ARC STARTER
BOX
Used With:
• TD-750 Cutting Systems
• Merlin 3000 Cutting Systems
January 13, 1997
A-00649
Instruction Manual
Manual No. 0-2475
WARNING
WARNING
Read and understand this entire Instruction Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this instruction manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Thermal Dynamics Arc Starter Box
Instruction Manual No. 0-2475
Published by
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1995 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 errors or
omissions in the Arc Starter Box Instruction Manual, whether
such errors result from negligence, accident, or any other cause.
Printed in the United States of America
January 13, 1997
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 .............................................................................. 6
1.08 Statement of W arr anty ................................................................................... 7
SECTION 2:
INTRODUCTION & DESCRIPTION..................................................................................... 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description....................................................................................... 9
2.03 Specifications & Design Features .................................................................. 9
SECTION 3:
INSTALLATION PROCEDURES ........................................................................................ 11
3.01 Introduction.................................................................................................. 11
3.02 Site Location................................................................................................ 11
3.03 Unpacking .................................................................................................... 11
3.04 Mounting Arc Starter Box ............................................................................ 11
3.05 Connecting Torch ......................................................................................... 12
3.06 Connecting Torch Leads Extension Assembly ............................................. 12
SECTION 4:
CUSTOMER/OPERATOR SER VICE.................................................................................. 13
4.01 Introduction.................................................................................................. 13
4.02 General Maintenance .................................................................................. 13
4.03 Troubleshooting Guide ................................................................................. 13
4.04 Test Procedures........................................................................................... 15
SECTION 5:
PARTS LISTS.....................................................................................................................19
5.01 Introduction.................................................................................................. 19
5.02 Ordering Information.................................................................................... 19
5.03 Replacement Parts - Box............................................................................. 20
5.04 Replacement Parts - Input/Output Connectors ............................................ 22
5.05 Replacement Parts - Pilot Gas Control ........................................................ 24
APPENDIX I: INTERCONNECTING DIAGRAM......................................................................... 25
APPENDIX II: 24 VAC WIRING BLOCK DIAGRAM FOR MERLIN 3000 PO WER SUPPLY ....... 26
APPENDIX III: MOUNTING HOLE TEMPLATE.......................................................................... 27
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 pr ocedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A pr ocedure 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.
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 1-603298-571 1 or your local distributor if you have any
questions.
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 r ead 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.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC 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 operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
Date: 10/15/99 1 GENERAL INFORMA TION
• 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.
• To protect your hearing from 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 Ar c 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 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 Broadway, New York, NY 10018
GENERAL INFORMATION 2 Date 10/15/99
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
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
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 Standard 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 Ar ch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, 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
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
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 + 603-298-571 1 ou votre distributeur
local si vous avez des questions.
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
FUMÉE et GAZ
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
La fumée et les gaz produits par le procédé de jet de
NOTE
Toute opération, procédure ou renseignement
plasma peuvent présenter des risques et des dangers de
santé.
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: 10/15/99 3 GENERAL INFORMA TION
• 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 différents
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
• 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.
• 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.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir
des éléments reconnu dans L’ état de la Californie,
qui peuvent causer des défauts de naissance et le
cancer . (La sécurité de santé en Californie et la code
sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
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
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
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.
GENERAL INFORMATION 4 Date 10/15/99
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.
• 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 auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
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 Welding 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
Date: 10/15/99 5 GENERAL INFORMA TION
1 1. 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 W117.2, 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 W elding Supply Association),
1900 Arch Street, Philadelphia, PA 19103
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 10/15/99
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.
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 standar ds and technical requirements among them ar e:
* 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.
* 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 pr oduct 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 manufactur ed 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 r epresentative: Steve W ard
Director of Operations
Thermadyne UK
Chorley England
Date: 10/15/99 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 ther eof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standar d industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
P ARTICULAR 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 fr om 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 To rch 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 10/15/99
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.03 Specifications & Design Features
The following applies to the Ar c Starter Box only:
A. System Configuration
2.01 Scope of Manual
This manual contains description, installation instructions
and maintenance procedures for the Thermal Dynamics
Arc Starter Box. 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 General Description
The Arc Starter Box Assembly is used to place the arc
starting circuit closer to the Torch Assembly and is designed to be mounted on the gantry near the Torch Assembly.
The T or ch, with short leads attached, connects to the output of the unit. The T orch Extension Leads Assembly connects to the input of the unit.
• TD-750 Cutting System:
Used with the TD-750 Plasma Cutting System
Control/Power Modules, Power Base Unit, and
Maximizer 300 Machine Torch.
• Merlin 3000 Cutting System:
Used with the Merlin 3000 Plasma Cutting Sys-
tem Power Supply and Maximizer 300 Machine
Torch.
B. Pilot) Circuitry
CD, Constant DC
C. Input Connection
Provides connection for the Torch Extension Leads
Assembly between the Plasma Power Supply and the
Arc Starter Box.
D. Output Connection
Provides connection for the Torch Leads between the
Arc Starter Box and the Maximizer 300 Torch.
E. Mounting
All gases and command signals are supplied to the Arc
Starter Box by the Torch Leads Assembly connected to
the Plasma Power Supply. The gases and command signals are then sent to the Maximizer 300 Liquid Cooled
Torch.
A-00649
Figure 2-1 Arc Starter Box
Designed for easy mounting to the Cutting T able gantry.
F. Weight
12 lb (5.4 kg)
Manual 0-2475 9 INTRODUCTION & DESCRIPTION
G. Dimensions
The following figure illustrates the overall dimensions
of the Arc Starter Box.
A-01385
8.5"
(21.6 cm)
13.5"
(34.3 cm)
6"
(15.2 cm)
Figure 2-2 Arc Starter Box Dimensions
INTRODUCTION & DESCRIPTION 10 Manual 0-2475
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This Section describes installation of the Ar c Starter Box.
These instructions apply to the Arc Starter Box Assembly only; installation procedures for the Plasma Power
Supply, T orch and Torch Leads, Options, and Accessories
are given in Manuals specifically provided for those units.
The complete installation consists of:
1. Site Selection
Two Screws And
External Star Washers
Mounting Bracket
2. Unpacking
3. Mounting Arc Starter Box
4. Connecting Torch and Torch Leads
5. Operator Training
3.02 Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged separately and
protected with a carton and packing material to prevent
damage during shipping.
A. Unpacking Procedure
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.
A-00650
Figure 3-1 Mounting Bracket Screw Removal
2. Slide the mounting bracket out of the two mounting
slots in the chassis of the Ar c Starter Box.
CAUTION
The Arc Starter Box should be mounted as shown
to prevent coolant from dripping into the signal
connector of the quick disconnect when the torch
is disconnected.
3. Mount the bracket to the cutting table gantry using
any of the five holes provided in the mounting bracket.
It is recommended to use at least two mounting points.
NOTE
Refer to Appendix III for Mounting Hole Template.
Mounting Bracket
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 Mounting Arc Starter Box
Mount the Ar c Starter Box to the cutting table gantry per
the following procedure:
1. Remove the two screws securing the mounting bracket
to the Arc Starter Box.
Manual 0-2475 11 INSTALLATION PROCEDURES
A-00651
Four Mounting Bolts And
Washers (Customer Supplied)
Figure 3-2 Mounting Bracket Installation
4. Place the Arc Starter Box slots over the two mounting
tabs on the mounting bracket (see note).
1. Depending on the type of Plasma Cutting System
installed do one of the following:
NOTE
The Arc Starter Box is designed to be mounted to
the mounting bracket in either direction depending on the application..
5. Secure the Arc Starter Box to the mounting bracket
with the two screws removed in Step 1 above.
3.05 Connecting Torch
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
Connect the torch with short leads attached to the mating quick disconnect receptacle, socket type, on the output panel of the Arc Starter Box.
• TD-750 Plasma Cutting System
Connect the Torch Leads Extension quick dis-
connect fitting onto the receptacle marked
TORCH on the front panel of the Power Base
Unit.
• Merlin 3000 Plasma Cutting System
Connect the Torch Leads Extension fittings to
the bulkhead fittings inside the front panel of
the Merlin 3000 Power Supply. Refer to the
Merlin 3000 Operating Manual for more details.
2. Connect the other end of the Torch Leads Extension quick disconnect fitting onto the mating receptacle, pin type, on the input panel of the Arc
Starter Box.
Torch Leads
Extension Connector
Torch Connector
Arc Starter Box
Torch Leads
Figure 3-3 Torch Connection to Arc Starter Box
3.06 Connecting Torch Leads Extension Assembly
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
A-00652
A-00653
Arc Starter Box
Torch Leads Extension
Figure 3-4 Torch Leads Extension Assembly
Connection to Arc Starter Box
INSTALLATION PROCEDURES 12 Manual 0-2475
SECTION 4:
CUSTOMER/OPERATOR
NOTE
Refer to Appendix I for the Interconnecting Diagram of the Arc Starter Box.
SERVICE
4.01 Introduction
This Section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than Thermal
Dynamics Trained personnel.
WARNING
Disconnect primary power at the source before
opening the Arc Starter Box Assembly.
4.02 General Maintenance
The only routine maintenance requir ed for the Ar c Starter
Box is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.
A. Cleaning
To clean the Arc Starter Box, first make sure that the
power is disconnected. Open the Arc Starter Box enclosure and blow out any accumulated dirt and dust
with compressed air. The unit should also be wiped
clean. If necessary, solvents that are recommended
for cleaning electrical apparatus may be used.
While the enclosure is open, inspect the wiring in the
unit. Look for any frayed wires or loose connections
that should be corrected.
B. How to use this Guide
The following information is a guide to help the Customer/Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text T ype)
Locate your symptom for the type cutting system, check
the causes (easiest listed first) then remedies. Repair as
needed being sure to verify that unit is fully operational
after any repairs.
A. TD-750 Cutting System - Start signal given to
Control Module. Gas flows for selected pre-flow
time then top Power Module DC LED and Control
Module PILOT LED flash momentarily. Control
Module DC LED is OFF, does not even come ON
momentarily.
1. Defective Pilot PCB or Power Module
In the Control Module check across W39 and W42
at the Pilot PCB. There should be a diode drop
across W39 to W42 in one direction and an open
in the other.
If shorted remove the wires at W39 and W42 at
the Pilot PCB and check again.
a. Replace Pilot PCB if shorted from W39 to W42
(with wires #39 and #42 removed).
B. Checking Quick Disconnect Fittings
The fitting of the quick disconnect connectors can become worn and cause improper cutting. Check the
fittings for any build up of material, worn o-rings,
damaged canted coil springs, etc. Replace any damaged or worn parts as required.
4.03 Troubleshooting Guide
A. Troubleshooting
This Sub-Section covers troubleshooting that requires
disassembly and electronic measurements. It is helpful
for solving many of the common problems that can arise
with this torch assembly.
Manual 0-2475 13 SER VICE
b. Defective Power Module. Refer to the Control/
Power Components Operating Manual 0-2473
to test the output of the Power Module(s).
2. Defective Pilot PCB or Torch Components
In the Control Module check across W39A and
W48 at the Pilot PCB. There should be a diode
drop across W39A to W48 in one dir ection and an
open in the other.
If shorted disconnect the Umbilical Cable from the
front of the Control Module. and check again.
a. Replace Pilot PCB if shorted from W39A to W48
(with Umbilical Cable removed).
b. Defective Torch Components (Torch, Torch
Leads, T orch Leads Extension Assembly or Arc
Starter Box) proceed to possible cause #3 to isolate possible defective component.
3. Defective Torch, Torch Leads, Torch Leads Extension
Assembly or Arc Starter Box
Reconnect the Umbilical Cable to the front of the
Control Module. In the Control Module check
across W39A and W48 at the Pilot PCB. There
should be a diode drop across W39A to W48 in
one direction and an open in the other.
If shorted remove the Torch Leads from the output of Arc Starter Box and check again.
a. If no longer shorted Torch or Torch Leads are
defective. Refer to Torch Instruction Manual
0-2476.
b. If short remains disconnect T o rch Leads Exten-
sion Assembly from input of Arc Starter Box
and check again.
c. If no longer shorted Arc Starter Box Assembly
is defective. Proceed to possible cause #4 to
isolate problem in Arc Starter Box.
d. If short remains disconnect Torch Leads Exten-
sion Assembly from front of the Power Base
Unit and check again.
e. If short remains the Torch Leads Extension As-
sembly, Umbilical Cable, or torch quick disconnects in the Power Base Unit are shorted.
4. Defective Arc Starter Box
Inside the Arc Starter Box remove the wire from
either E1 or E2 on Arc Starter PC Boar d. Make an
ohms check across E1 to E2.
a. If shorted, replace defective Arc Starter PC
Board.
b. If not shorted the problem is in the input or
output quick disconnects on the Arc Starter Box.
Repair as needed.
B. TD-750 Cutting System - Start signal given to
Control Module. Gas flows for selected pre-flow
time then top Power Module DC LED and Control
Module DC and PILOT LEDs are ON steady. No
spark at spark gap in Arc Starter Box.
1. Bad Connection in Arc Starter Box
a. Connection at J1 on the Ar c Starter PC Boar d is
bad. Check connection by removing and reinstalling the plug.
2. Arc Starter PC Board, Power Base Unit, To rch, Torch
Leads, or Torch Leads Extension Assembly defective
a. Refer to Section 4.04 Test Procedures to isolate
the defective assembly.
C. TD-750 Cutting System - Start signal given to
Control Module. Gas flows for selected pre-flow
time then Control Module Pilot and DC LEDs are
ON steady. Pilot doesn't come ON but there is a
spark (repetitive snapping sound) from the spark
gap in Arc Starter Box.
For the spark gap to fire, the Power Supply DC output has to be getting to the Arc Starter Box.
1. Consumable Torch parts are shorted
a. Check or replace the consumable Torch parts
2. Arcing or burning inside Torch Head Assembly
a. Remove the consumables from the Torch Head
Assembly and check for signs of arcing or burning inside the torch head. Replace Torch Head
Assembly if required.
3. Arcing or burning between the To rch fittings or from
the fittings to the Mounting Tube
a. Remove the Torch Head Assembly from the
mounting tube and check for arcing or burning
between the fittings or from the fittings to the
tube. Repair as required.
4. Defective CD transformer
a. Check for arcing around the CD Transformer
(while spark gap is firing) and look for any
cracks in the ferrite cores. If either problem
exists replace the CD Transformer .
5. Defective canted coil springs
a. Check for burnt or missing canted coil springs
inside the quick disconnect sockets.
6. Arcing between quick disconnect fittings
a. Remove the Torch Quick Disconnect Boot and
check for arcing between the quick disconnect
fittings. Repair as required.
D. Merlin 3000 Cutting System - Start signal given to
the Power Supply. Gas flows for selected preflow time then Pilot LED flashes momentarily.
DC LED is OFF, does not even come ON momentarily.
1. Problem not in the Arc Starter Box. The Power Supply
is has no DC voltage output.
a. Refer to the Power Supply Service Manual
0-2569 to test the output of the Power Supply
SERVICE 14 Manual 0-2475
E. Merlin 3000 Cutting System - Start signal given to
Power Supply. Gas flows for selected pre-flow
time then Pilot and DC LEDs are ON steady. Pilot
doesn't come ON but there is a spark (repetitive
snapping sound) from the spark gap in Arc Starter
Box.
For the spark gap to fire, the Power Supply DC output has to be getting to the Arc Starter Box.
1. Consumable Torch parts are shorted
a. Check or replace the consumable Torch parts
2. Arcing or burning inside Torch Head Assembly
a. Remove the consumables from the Torch Head
Assembly and check for signs of arcing or burning inside the torch head. Replace Torch Head
Assembly if required.
4.04 Test Procedures
This sub-section is divided into two paragraphs as follows:
A. Fault Isolation for TD-750 Cutting Systems
B. Fault Isolation for Merlin 3000 Cutting Systems
Depending on the type system installed refer to the appropriate paragraph.
A. Fault Isolation for TD-750 Cutting Systems
WARNING
High voltage may be present in the Arc Starter
Box
3. Arcing or burning between the To rch fittings or from
the fittings to the Mounting Tube
a. Remove the Torch Head Assembly from the
mounting tube and check for arcing or burning
between the fittings or from the fittings to the
tube. Repair as required.
4. Defective CD transformer
a. Check for arcing around the CD Transformer
(while spark gap is firing) and look for any
cracks in the ferrite cores. If either problem
exists replace the CD Transformer .
5. Defective canted coil springs (Merlin 3000 Only)
a. Check for burnt or missing canted coil springs
inside the quick disconnect sockets.
6. Arcing between quick disconnect fittings (Merlin 3000
Only)
a. Remove the Torch Quick Disconnect Boot and
check for arcing between the quick disconnect
fittings. Repair as required.
F. TD-750 and Merlin 3000 Cutting Systems - Start
signal given to Power Supply. Gas flows for
selected pre-flow time then Pilot and DC LEDs
are ON steady. Pilot doesn't come ON and there is
no spark (no repetitive snapping sound) from the
spark gap in Arc Starter Box.
The following procedure is to isolate the faulty assembly
to the Ar c Starter PC Board, Power Base Unit, T or ch, T orch
Leads, or Torch Leads Extension Assembly
1. To remove the voltage remove start signal from Control Module.
2. Place RUN/PURGE/SET in SET or PURGE position.
3. Control Module DC and PILOT LEDs are OFF.
4. Remove cover from Arc Starter Box.
5. On the Arc Starter PC Board measure for 24vac between J1-1 and J1-3. Later versions of the Arc Starter
PC Board have an LED indicator that is ON when the
24 vac is present.
• If 24 VAC is present, proceed to Step 15.
• If 24 VAC is not present, proceed to Step 6
NOTE
Connector J1 must be connected to the Arc Starter
PC Board.
6. Remove connector J1 from the Arc Starter PC Board
and reconnect making a good connection.
7. On the Arc Starter PC Board measure for 24vac between J1-1 and J1-3.
• If present proceed to Step 15.
1. Defective Arc Starter PC Board, blown fuse, or faulty
connections in the 24 VAC circuit.
a. Refer to Section 4.04 Test Procedures to isolate
the defective assembly.
Manual 0-2475 15 SER VICE
• If not present proceed to Step 8
8. Remove connector J1 from the Arc Starter PC Board.
9. Measure for 24vac between J1-1 and J1-3 on the connector.
• If 24vac is at the connector, Arc Starter PC Board is
defective.
• If 24vac is not present at J1 proceed to Step 10.
Note
10. Place the RUN/SET/PURGE switch on the Control
Module to the RUN position.
11. Place the main power circuit breaker on front panel
of the Power Base Unit to OFF.
12. Remove the Torch Leads Extension Assembly from
the quick disconnect at the front panel of the Power
Base Unit.
13. Turn the main power circuit breaker on the front of
the Power Base Unit to ON.
14. Check for 24vac between pins 5 and 8 of the quick
disconnect signal connector .
• If not present, problem is in the Power Base Unit.
• If present, check for open in Torch Leads Extension
Assembly signal wires.
Signal Connector
A-00809
4
5
9
14
12
3
678
10111213
A dirty or incorrect gap in spark gap could cause
the same problem. Gap should be 0.015 +/- 0.001"
and is not adjustable.
• If voltage is less than 220vdc proceed to Step 18.
18. In the Control Module measure the voltage between
W39 and W48 on the Pilot PC Board.
• If greater than 220vdc check for open connections
through the Umbilical Cable, Power Base Unit 2
and 4 pin disconnects, Torch Leads Extension Assembly, and Arc Starter Box input and output disconnects.
• If less than 220vdc refer to the Control/Power Mod-
ule Operating Manual 0-2473, Section 5.03 T roubleshooting, for low output volts.
B. Fault Isolation for Merlin 3000 Cutting
Systems
WARNING
High voltage may be present in the Arc Starter
Box.
Torch (+)
Coolant Return
Secondary
Gas
Torch (-)
Figure 4-1 Signal Connector Pin Location
15. If 24vac was present at J1 from test in Step 5 or 9
place RUN/SET/PURGE to RUN position.
16. Press start after pre-flow and go through start sequence. PILOT and DC LEDs are ON.
WARNING
High voltage (300-400vdc) is present in Arc Starter
Box.
17. Measure between E1 (+) and E2 (-) on the Arc Starter
PC Board
• If voltage more than 220 vdc is present Arc Starter
PC Board is defective.
The following two things are needed for the spark gap to
fire in the Arc Starter Box:
• 24 VAC bias voltage
The 24 VAC should be present anytime the Power
Supply is turned ON. Refer to Appendix II, 24
VAC Wiring Block Diagram.
• Greater than 220 VDC Power Supply output
The Power Supply DC output should be grearter
than 220 VDC when the Power Supply is activated
and the DC and PILOT LED's are ON. The voltage will be present across the torch tip (+) and electrode (-).
The following procedure is to isolate the faulty assembly
to the Arc Starter PC Board, Power Supply, Torch, Torch
Leads, or Torch Leads Extension Assembly
1. T o r emove the voltage remove start signal from Power
Supply.
2. Place RUN/PURGE/SET in SET or PURGE position.
3. Power Supply DC and PILOT LEDs are OFF.
4. Remove cover from Arc Starter Box.
5. On the Arc Starter PC Board locate the red LED indicator . When the indicator is ON the 24 VAC between
J1-1 and J1-3 is present to the Arc Starter PC Board.
SERVICE 16 Manual 0-2475
NOTE
Connector J1 must be connected to the Arc Starter
PC Board.
• If red LED is ON proceed to Step 15.
• If red LED is OFF proceed to Step 6
6. Remove connector J1 from the Arc Starter PC Board
and reconnect making a good connection.
7. On the Arc Starter PC Boar d check the red LED indicator.
• If red LED is ON proceed to Step 15.
• If red LED is OFF proceed to Step 8
8. Remove connector J1 from the Arc Starter PC Board.
9. Measure for 24 VAC between J1-1 and J1-3 on the connector.
• If 24 VAC is at the connector, Arc Starter PC Board
is defective.
• If 24 VAC is not present at J1 proceed to Step 10.
10. Place the RUN/SET/PURGE switch on the Power
Supply to the RUN position.
11. Place the main power switch on front panel of the
Power Supply to OFF.
12. Remove the Torch Leads Extension Assembly from
the bulkhead connection at the front panel of the
Power Supply.
13. T urn the main power switch on the front of the Power
Supply to ON.
14. Check for 24 VAC between pins 5 and 8 of the Torch
Control connector (J14) at the Power Supply bulkhead.
NOTE
Refer to the Power Supply Operating and Service
manuals for more details.
• If not present, problem is in the Power Supply.
Check the 24 VAC circuit Fuse F3 (1A, 250V) located on a panel above the Main Transformer on
the right side of the Power Supply (facing the front
of unit). Check the fuse and replace as necessary.
If the Fuse (F3) blows again on power up or when
you try to start the pilot, Arc Starter PC Board is
defective.
If Fuse (F3) blows once cutting starts there may
be a short in the OK-To-Move circuit. The same
24 V AC is used for OK-To-Move if selected by SW5
on the Power Supply Logic PC Board. Refer to
the Power Supply Operating Manual for OK-ToMove options.
Note
If the Remote Control RC6010 is used the 24 VAC
OK-To-Move should not be selected at SW5 in the
Remote Control.
• If present, check for open in Torch Leads Extension
Assembly signal wires.
Signal Connector
A-00809
12
3
678
10111213
Secondary
Gas
Torch (-)
Torch (+)
Coolant Return
4
5
9
14
Figure 4-1 Signal Connector Pin Location
15. If the Arc Starter PC Boar d 24 VAC red LED was ON
from the test in Step 5 or 9, place RUN/SET/PURGE
to RUN position.
16. Press start after pre-flow and go through start sequence. PILOT and DC LEDs are ON. When the
Power Supply is activated and the DC and PILOT
LED's are ON, there should be greater than 220 VDC
between the torch tip (+) and electrode (-).
WARNING
High voltage (300-400vdc) is present in Arc Starter
Box.
17. Measure between E1(+) and E2 (-) on the Arc Starter
PC Board.
• If voltage more than 220 VDC is present Arc Starter
PC Board is defective.
NOTE
A dirty or incorrect gap in spark gap could cause
the same problem. Gap should be 0.015 +/- 0.001"
and is not adjustable.
Manual 0-2475 17 SER VICE
• If voltage is less than 220 VDC proceed to Step 18.
18. In the Power Supply measure the voltage at the torch
bulkhead in the Power Supply (marked + and -).
• If greater than 220 VDC check for open connections
through the Power Supply connections, Torch
Leads Extension Assembly, and Arc Starter Box
input and output connections.
• If less than 220 VDC can be caused by a shorted
torch or torch leads.
• No voltage can be caused by the Pilot Control (PCR)
contactor in the Power Supply not closing. Refer
to the Power Supply Service Manual under symptoms of No Pilot.
SERVICE 18 Manual 0-2475
SECTION 5:
PARTS LISTS
5.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. The Arc Starter Box Assembly is field serviceable, so a complete breakdown of parts is provided.
The parts lists are arranged as follows:
Section 5.03: Replacement Parts - Box
Section 5.04: Replacement Parts - Input/Output
Connectors
Section 5.05: Replacement Parts -Pilot Gas Control
NOTE
Parts listed without item numbers are not illustrated, 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. Materials returned to Thermal Dynamics without proper authorization will not be accepted.
5.02 Ordering Information
Order replacement parts by catalog number and complete
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 torch. Address all inquiries to
your authorized Thermal Dynamics distributor .
Manual 0-2475 19 PARTS LISTS
5.03 Replacement Parts - Box
Item # Qty Description Catalog #
1 Assembly, Arc Starter Box Includes: 3-6103
1 1 Cover 8-3475
2 1 Assembly, CD Transformer, Torch Box 8-3478
3 Base (Refer To Sections 5.04 And 5.05 For Parts)
4 1 Assembly, Arc Starter PCB 8-3477
5 1 Assembly, RF Filter PCB 8-3476
6 1 Mounting Plate 8-3479
PARTS LISTS 20 Manual 0-2475
5
4
6
3
1
2
A-00655
Manual 0-2475 21 PARTS LISTS
5.04 Replacement Parts - Input/Output Connectors
Item # Qty Description Catalog #
1 4 Bumper , Locking Tab, Signal Connector 9-6240
2 4 Retaining Ring, Ext., SS, 9/16 Shaft x 0.035 Thk 9-4488
3 1 Assembly, Quick Disconnect Body, Console, 4 Pin (Socket T ype) 9-5917
4 1 Assembly, Quick Disconnect Body, T or ch Lead, 4 Pin (Pin Type) 8-4432
5 2 Washer, Plastic, 4.5 OD x 2.812 ID x 0.063 Thk 9-4489
6 2 Ring, Retaining, 2.938 Dia 9-4490
7 2 Buss Bar , Pilot, Torch Box 9-4542
8 1 Buss Bar , Main, Torch Box 9-4491
9 1 Assembly, Wire Harness, Arc Starter Box (includes all wiring in box) 9-4543
10 Base (Refer To Section 5.05 For Pilot Gas Control Parts)
11 1 Hose Assembly, #4, Plasma Input 9-4544
12 1 Hose Assembly, #4, Coolant Supply 9-4545
13 1 Hose Assembly, #4, Plasma Output 9-4546
14 1 Hose Assembly, #4, Secondary 9-4547
15 1 Hose Assembly, #4, Coolant Return 9-4588
16 4 Spring, Canted Coil 9-4492
17 1 Fitting, Q.D., Male To 9/16-18 And #4 JIC 9-4493
18 1 Fitting, Quick Disconnect, Tor ch, Male/O2B 9-4518
19 1 Fitting, Quick Disconnect, Torch, Male/Inert B L.H. 8-4434
20 1 Fitting, Quick Disconnect, Torch, Male/Fuel B 9-4519
21 4 O-Ring 8-0526
22 1 Nut, 9/16-18 w/ 3/4 Flats 9-4494
23 1 Nut, Jam, 9/16-18 L.H., 11/16 Hex 9-4520
23 4 Retaining Ring, Ext., SS, 1/2" Shaft x 0.035 Thk 9-4424
PARTS LISTS 22 Manual 0-2475
5
9
6
7
14
13
7
19
15
16
11
18
23
20
21
12
6
5
1
22
2
3
8
17
4
10
23
1
A-00656
Manual 0-2475 23 PARTS LISTS
5.05 Replacement Parts - Pilot Gas Control
Item # Qty Description Catalog #
1 1 Base, Arc Starter Box 9-4548
2 1 Assembly, Solenoid, 3-W ay, Plasma 9-4549
3 1 Adapter , Inert B/ 1/4 NPT Female w/Ring Groove 9-6232
4 1 Adapter , Rear Panel Fitting 9-6247
5 1 Retaining Ring, .750 Dia. Shaft 9-6233
6 1 Hex Nipple, 1/4 NPT - 1/8 NPT 9-1047
7 1 1/8 NPT Female Tee 8-0312
8 1 Fitting, 1/8 NPT x 1/4 Tube Str 8-3360
9 1 Pressure Switch-35 PSI 9-1044
10 4 PC Board Support 9-5333
11 1 Anti-Rotation Ba r, Torch Box 9-4550
8
7
6
5
4
9
10
11
1
3
A-00657
2
PARTS LISTS 24 Manual 0-2475
APPENDIX I: INTERCONNECTING DIAGRAM
Torch (+)
Coolant
Return
4
5
9
14
13
1
2
3
8
6
7
12
10
11
Input Connector (Front View)
J2
Secondary Gas
Torch (-)
J3
1
2
4
5
3
6789
10 111213 14
Output Connector (Front View)
Torch (+)
Coolant
Return
Part of Input
Quick Disconnect
From Power Supply
Part of Output
Quick Disconnect
T o Torch
A-00658
Manual 0-2475 25 APPENDIX
APPENDIX II: 24 VAC WIRING BLOCK DIAGRAM FOR
MERLIN 3000 POWER SUPPLY
Merlin 3000 Power Supply
F3
(1A, 250V)
24 V AC
(108)
(109)
Torch Control
Connector
J14-5
J14-8
Torch Leads
Extension
Quick Disconnect
J2-5
J2-8
(14)
(15)
Arc Starter Box
Arc Starter PC Board
J1-1
J1-3
24 V AC Present
(Red LED On)
A-01254
APPENDIX 26 Manual 0-2475
5.545
REF.
APPENDIX III: MOUNTING HOLE TEMPLATE
BEND LINE
D 0.375
TYP. 4 PLCS.
3.760
0.938
0.688
4.305
A-01384
5.680
REF.
Manual 0-2475 27 APPENDIX
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