J37 17 J15 5 J50 12 st J1 5 1 J1 4 1037 27 J15 33 50 10 ENABLE TB2 1 2 J37 26 J15 32 J50 11l TB2 2 To AMP VOLT Display Enable 01137 Enable Circuit Diagram C Blown Fuse F1 or F2 1 Ashorted or frozen motor will cause F1 to fail To check the motors disconnect J20 pump motor and 139 fan motor Reconnect one at a time to determine which component is faulty A shorted or open fan motor starting capacitor C32 may also cause FI to fail 2 F2 fuses the 110 VAC circuit MC1 or MC2 T2 T3 and the gas solenoids are energized when power is first applied If shorted any one of these com ponents would cause F2 to fail W1 or W2 and PCR energize after the torch switch or remote start switch is activated Disconnect all components and reconnect one at a time to establish which compo nent is faulty D Motor Control Contactor Check MC1 or MC2 NOTE Refer to Appendix VI for 120 VAC Circuit Dia gram 120 VAC is supplied to the Motor Control Contactors MC1 and MC2 from the Voltage Selection PC Board which selects the proper tap on the Main Transformer T1 The return path travels from wire 110 through the remote connector J15 on the rear panel to the E Stop switch or if no remote is used through K1 on SE
114. r Inlet to Gauge 8 4517 49 1 Hose Assembly Plasma Gas Inlet to Regulator 8 4515 50 1 Hose Assembly Plasma Gas Regulator To Bulkhead 8 4513 51 1 Hose Assembly Plasma Gas Regulator To Gauge 8 4513 52 1 Voltage Divider Replacement Kit 9 1416 N 01226 Manual 0 2533 61 PARTS LISTS 6 09 Main Heatsink Assembly Replacement Parts Item Qty CAN TF C 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PARTS LISTS e e RP OD WR RP RP NR WOR CO RRP Nme RP e NR me on lt gt Description Main Heatsink Capacitor 550 mfd 400VDC Bracket Capacitor Heatsink Support Air Foil Capacitor Clamp Support Heatsink Assembly Thermstrate Transistor Transistor 300A 550V Darlington Refer to Section 6 08 Item 2 Capacitor 10 mfd 400V Poly Hi Current Bracket Capacitor Mounting 70 Amp STR Diode Replacement Kit Includes Diode 70A 600V STR Fast Thermal Interface Pad 75 Dia Capacitor 15 pf 630V Poly Hi Current Suppression Coil Assembly Bracket Diode Lead Assembly Heatsink Suppression PC Board Support Capacitor Bracket PC Board Resistor 100 Ohm 100W Style J Internal Wire Assembly Package Resistor 3k Ohm 100W Style J Relay Socket Relay DPDT 110 VDC Plate Negative Diode Plate Positive Diode Diode Suppression PC Board Assembly 150 Amp REV
115. r 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 Con trol PC Board This enables the pulse width modula tor PWM on the Switching Control PC Board If no DC voltage is detected within 75 ms at J1 24 on the Logic PC Board the enable signal on J10 9 is re moved and the Main Contactor opens Connecting TP4 to TP1 ground on the Logic PC Board disables this function for troubleshooting if no DC output is found Manual 0 2533 27 Transistor Coil Bracket Switching Transistor Large Blue Capacitors A 01085 Q1 Location To check for a defective Q1 first disconnect J27 from the Driver PC Board 01083 Driver PC Board Driver PC Board Location On a X1 or X10 scale or with a digital meter set for diode measure between 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 read ing is from about 50 to 150 ohms digital meter on ohms not diode scale a short zero ohms or an open indicates a defective O1 NOTE
116. rc is established the pilot arc shuts off The pilot can auto 11 Coolant R irC it C Qa matically restart factory set for No Auto Restart when 2 gallons 8 8 liters the main arc stops as long as the torch remains activated Capable of handling a total of 150 feet 45 7m of torch NOTE lead In gH For the arc to restart automatically AUTO RE 12 Power Supply Dimensions START must be enabled at switch settings inside the Power Supply Enclosure Only Width 24 12 in 0 61 m Height 38 38 in 0 98 m D Main Cutting Arc The Power Supply accepts 50 or 60 Hz three phase line input An internal changeover switches input line volt Depth 34 25 in 0 87 m ages in three ranges for 200 220 230V 380 415 460V or 500 575V operation The power supply converts AC Fully Assembled input power to DC power for the main cutting arc The negative output is connected to the torch electrode ne torch lead The positive output is Height 43 38 in 1 10 m connected to the workpiece via the work cable and clamp connection Depth 43 75 in 1 11 m 13 Weight of Power Supply Only 678 Ibs 308 kg INTRODUCTION amp DESCRIPTION 12 Manual 0 2533 E RF Shielding machine torch systems are shielded to minimize ra dio frequency RF interference which results from the high frequency arc initiation These shielded systems are designed with features such as a wire for establishing an earth ground and
117. re re in stalling in the Internal Filter Assembly Coolant Level and Conductivity 1 Coolant Level The coolant level should be checked every day at the rear panel coolant gauge If the coolant in the reservoir is more than 2 inches 50mm from the top of the reservoir then add Torch Coolant 2 Coolant Conductivity The coolant conductivity LED on the front panel must be ON for normal operation If the LED is OFF then drain the old coolant from the Power Supply and torch leads and replace with new cool ant Check the condition of the deionizer bag in the reservoir basket if the bag is yellowish brown straw color replace the bag Draining Coolant Remove the old coolant from the Power Supply res ervoir per the following procedure 1 Remove the right side and top panels from the Power Supply 2 Disconnect the coolant hose input to the rear panel filter assembly 3 Carefully lower the hose out the right side of the Power Supply and drain the coolant into an ac ceptable container CAUTION Handle and dispose of the used coolant per recom mended procedures Coolant Hose Connection Figure 4 2 Draining Coolant From Reservoir SERVICE TROUBLESHOOTING 4 Reconnect the hose to the filter assembly 5 Install new coolant and deionizer bag 6 Reinstall the top and right side panels 4 03 System Theory A Circuit Description The Merlin 3000 system is designed for mechanized cutting onl
118. red replace the LED PC board If the volt age at J3 4 is less than 4V replace the Logic PC Board G Pressure Sensing Circuit Pressure switches PS1 and PS2 are connected in se ries to J1 7 on the Logic PC Board PS2 is jumpered out by SW3 B when the unit is set to the O2 no sec ondary gas or water secondary mode or by SW2 B in the GC3000 Gas Control if that option is installed Manual 0 2533 25 1 Check the voltage at J1 7 for less than 1 VDC with gases flowing and operating pressure greater than 35 psi 2 4 BAR 2 If the voltage at J1 7 is less than 1 VDC check the voltage at J3 3 If the voltage at J3 3 is greater than 12 VDC replace the Logic PC Board If the volt age at J3 3 is less than 12 VDC replace the LED PC Board Gas Solenoid Circuits 1 Set the RUN SET PURGE switch to SET position Measure continuity between the center terminal of the switch wire 62 and each outer terminal wires 61 and 63 If the resistance is less than 1000 ohms replace the RUN SET PURGE switch 2 If the resistance is greater than 1000 ohms apply power and check for 120 VAC between wire 110 and J2 3 for plasma and J2 7 for secondary If 120 VAC is present at one point and not the other re place the Logic PC Board 3 If no voltage is present at J2 3 or at J2 7 check for 120 VAC at J2 5 the Logic PC Board input If 120 VAC is present at J2 5 replace the Logic PC Board If not check the 120 VAC voltage supply ref
119. 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 May 6 1999 GENERAL INFORMATION 8 Date 6 22 99 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This Manual provides Service Instructions for Thermal Dynamics Merlin 3000 Power Supply Refer to Operating Manual 0 2532 for individual oper ating procedures Information in this edition is therefore particularly applicable to the Troubleshooting and Repair of the equipment and is intended for use by properly trained Service Technicians familiar with this equipment Read this Manual and the Operating Manual 0 2532 thoroughly A complete understanding of the capabili ties and functions of the equipment will assure obtaining the performance 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 confi
120. revers ing the above procedure and noting the follow ing Remove the Fittings from the old Pump Assem bly and install on the replacement Pump As sembly Besureto align the Pump Assembly to the Pump Mounting Plate as noted in Step 4 above 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 40 The Power Driver PC Board Replacement Kit is a di rect parts replacement for the failed Driver PC Board and Switching Transistor Q1 Assemblies in the Power Supply A WARNING Disconnect primary power at the source before as sembling or disassembling power supply torch parts or torch and leads assemblies 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 Remove the top panel of the Power Supply To remove the top panel of the Power Supply requires the removal of several phillips head screws Care fully remove all the screws before attempting to remove the top panel 4 Locate the old Driver PC Board Assembly on the inside left side behind the front panel as viewed from the front of the unit Manual 0 2533 iic Driver PC Board 5 Noteand label the two wiring connectors that con nect to the Driver PC Board Disco
121. rm 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 operators responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or mali cious 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 If to be returned the replaced Printed Circuit Board As semblies must be properly packaged in protective mate rial and returned intact per normal procedures Manual 0 2533 2 03 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities He should be prepared to rec ommend arrangements of components which will pro vide 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 Depa
122. rtment at West Lebanon for assistance 9 INTRODUCTION INTRODUCTION 10 Manual 0 2533 SECTION 3 INTRODUCTION amp DESCRIPTION 3 01 Scope of Manual The information in this Section is the same information contained in Section 2 of the Operating Manual It is sup plied here to familiarize the Service Technician with the 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 Power Supply contains all operator controls electri cal and gas inputs and outputs and the torch leads re ceptacle Many options and accessories can be added to further improve the versatility of the system A 00907 Figure3 1 Power Supply The Standard Coolant supplied with the Power Supply can be used in ambient temperatures down to 10 F 12 C If the ambient temperature will be below 10 F 12 C then Super Coolant should be used This coolant can be used in areas where the ambient temperature drops to 34 36 C A typical system configuration will contain the follow ing Manual 0 2533 Power Supply with Running Gear and Handles Arc Starter Box Maximizer 300 Machine Torch with Mounting As sembly and Leads Torch Leads Extension Maximizer 300 Spare Parts Kit 25 ft 7 6 m Work Ca
123. s For interfacing the power supply with a computer or auxiliary control device Available in various cable lengths SC 10 or SC11 Standoff Control NOTE Standoff Control SC10 requires installation of Re mote Control RC6010 For machine torch systems the SC 10 automatically finds height and maintains torch standoff with a high speed torch lifter motor High Pressure Regulators Available for air oxygen argon hydrogen nitrogen CO and water E High Flow Water Shield HFWS Assembly Reduces arc glare noise and fumes during the cut ting process F Two Stage Air Line Filter Removes damaging contaminants as small as 5 mi crons from the plasma stream when using compressed air INTRODUCTION amp DESCRIPTION G Hour Counter Meters Meter assembly containing two meters One meter indicates the total number of hours that the main cut ting arc has been on The second meter counts the number of times that the cutting arc has been started Both meters display a maximum of 999999 hours or starts and cannot be reset H Plasma Secondary Gas Control A remote control to select one of various plasma and secondary gases including secondary water that can be connected to the Power Supply INTRODUCTION amp DESCRIPTION 14 Manual 0 2533 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 4 01 Introduction This Section provides service diagnostics for the Merlin 3000 Power Supply allowing the Technician to i
124. s pressure set too low a Adjust pressure Faulty pressure switch PS1 or PS2 a Jump switches one at a time and check for indi cator to determine which has failed Replace switch if necessary Faulty Logic PC Board a Refer to Section 4 05 G Pressure Sensing Cir cuit Replace Logic PC Board if necessary Faulty LED Current Control PC Board a Refer to Section 4 05 G Pressure Sensing Cir cuit Replace LED Current Control PC Board if necessary Faulty SW3 B secondary mode set to O2 or H20 a With secondary mode set to O2 or H2O check for continuity from wire 52 to 55 on SW3 B If open replace SW3 B If using Gas Control Option GC3000 set for Water Secondary faulty SW2 C in Gas Control a With Merlin front panel secondary mode set to GAS and the Gas Control GC3000 set to WATER there should be continuity from wires 52 to 55 Tf not S W2 C or connections to it are faulty I GAS indicator off plasma and or secondary gas does not flow 1 Front panel RUN SET PURGE switch set to PURGE or PURGE selected at Remote Control a Normal operation purges plasma line only sec ondary does not flow 2 Secondary mode set to O2 a No secondary flow is normal operation in O2 mode but GAS indicator should be ON Re fer to symptom H above 20 Manual 0 2533 3 Gas Control GC3000 on wrong setting a Select input that has gas connected 4 Gas supply turned off or tank empty a Check g
125. slolate any faulty Subassemblies Refer to Section 5 Repairs amp Replacement Procedures for parts replacement instruc tions 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 Merlin 3000 Power Supply only Trouble shooting other parts of the system is covered in the separate manuals for that product 4 02 Periodic Inspection amp Procedures NOTE Refer to Appendix XV for a recommended mainte nance schedule for water cooled plasma cutting systems This subsection describes inspection procedures which should be performed at periodic intervals as required A Fan Motor and Pump Lubrication The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation To oil the motor remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor NOTE Some units may utilize a sealed motor design which does not require lubrication Routine Maintenance The only other routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment Manual 0 2533 To clean the unit first make sure that the power is disconnected Remove the side panels and
126. source before diconnecting any gas Hose As semblies Each Subsection is referenced to Section 6 for parts lists and overall detailed drawing 33 REPLACEMENT PROCEDURES A WARNING Disconnect primary power from the source before opening or disassembling the power supply Make sure AC indicator on the Power Supply front panel is OFF Before disassembling any part of the Power Supply first read the procedure for the part to be replaced then pro ceed with the disassembly 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 Handle Replacement The Power Supply has two Handles on each side of the unit The Handles are the same and are replaced in the same manner 1 Remove the four screws securing the Handle to the side of the unit 2 Remove the Handle from the unit 3 Place the replacement Handle onto the unit 4 Secure the Handle to the side of the unit with the four screws removed in Step 1 B 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 REPLACEMENT PROCEDURES 34 END Side Panel Screws 10 Places Remove the Handle per paragraph A above A 00954 Remove the four screws that secure the rear of the Side Panel to th
127. spark visible at spark gap points inside the Arc Starter Box 1 Electrode shorted against tip a Thread electrode securely into torch head or replace tip and electrode 2 Shorted torch head a Check and replace if necessary SERVICE TROUBLESHOOTING 22 3 Broken conductor in torch lead a Check and replace if necessary 4 Shorted torch lead a Check and replace if necessary 5 Dirty or wet torch lead a Clean and dry torch lead Pilot arc on No main arc transfer torch brought within range of work 1 Work cable not connected a Connect work cable securely 2 Defective current control pot on front panel or remote a If Remote Control is used disconnect J15 and set current at power supply front panel If trans fer is correct or Remote Control is not used re fer to Section 4 05 O Current Control Display and CSD Checks Main arc starts but goes out immediately Main contactor W1 or W2 goes off 1 Fault condition causes output greater than 175 amps a Shorted Q1 or faulty Switching Control PC Board Refer to Section 4 05 M Switching Con trol Check 01 Main arc transfers but doesn t pierce through the plate or pierce is too slow 1 Corner slowdown CSD setting too low on Remote Control a Most cutting machines activate CSD during piercing if so CSD must be set at or near maxi mum 2 Cutting current too low a Set for higher current b Current control circuit defective Refer t
128. t 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 protection Date 6 22 99 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 BRUIT 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 l our prot ger votre ouie 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 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 1 06 Documents De Reference Consultez les normes suivantes ou les r
129. ted accessories 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 Director of Operations Thermadyne UK Chorley England Date 6 22 99 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 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 th
130. teflon sealer before installing on the replacement Check Valve M Secondary Gas Check Valve Replacement 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the two Secondary Gas Water Hose Assemblies from the T Fitting connection at the Check Valve 3 Carefully remove the Check Valve and Fittings from the Secondary Gas Regulator Assembly 4 Remove the Fittings from the input of the old Check Valve NOTE The output ofthe replacement Check Valve should be pointing away from the Pressure Regulator As sembly when installed The output is designated by an arrow on the side of the part 5 Install the replacement Check Valve by reversing the above procedure and noting the following Coat the threads of the Fittings with a teflon sealer before installing on the replacement Check Valve 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 Manual 0 2533 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 70 Amp 600V Str Diode Assembly 1 each 0 75 inch diameter Thermal Interface Pad 1 each Tube of RTV 1 each 1 Turn OFF main input power to the Power Supply both at the Power Supply ON OFF switch and at the main p
131. ti Plasma Gas Pressure T Connection To T Connection rang Gauge Front Panel T Fitting Plasma Gas Hose Assembly T Connection To Pressure Gauge Secondary Water Solenoid yis Secondary Water Hose Assembly Check Valve To T Connection Plasma Gas Hose Assembly T Connection To Bulkhead Check Valve Symbol Secondary Gas zen Pressure Gauge T Fitting Front Panel gt Direction Of Flow Secondary Gas Water Hose Assembly T Connection To Bulkhead Bulkhead Front Panel Coolant Pressure Plasma Gas Coolant Supply Hose Assembly Gauge Front Panel Coolant Filter To Pump Coolant Supply Hose Assembly Pump To Pressure Gauge Coolant Filter Assembly a Check Valve J Coolant Supply Rear Panel PUMP Assembly Ting 20 essei pply Secondary Gas 1 Coolant Supply Hose Assembly Coolant Return Coolant Supply Hose Assembly Pump To Bulkhead Tank To Coolant Filter Coolant Return Hose Assembly c Coolant Return Hose Assembly Internal Filter To Flow Switch Bulkhead To Radiator A 01227 Tank Y Radiator Top In 44 Flow Internal Filter C Out Bottom Out IIX XIGNAddV INVHOVIG HJO1A 3SOH APPENDIX XIV SYSTEM SCHEMATIC TI
132. trol SC10 When an RC6010 is included the CNC signals are con nected to the RC6010 through the rear panel CNC connector J29 or may be wired directly to J6 a termi nal strip inside the RC6010 All CNC inputs are opti cally isolated to reduce noise interference The RC6010 allows remotely controlling the cutting current set ting reduced current for corner slowdown and select ing gas PURGE and SET functions A digital AMPS display allows accurate setting and monitoring of the output current An ENABLE switch shuts down the power supply and coolant pump for changing torch consumables H Standoff Control 1 Model SC10 Standoff Control The Standoff Control SC10 includes an ARC VOLTS display a control to set the desired arc voltage as well as PIERCE HEIGHT PIERCE DE LAY and END OF CUT RETRACT There are also manual UP and DOWN switches The Stand off Control operates a lifter motor assembly mov ing the torch vertically to control torch tip to work distance When used with the Remote Control RC6010 all inputs and outputs to the Standoff Control ex cept lifter motor drive is via an internal ribbon cable between Remote Control RC6010 J5 and Standoff Control 5 10 J7 No additional con nections are required between Standoff Control and Power Supply 2 Model SC11 Standoff Control Standoff Control SC11 is used without a Remote Control RC6010 The Standoff Control has ad ditional connectors on the rear pan
133. tting on the Gas Solenoid Valve Assembly 4 Disconnect the two wires connected to the Sole noid Valve Assembly 5 Remove the Panel Nut securing the assembly to the Rear Panel Assembly 6 Pull theold Gas Solenoid Valve Assembly from the Rear Panel Assembly Manual 0 2533 37 7 Install the replacement Solenoid Valve Assembly by reversing the above procedure and noting the following Remove the fittings from the old assembly and install on the replacement assembly Secondary Water Solenoid Valve Assembly Replacement 1 Remove the water supply from the Secondary Water connection at the Rear Panel Assembly 2 Remove the Top Panel per Section 5 04 B 3 Disconnect the internal Hose Assembly connected to the elbow fitting on the Secondary Water Soleniod Valve Assembly inside the unit 4 Carefully disconnect the two wire connector to the Secondary Water Solenoid Valve Assembly 5 Remove the Panel Nut securing the assembly to the Rear Panel Assembly 6 Pull the old Secondary Water Solenoid Valve As sembly from the Rear Panel Assembly 7 Install the replacement Secondary Water Solenoid Assembly by reversing the above procedure and noting the following Remove the fittings and Check Valve from the old assembly and install on the replacement as sembly Rear Panel Coolant Filter Assembly Replacement The Coolant Filter Assembly is located on a bracket on the Rear Panel Assembly of the unit
134. ubsection 1 03 Publica tions Disconnect power source before performing any ser vice 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 mate rial 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 Provide 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 Apo 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 For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual m P
135. uit Diagram The start signal from the cutting machine controller enters the RC6010 at J29 or J6 and may be either a momentary closure J29 1 or sustained closure J29 3 It passes through optical isolation circuits and if the ENABLE is on and the station select input is ac tive lights internal led D103 If the Standoff Control SC10 is not used start goes to the remote cable at 137 9 If the Standoff Control SC10 is connected then start signal goes to it active low at J5 13 lights inter nalindicator D79 and starts the find height sequence Once height is found the front panel PLASMA ON inicator comes ON If FIND HT is not ON the find height function is by passed and PLASMA ON comes on immediately The start signal then is returned to the Remote Control RC6010 active low on J7 17 and to the remote cable on J37 9 to the Power Supply re mote connector J15 24 and TB2 3 and on to the Power Supply Logic PC Board If the Standoff Control C10 is installed and the sys tem won t find height the problem is in the Standoff Control 5 10 Remote Control RC6010 or the in terconnections to the cutting machine Set FIND HT off it the torch starts now the problem is in the Stand off Control SC10 NOTE Refer to Section 5 Customer Operator Service in the Standoff Control Instruction Manual If it doesn t start open the cover of either the Standoff Control SC10 or Remote Control RC6010 which ever one is on t
136. urrent control receives it s high level 10 VDC on J10 17 and it s low level 3 3 VDC on J10 13 Verify those voltages with re spect to TP1 on the Switching Control PC Board then measure the pot s wiper between J10 15 and TP1 It should vary from 3 3 to 10 VDC as the control is moved from minimum to maximum If it does not vary or is less than 3 3 VDC then the control pot in the LED PC Board is faulty or the ribbon cable is faulty If the high and low 3 3 VDC and 10 VDC are incorrect the Switching Control PC Board is faulty or the ribbon cable is shorted 3 Remote Current Control NOTE Refer to Appendix X for Current Control Display Circuit Diagram The Remote Control RC 6010 has front panel controls for OUTPUT AMPS and CSD The up per and lower limits of the current control range are set by the POT HI 10 VDC and POT LOW Manual 0 2533 29 3 3 VDC signals from J50 8 and J50 6 on the Switching Control PC Board sent to the remote via the remote cable The CSD control upper limit is set by the wiper of the OUTPUT AMPS control thus the CSD range is a percentage of the main output The wiper of the main pot is sent through the normally closed CSD relay contact out the remote cable to J7 18 on the Switching Control PC Board If CSD is en abled indicated by illuminating the 3 decimals in the display then the CSD wiper provides the cur rent control signal to J7 18 NOTE Refer to Appendix XI for Corner Slowdo
137. wn CSD Circuit Diagram If the OUTPUT AMPS control or the CSD control have no effect on current level see if the panel con trol does if so there may be a poor connection in the REMOTE INSTALLED circuit between the re mote and Switching Control PC Board Check TP1 to J7 20 if it does not measure less than 2v there is a faulty connection otherwise the Switching Con trol PC Board is faulty If the front panel control had no effect which it shouldn t measure from TP1 to J7 18 while mov ing the OUTPUT AMPS control from min to maxi mum The voltage at J7 18 should vary from 3 3v to 10 v If it does the Switching Control PC Board is faulty If voltage is incorrect at J7 18 check J50 8 for 10 v and J50 6 for 3 3 v If OK then the remote is defec tive or the connections remote cable or Merlin harness are open 4 Remote AMPS Display The AMPS display shows control pot setting pre view and actual cutting amps The decimal points indicate when CSD standoff inhibit is on by light ing all 3 decimals and when OK To Move is not on by lighting the left hand decimal The AMPS display is driven by a signal from the Merlin Switching Control PC Board J7 2 NOTE Refer to Appendix X for Display Circuit Diagram Positive 3 3 to 10 volts at J37 1 gives a display from 50 to 150 AMPS Prior to cutting arc transfer the display signal is in the preview mode as indi cated by the left hand decimal being on The dis play is
138. y 4 Remove the Conductivity Sensor Assembly from the Coolant Tank 5 Install the replacement Conductivity Sensor As sembly by reversing the above procedure 6 Refill the Coolant Tank with the coolant removed or add fresh Thermal Arc Torch Coolant J Secondary Water Check Valve Replacement 1 Remove the Top Panel per Section 5 04 B 2 Disconnect the Secondary Gas Water Hose Assem bly from the Elbow Fitting connection at the Check Valve 3 Carefully remove the Check Valve and Elbow Fit ting from the Secondary Water Solenoid Assem bly NOTE The output of the replacement Check Valve should be pointing towards the rear of the unit when in stalled The output is designated by a symbol on the side of the part as shown in the following Fig ure Check Valve Symbol gt Direction Of Flow A 00370 4 Install the replacement Check Valve by reversing the above procedure and noting the following Coat the threads of the Elbow Fitting with a teflon sealer before installing the replacement Check Valve Manual 0 2533 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 B 1 2 3 4 5 39 A WARNING The removal of this Assembly requires the use of a mechanical lift Remove the Left and Right Side Panels per Section 5 04
139. y and consists of the Merlin 3000 plasma power supply the Maximizer 300 Torch Torch Leads Extension and Arc Starter Box An Optional Remote Control RC6010 Standoff Control SC10 or SC11 see notes and Gas Control GC3000 may be used in vari ous combinations Different interconnect and input output I O cables may be used depending on which options are installed An Optional Dual Meter Arc Hours and Arc Starts Counter may be included on the Power Supply front panel NOTES The Standoff Control SC10 must be used with the Remote Control RC6010 The Remote Control RC6010 is not used if the Standoff Control SC11 is used Input Voltage Selection The main transformer T1 has busbar connections to select one of three input voltage ranges Each main transformer 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 volt agerange 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 cir

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