Tweco 1000 User Manual
MERLIN ® 1000
Automated Plasma Cutting
Power Supply (CE)
Operating Manual
September 30, 1999
A-02157
Manual No. 0-2731
WARNING
WARNING
Read and understand this entire manual and your employer’s
safety practices before installing, operating, or servicing the
equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
®
Merlin
1000 Automated Plasma Cutting Power Supply (CE)
Operating Manual Number 0-2731
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1998 by
Thermal Dynamics Corporation
All 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 liabil-
ity to any party for any loss or damage caused by any error or
®
omission in the Merlin
1000 Automated Plasma Cutting Power
Supply (CE) Operating Manual, whether such error results from
negligence, accident, or any other cause.
Printed in the United States of America
September 30, 1999
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et A v ertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 7
1.08 Statement of W arr anty................................................................................... 8
SECTION 2:
INTRODUCTION ................................................................................................................. 9
2.01 Scope of Manual............................................................................................ 9
2.02 Pow er Supply Gener al Description ................................................................ 9
2.03 Specifications & Design Features ................................................................ 10
2.04 Po wer Supply Options and Accessories ...................................................... 11
2.05 Theory Of Operation.................................................................................... 11
SECTION 3:
INST ALLATION PROCEDURES ........................................................................................ 13
3.01 Introduction.................................................................................................. 13
3.02 Site Selection............................................................................................... 13
3.03 Unpacking ................................................................................................... 13
3.04 Input Pow er Cab le Connections................................................................... 13
3.05 Gas Connections......................................................................................... 14
3.06 Connecting Torch Leads To System Without Optional Remote Arc Starter .. 17
3.07 W ork Cable And Ground Connections......................................................... 18
3.08 Filling Pow er Supply Coolant ....................................................................... 19
3.09 External Cable Connections ........................................................................ 20
3.10 Lifting Options.............................................................................................. 20
3.11 Optional Remote Arc Starter ....................................................................... 21
SECTION 4:
OPERATION ...................................................................................................................... 25
4.01 Introduction.................................................................................................. 25
4.02 Functional Overview .................................................................................... 25
4.03 Front and Rear P anel Descriptions.............................................................. 25
4.04 Sequence of Operation................................................................................ 28
4.05 Preparations for Operating........................................................................... 29
4.06 Cut Quality................................................................................................... 30
4.07 System Operation........................................................................................ 32
4.08 Optional Pow er Supply Settings................................................................... 32
TABLE OF CONTENTS (continued)
SECTION 5:
MAINTENANCE & CUSTOMER/OPERATOR SER VICE................................................... 35
5.01 Introduction.................................................................................................. 35
5.02 Recommended Routine Maintenance Schedule .......................................... 35
5.03 General Maintenance .................................................................................. 35
5.03 Common Operating Faults........................................................................... 37
5.04 Common Operating Problems ..................................................................... 37
5.05 Troubleshooting Guide ................................................................................. 38
5.07 Test Procedures For Optional Remote Arc Starter....................................... 41
5.08 Pow er Supply Parts Replacement ............................................................... 43
SECTION 6:
PARTS LISTS.....................................................................................................................45
6.01 Introduction.................................................................................................. 45
6.02 Ordering Information.................................................................................... 45
6.03 Complete System Replacements ................................................................ 46
6.04 Pow er Supply Replacement Only ................................................................ 46
6.05 Basic Replacement Parts ............................................................................ 46
6.06 Options and Accessories............................................................................. 46
APPENDIX I: INPUT WIRING REQ UIREMENTS ...................................................................... 47
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 48
APPENDIX III: TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM ........................... 49
APPENDIX IV: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM .. 50
APPENDIX V: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES ........... 51
APPENDIX VI: POWER SUPPLY CNC INTERF A CE DIA GRAM................................................ 52
APPENDIX VII: OPTIONAL REMOTE ARC STARTER INTERCONNECTING DIAGRAM......... 53
APPENDIX VIII: 36 VAC CIRCUIT DIAGRAM............................................................................ 54
APPENDIX IX: SYSTEM SCHEMATIC ...................................................................................... 56
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
W ARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• 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. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
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 in an area where combustible 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.
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. Persons who work near plasma arc cutting applications should consult their medical health professional 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 instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: 6/22/99 1 GENERAL INFORMA TION
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 operator or others in the workplace.
ELECTRIC SHOCK
• Never touch any parts that are electrically “live” or
“hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material 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 wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater 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 dissipated. T rapped hydr ogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o pr otect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (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.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect 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 workpiece.
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, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE
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 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION 2 Date 6/22/99
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFP A Standar d 70, NA TIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable 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 Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS 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 RESPIRATORY 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 utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
A VERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
Date: 6/22/99 3 GENERAL INFORMA TION
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
P AS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
RAYONS D’ARC DE PLASMA
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
GENERAL INFORMATION 4 Date 6/22/99
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L ’ARC ET AU GAZ, disponible aupr ès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRA TIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American W elding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W1 17.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
Date: 6/22/99 5 GENERAL INFORMA TION
14. Norme A WSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès 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
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Dir ective.
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 requir ements 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 boar ds used.
* CENELEC EN50199 EMC Product Standard for Ar c W elding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated 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 accor ding 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 pr oduct 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 repr esentative: Steve W ard
Director of Operations
Thermadyne UK
Chorley England
Date: 6/22/99 7 GENERAL INFORMA TION
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 stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry prac tice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PA R TICULAR 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 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 & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits 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
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 6, 1999
GENERAL INFORMATION 8 Date 6/22/99
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the Merlin 1000
Automated Plasma Cutting Power Supply (CE). Service
of this equipment is restricted to Thermal Dynamics
trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
2.02 Power Supply General Description
This Power Supply is designed to cut most metals up to
1-1/4 inches (31.8 mm) using air , oxygen, nitrogen, or argon/hydrogen as the plasma gas. This system is also capable of satisfying many mechanized gouging applications.
The Merlin 1000 is designed to use the Maximizer 300
torch in automated applications. T orch will pr ovide piercing and production cutting up to 1/2 inch (12.7 mm) and
maximum cut capacity of 1-1/4 inches (31.8 mm). The
torch is available in the following configurations:
• 180° Torch Head using 1-3/8 inch diameter Rack
and Pinion Mounting Assembly
• 70° or 90° T orch Head with Machine Mounting Point
NOTE
For more information about the Maximizer Torch,
refer to Instruction Manual 0-2710.
This unit provides 100 amp maximum output and includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, torch leads receptacle and a 20
foot (6.1 m) work cable with ring terminal. All Merlin
1000 systems also include a CNC Interface Cable or Remote Pendant Control.
NOTE
A-02157
Figure 2-1 Merlin 1000 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 dr ops
to -34° F (-36° C).
A. Typical System
A typical system configuration will contain the following:
• Power Supply
• 20 ft (6.1 m) Work Cable and Ring Terminal
• Maximizer 300 180° T o rch with 25 ft (7.6 m) or 50 ft
(15.2 m) Lead length as ordered
• Maximizer 300 Spare Parts Kit
• CNC Interface Cable 25 ft (7.6 m) or 50 ft (15.2 m)
length as ordered or Remote Pendant Control
• Standard Thermal Ar c Coolant - 3 gallons
NOTE
The power supply can be ordered in various options factory installed.
Refer to Section 2.04 for list of Power Supply Options and Accessories.
Manual 0-2731 9 INTRODUCTION
Refer to Section 2.04 for complete list of Power Supply Options and Accessories.
B. Requirements to Complete System
7. Duty Cycle
To complete the system, the user needs to provide the
following:
• Primary input power
• Gas supplies
2.03 Specifications & Design Features
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
• ON/OFF and RUN/SET Switches
• Output Current Control
• Work Cable Connection
• Torch Leads Connection
2. Front Panel LED Indicators
• AC
• TEMP
• GAS Pressure/Coolant Flow
• DC Output
3. Gas Control Panel
• Plasma and Secondary Gas Pressure Controls and
Gauges
• Plasma Gas Flowmeter
• Secondary Lo-Flow Gas Flowmeter
• Secondary Mode Selector Switch
• Secondary Water Mist Flowmeter
4. Rear Panel
• Primary Input Power Cable Strain Relief
• Plasma Gas Supply Connection
• Secondary Gas Supply Connection
• Secondary Water Supply Connection
• Dual Stage Air Filter
5. Input Power (see NOTES)
380-415 VAC (±10%), 50/60 Hz, Three-Phase
NOTES
Refer to Appendix I for suggested input wiring size,
current ratings and circuit protection r equirements.
6. Output Power
100% Duty Cycle @ 130V output at 100 amps
8. Cut Capacity
Pierce and Production Rating: 1/2 inch (12.7 mm)
9 Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC (See Note)
NOTE
Optional Remote Arc Starter available.
10. CNC Interface Signals
Start/Stop and OK-To-Move
11. Coolant Pressure
Internal Service-adjustable
130 psi (8.8 bar) at zero flow
120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)
12. Coolant Flow Rate
0.5 gpm (1.9 lpm) with 150 feet of total torch and torch
leads at 70°F (21°C)
NOTE
The flow rate varies with lead length, torch configuration, ambient temperature, amperage level,
etc.
13. Cooling Capacity
4,000 to 10,000 BTU
NOTE
Maximum value based on “free flow” condition.
14. Coolant Reservoir Capacity
2 gallons (Use Thermal Arc® coolant only)
Capable of handling a total of 150 feet of torch lead
length
15. Secondary Water
Clean drinking quality tap water can be used as a secondary and must be capable of delivering the following minimums:
• Water pressure of 50 - 100 psi (3.5 - 6.9 bar)
• Flow of 9 gph (34 lph)
Continuously variable from 30 to 100 amps (±5%)
INTRODUCTION 10 Manual 0-2731
16. Overall Dimensions
Height: 40-1/2 inches (1.03 m)
Width: 20-1/2 in (0.52 m)
Depth: 30-1/4 inches (0.77 m)
17. Weight
Power Supply with Torch: 275 lbs (125 kg)
2.04 Power Supply Options and Accessories
With a simple change of torch parts, the system can also
be used for plasma arc gouging. Plasma arc gouging uses
the same process to remove material to a controlled depth
and width.
B. Input and Output Power
The unit converts AC input power to DC power for the
main cutting arc. The negative output is connected to
the torch electrode through the negative torch lead, and
the positive output connects to the workpiece through
the work cable.
C. Pilot Arc
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for this
Power Supply:
A. High Pressure Regulators
High pressure regulators ar e available for air , oxygen,
argon-hydrogen and nitrogen. The r egulators are used
to set the proper pressure for the type of gas being
used.
B. Standoff Control (SC11)
Optional Standoff Control automatically finds height
and maintains torch standoff with a high speed torch
lifter motor . Refer to Standoff Control (SC1 1) Manual,
0-2556, for more information.
C. Remote Arc Starter
Option available to remote the arc starting circuits
closer to the Torch Head Assembly. The option includes a Remote Arc Starter and Torch Supply Leads.
The Torch Supply Leads are available in 25 ft (7.6 m)
to 100 ft (30.5 m) lengths.
When the torch is activated there is a 2 second (service
adjustable) gas pre-flow, followed by an uninterrupted
pulsed DC pilot arc established between the electrode and
tip. The pilot arc is initiated by a momentary high frequency pulse from the Power Supply or the Optional
Remote Arc Starter. The pilot creates a path for the main
arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated.
D. Main Cutting Arc
The power supply converts the AC input power to DC
power for the main cutting arc. The negative output is
connected to the torch electrode through the negative
torch lead. The positive output is connected to the workpiece via the work cable and ring lug connection.
E. RF Shielding
All machine torch systems are shielded to minimize radio frequency (RF) interference which results from the
high frequency arc initiation. These shielded systems are
designed with features such as a wire for establishing an
earth ground and shielded torch and control leads.
F. Interlocks
D. Remote Pendant Control
Control used to manually start and stop cutting operations from a location up to 25 ft (7.6 m) from the
Plasma Power Supply.
2.05 Theor y Of Operation
A. Plasma Arc Cutting and Gouging
Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma
gas to transfer an electric arc to a workpiece. The metal
to be cut is melted by the intense heat of the arc and then
blown away by the flow of gas.
Manual 0-2731 11 INTRODUCTION
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down
the system, the fault condition must be remedied and the
system recycled using the applicable control device.
1. Parts-In-Place (PIP) Interlock
The Power Supply has a built-in parts-in-place interlock 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
A pressure switch acts as an interlock for the
plasma gas supply . If the plasma gas supply pressure falls below minimum requirements the pr essure switch will open, shutting off the power to
the contactors, and the GAS indicator will go out.
When adequate plasma supply pressure is available the pressure switch will close, allowing power
to be resumed for cutting.
NOTE
There is no gas pressure interlock for secondary
gas.
INTRODUCTION 12 Manual 0-2731
SECTION 3:
INSTALLATION
vide sufficient clearance in front of the unit to allow access to the front panel controls (minimum 6 inches or 0.15
m).
PROCEDURES
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all sub-sections be read for general information.
This section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Work cable
c. Gas connections
d. Torch Installation
e. Connecting auxiliary devices
4. Grounding
5. Operator training
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
NOTE
Equipment that was ordered as a system is packaged in one shipping carton. All options and the
torch are factory installed.
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system
installation.
3.04 Input Power Cable Connections
The Power Supply is factory wired to accept input voltages of 380-415 VAC, 50 or 60 Hz, three-phase power.
A. Power Source
The power source must conform to local and national electric codes. For suggested circuit protection and wiring
requirements refer to Appendix I.
3.02 Site Selection
Select a clean, dry location with good ventilation and adequate working space around all components.
NOTE
Review Important Safety Precautions (page 1) to
be sure that the selected location meets all safety
requirements.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be obstructed. Provide at least 2 feet (0.61 m) in the rear and at
least 6 inches (0.15 m) on each side for clearance . Pro-
Manual 0-2731 13 INST ALLATION PROCEDURES
Disconnect primary power at the source before assembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
B. Input Power Cable Connections
The shielded input power cable must be connected to a
380-415 V AC, three-phase power sour ce. Refer to the following procedure:
W ARNING
CAUTION
The input power cable must not be modified in any
way as shielding is installed on the cable.
1. At the free end of the input power cable, cut back
the insulation on the individual wires approximately 1/8 - 3/16 inch (3-5 mm).
2. Connect the ends of the individual wires and shield
to a customer supplied plug or disconnect box per
the following (see NOTES):
• Brown wire to Line 1 (Live)
This sub-section includes information for connecting the
gas supplies to the Power Supply. The information is
grouped in paragraphs for different types of gases and
options per the following:
A. Using Shop Air
B. Using High-Pressure Gas Cylinders
C. Using Plasma Shop Air and Secondary High-
Pressure Gas Cylinder
D. Using Water Secondary
Refer to the appropriate paragraph(s) for the desired application to be used.
• Blue wire to Line 2 (Live)
• Black wire to Line 3 (Live)
• Y ellow/Gr een wire to Gr ound (power gr ound)
• Cable shield to earth ground
NOTES
The shield braid on the free end of the input cable
must be connected to a solid earth ground with as
short a connection as possible at the plug or disconnect box. Refer to Subsection 3.07 for procedures on installing an earth ground.
Make sure that the yellow/green wir e is connected
to power line safety ground.
3.05 Gas Connections
The Power Supply provides the liquid cooling and gases
to support operation of the Liquid Cooled Maximizer 300
T orch.
NOTE
Refer to the Liquid Cooled Maximizer 300 Torch
Instruction Manual (Cat. No. 0-2710) for information on plasma and secondary gas selection and
requirements.
The following are available gases that can be used with
the Liquid Cooled Maximizer 300 Torch:
A. Using Shop Air
NOTE
The Two Stage Air Line Filter Assembly is to be
used when using shop air as the Plasma Gas.
An inline pneumatic dryer/evaporator type air filter , capable of filtering particulates to at least 5 microns with a
dew point of 35°F (1.7°C), is required when using air fr om
a compressor. This type filter will insure that moisture,
oil, dirt, chips, rust particles, and other contminants from
the supply hose do not enter the torch. For highly automated applications, a refrigerated drier plus a particulate filter may be used to chill the air to remove all moisture.
CAUTION
Excessive oil or moisture in compressed air will
reduce torch parts life and cutting performance and
may cause torch failure.
All Merlin 1000 Systems are supplied with a Two Stage
Air Line Filter attached to the rear of the Power Supply.
The following procedure is the recommended shop air
connection method:
Connect the air supply hose (see note) to the Air Line
Filter input port (IN) barb fitting and secure with a customer supplied hose clamp.
Plasma Gases: Compressed Air , Oxygen (O2), Nitr ogen (N2), or Argon/Hydrogen (Ar/H2)
Secondary Gases: Compressed Air, Oxygen (O2),
Nitrogen (N2), Carbon Dioxide (CO2), or Tap Water
Gas requirements vary depending on the application. The
gases are connected to the rear panel connections of the
power supply. Depending on the options installed and
the source of the gases will determine the installation of
filters and regulators.
INST ALLATION PROCEDURES 14 Manual 0-2731
2. Each cylinder must be equipped with an adjustable
high-pressure regulator capable of pr essures up to 125
psi (8.6 BAR) maximum and flows of up to 700 scfh
(328 lpm) for cutting or gouging.
CAUTION
PLASMA GAS
SECONDARY
GAS
Barb Fitting
Two-Stage
Air Filter
Air Supply Hose
(Customer Supplied)
A-02348
Figure 3-1 Supply Hose Connections
NOTE
The supply hose must be 1/4 inch (6.3 mm) minimum inside diameter to provide adequate air flow .
Maximum input pressure to the internal regulator on the Power Supply must not exceed 125 psi
(8.6 BAR).
NOTE
A typical 50 lb. CO2 cylinder can deliver a continuous flow rate of 35 scfh (16.5 lpm). To obtain
the required flow rate for the torch, it may be necessary to manifold several CO2 cylinders. Continuous flow requirements will depend on the specific application and duty cycle.
3. Connect the gas supply to the Power Supply per
the following:
a. Remove the plasma and secondary gas hoses
and adapters from the PLASMA and SECONDARY fittings at the r ear panel.
Adapter
Fitting
Plasma Gas
Hose
B. Using High-Pressure Gas Cylinders
NOTES
Refer to the regulator manufacturer’s specifications
for installation and maintenance procedures. Refer to Section 6.05, System Options and Accessories, or a listing of available high-pressure regulators.
Do not use an air line filter with high pressure gas
cylinders.
1. Examine the cylinder valves to be sure they are clean
and free of oil, grease or any foreign material. Momentarily open each cylinder valve to blow out any
dust which may be present.
WARNING
Do not stand in front of the valve outlet when opening.
PLASMA GAS
Fitting
SECONDARY
GAS Fitting
Adapter Fitting
Secondary Gas
Hose
A-02355
Figure 3-2 Removal Of Factory Installed Hardware
b. Connect the gas hose from the plasma gas
source directly to the input fitting on the rear
panel of the Power Supply marked PLASMA.
Manual 0-2731 15 INST ALLATION PROCEDURES
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