Page 1
ARC STARTER
BOX
Used With Merlin 6000 Cutting System
A-01435
Instruction Manual
March 13, 2002
Manual No. 0-2572
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Page 3
W ARNINGS
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 the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Thermal Dynamics Arc Starter Box
Instruction Manual No. 0-2572
Published by:
Thermal Dynamics Corporation
82 Benning Street
W est Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 1997 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 liability to
any party for any loss or damage caused by any error or omission in this
Manual, whether such error results from negligence, accident, or any
other cause.
Printed in the United States of America
Publication Date: March 13, 2002
Record the following information for W arranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
T or ch Serial #: _______________________________________
Page 4
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 Avertissement................................................................... 3
1.05 Precautions De Securite Importantes ........................................................... 3
1.06 Documents De Reference............................................................................. 5
1.07 Declaration of Conformity.............................................................................. 7
1.08 Statement of Warranty .................................................................................. 8
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 Supply Leads.................................................................. 13
3.07 Dual Power Supply - Connecting To Slave Unit........................................... 15
SECTION 4:
CUSTOMER/OPERATOR SERVICE ................................................................................. 17
4.01 Introduction ................................................................................................. 17
4.02 General Maintenance .................................................................................. 17
4.03 Troubleshooting Guide................................................................................. 17
4.04 Test Procedures .......................................................................................... 18
SECTION 5:
PARTS LISTS .................................................................................................................... 21
5.01 Introduction ................................................................................................. 21
5.02 Ordering Information ................................................................................... 21
5.03 Replacement Parts - Box ............................................................................ 22
5.04 Replacement Parts - Bulkhead Side ........................................................... 24
5.05 Replacement Parts - Signal Side ................................................................ 26
APPENDIX I: INTERCONNECTING DIAGRAM ....................................................................... 29
APPENDIX II: 24VAC WIRING BLOCK DIAGRAM................................................................... 30
MOUNTING HOLE TEMPLATE ................................................................................................. 31
Page 5
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.
WARNING
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
HEAL TH.
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.
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.
• 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: No v ember 15, 2001 1 GENERAL INFORMATION
Page 6
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to 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 where
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 hydrogen 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 protect your hearing from loud noise, wear pr otective 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 RA YS
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 HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
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, Washington, 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
GENERAL INFORMATION 2 Date: Nov ember 15, 2001
Page 7
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 Standar d 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. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFP A 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 W1 17.2, 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 PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédur e pouvant r ésulter
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.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA TOR Y
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 :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: No v ember 15, 2001 3 GENERAL INFORMATION
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
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
Page 8
• 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.
• 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.
• 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.
• 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
• 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. (V oir 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.
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 PAS
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.
Les chocs électriques peuvent blesser ou même tuer. Le
RAYONS D’ARC DE PLASMA
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.
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
GENERAL INFORMATION 4 Date: Nov ember 15, 2001
Page 9
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 oculair e.
• 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 démontr er que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
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 TRA VAIL 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 Superintendent 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 TRAV AIL 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
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. V ous dú4ez vous pr otéger 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.
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
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT 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 (NFPA), 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, Batterymar ch Park,
Quincy, MA 02269
Date: No v ember 15, 2001 5 GENERAL INFORMATION
Page 10
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 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.Livret 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
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDA TIONS DE PRA TIQUES
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: Nov ember 15, 2001
Page 11
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
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 standards and technical r equirements. 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.
* 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 manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: No v ember 15, 2001 7 GENERAL INFORMATION
Page 12
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 practice,
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
PAR 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 Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Y ear 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Year 1 Y ear
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMATION 8 Date: Nov ember 15, 2001
Page 13
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.01 Scope of Manual
NOTE
The information in this Manual covers different
revision levels of the product. As equipment improvements and updates are made the actual units
may differ from the illustrations shown in this
Manual.
A-01435
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 orch, with short leads attached, connects to the output of the Plasma Power Supply . The Torch Supply Leads
Assembly connects to the input of the Plasma Power Supply .
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.
The Arc Starter Box is designed for use with Merlin 6000
Single (Master) or Dual (Slave) Plasma Power Supplies.
Figure 2-1 Arc Starter Box
2.03 Specifications & Design Features
The following applies to the Arc Starter Box only:
A. System Configuration
Used with the Merlin 6000 Plasma Cutting System
and Maximizer 300 Machine Torch only.
B. Pilot) Circuitry
CD, Constant DC
C. Input Connection
Provides connection for the Torch Supply 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
Designed for easy mounting to the Cutting T able gantry .
F. Weight
12 lb (5.4 kg)
Manual 0-2572 9 INTRODUCTION & DESCRIPTION
Page 14
INTRODUCTION & DESCRIPTION 10 Manual 0-2572
Page 15
SECTION 3:
INSTALLATION
PROCEDURES
1. Remove the four screws securing the cover to the
base assembly of the Arc Starter Box.
3.01 Introduction
This Section describes installation of the Arc Starter Box.
These instructions apply to the Arc Starter Box Assembly only; installation procedures for the Plasma Power
Supply, Torch and Torch Leads, Options, and Accessories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site Selection
2. Unpacking
3. Mounting Arc Starter Box
4. Connecting Torch and Supply 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.
A-01436
Screws
(Four Places)
Figure 3-1 Cover Screw Removal
2. Slide the cover up and off the base assembly.
Cover
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.
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 Arc Starter Box to the cutting table gantry
per the following procedure:
Base Assembly
A-01969
Figure 3-2 Cover Removal
3. Mount the base assembly of the Arc Starter Box to the
cutting table gantry using the four holes provided in
the base.
NOTE
The last page of this Manual has a full size hole
template for use in locating the mounting holes.
Manual 0-2572 11 INSTALLATION PR OCEDURES
Page 16
To Plasma
Power Supply
Base
Assembly
A-01970
Four Mounting Bolts And
Washers (Customer Supplied)
Figure 3-3 Mounting Bolt Installation
3.05 Connecting To rch
W ARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
5. Feed the torch leads through the supplied Hose
Clamp.
6. Connect the torch leads connectors to the bulk-
head connections per the following figure.
NOTE
The Revision Letter is the last digit of the Serial
Number on the Data Tag.
Coolant Return
(Left-Hand Thread)
Secondary Gas
T o Torch
Plasma Gas
(Left-Hand Thread)
Coolant Supply
A-01440
Torch Leads
Units Before Revision Letter 'C'
The Torch Leads connect directly to a bulkhead inside
the Arc Starter Box. Connect the Torch Leads per the
following procedure:
1. Remove the cover from the Arc Starter Box if installed.
2. Remove the tape securing the shield of the torch
leads to the leads.
3. Unfold the shield towards the end of the leads.
4. Feed the torch leads through the boot on the torch
end of the Arc Starter Box.
Torch Leads
Hose Clamp
Torch Leads
Shield Assembly
(Brass Hub)
Shield Braid
Plasma Gas
(Left-Hand Thread)
A-01972
Coolant Supply
Coolant Return
(Left-Hand Thread)
Secondary Gas
Torch Leads
Units With Revision Letter 'C' or Later
Figure 3-5 Torch Leads Connections
7. Pull the shielding braid towards the end panel as
far as it will go up and over the brass hub. The
hub is part of the Boot Assembly and provides
the grounding point for the shielding in the torch
leads.
A-01971
Figure 3-4 Hose Clamp
INSTALLATION PROCEDURES 12 Manual 0-2572
Page 17
NOTE
The shielding braid must not make contact with
the four mounting studs.
3.06 Connecting To rch Suppl y Leads
W ARNING
Torch Leads
Shield Assembly
(Brass Hub)
Mounting
Stud
Shield Braid
A-01777
Torch Leads
Figure 3-6 Shield Braid Installation
8. Place the hose clamp over the shield and hub.
Tighten the hose clamp to secure the shielding
braid to the hub.
NOTE
Disconnect primary power at the source before disassembling the torch or torch leads.
Connect one end of the Torch Supply Leads to the internal bulkhead inside the Arc Starter Box per the following:
1. Remove the cover from the Arc Starter Box if installed.
2. Feed the four hose assemblies on the Torch Supply Leads through the boot on the lead end of the
Arc Starter Box. The lead end of the Arc Starter
Box has a boot and control connector installed.
3. Connect the control cable connector to the mating
connector on the end of the Arc Starter Box.
4. Connect the four hose assemblies to the internal
bulkhead per the following figure.
Secondary Gas
(Left-Hand Thread)
Coolant Return
(Left-Hand Thread)
Make sure that the shielding braid is pulled back
as far as possible from the bulkhead connections.
Leave any extra shielding braid between the hose
clamp and the end panel area.
Hose Clamp
Shield Braid
Under Clamp
A-01778
Torch Leads
Control
Cable
Plasma Gas
A-01444
Coolant Supply
Units Before Revision Letter 'C'
Secondary Gas
(Left-Hand Thread)
Plasma Gas
Control
Cable
Coolant Supply
Coolant Return
(Left-Hand Thread)
Units With Revision Letter 'C' or Later
A-01973
Figure 3-7 Hose Clamp Installation
Figure 3-8 Torch Supply Leads Connections
Manual 0-2572 13 INSTALLATION PR OCEDURES
Page 18
5. Connect the other end of the Torch Supply Leads
fittings onto the mating connections at the input
panel of the Master Plasma Power Supply.
Master Power Supply
Control Cable
Secondary
Gas Lead
Bulkhead
Plasma
Gas Lead
Coolant Return
Lead
Coolant Supply
Lead
7. Feed the pilot lead through the boot and connect
to the pilot connection per the following procedure:
a. Remove the nut and external star washer from
the pilot connection bolt.
b. Place the ring lug on the pilot wire over the
end of the bolt.
c. Re-install the external star washer and nut to
secure the lead.
Torch Supply Leads
Supply Leads Boot
A-01447
Figure 3-9 Torch Supply Leads Connection To
Master Power Supply
6. Feed the power lead through the boot and connect to the buss bar per the following procedure:
a. Remove the nut and washer from the lower
bolt.
b. Remove the bolt and washer from the lower
hole of the buss bar.
c. Place the ring lug on the power lead over the
end of the bolt.
d. Re-install the bolt and washer with the lug
into the lower hole of the buss bar.
e. Re-install the nut and washer to secure the
lead.
NOTE
Installing the power lead on the lower bolt will
make it easier to install the second power lead if a
dual system is to be used.
A-01975
Star
Washer
Nut
Pilot Lead
Pilot Lead
Connection
Figure 3-11 Pilot Lead Connection
8. Connect the other end of the Pilot Lead, two wires,
to the Master Power Supply per the following procedure:
a. Remove the right side panel from the Master
Power Supply.
Buss Bar
b. Feed the Pilot Lead, two wires, through the
small strain relief at the front panel of the Mas-
Nut
ter Power Supply.
c. Remove the nut and star washer on the ground
terminal of the pilot connection inside the
power supply.
Washer
Bolt
A-01974
Washer
Power Lead
Figure 3-10 Power Lead Connection
INSTALLATION PROCEDURES 14 Manual 0-2572
Page 19
Nut
Small Strain
Relief
Star Washer
Ground T erminal
Pilot T erminal
c. Secure the power lead to the connection with
the nut removed above.
3.07 Dual Po wer Suppl y Connecting To Sla ve Unit
For systems that are using the dual power supplies, Master and Slave, additional connections must be made inside the Arc Starter Box.
1. Remove the cover from the Arc Starter Box.
2. Feed the Slave Power Supply pilot lead through
the boot at the end of the Arc Starter Box.
Black Wire
of Pilot Lead
Red Wire
of Pilot Lead
A-01495
Figure 3-12 Pilot Lead Connection at Power Supply
d. Secure the shield lead (black) to the ground
connection with the nut and star washer removed above.
e. Remove the nut and star washer from the other
pilot connection inside the power supply.
f. Secure the pilot lead (red) to the pilot connec-
tion with the nut and star washer removed
above.
9. Connect the other end of the Power Lead to the
Master Power Supply per the following procedure:
a. Feed the Power Lead through the large strain
relief at the front panel of the Master Power
Supply.
b. Remove the nut from the power connection
terminal inside the power supply.
Power Lead
Terminal Bolt
3. Connect the pilot lead to the pilot connection per
the following procedure:
a. Remove the nut and external star washer from
the pilot connection bolt.
b. Place the ring lug on the pilot wire over the
end of the bolt.
c. Re-install the external star washer and nut to
secure the lead.
A-01976
Star
Washer
Nut
Pilot Lead
Connection
Slave Pilot Lead
Figure 3-14 Pilot Lead Connection - Slave
Large
Strain Relief
Power Lead
4. Feed the Slave Power Supply power lead through
the boot at the end of the Arc Starter Box.
Nut
A-01496
Figure 3-13 Power Lead Connection at Master
Power Supply
Manual 0-2572 15 INSTALLATION PR OCEDURES
Page 20
5. Connect the power lead to the buss bar per the
following procedure:
a. Remove the nut and washer from the upper
bolt.
b. Remove the bolt and washer from the upper
hole of the buss bar.
c. Place the ring lug on the power lead over the
end of the bolt.
d. Re-install the bolt and washer with the lug
into the upper hole of the buss bar.
e. Re-install the nut and washer to secure the
lead.
Buss Bar
Nut
Washer
Bolt
A-01977
Washer
Power Lead
Star Washer
Nut
Small Strain
Relief
Black Wire
of Pilot Lead
Ground T erminal
Red Wire
of Pilot Lead
Pilot T erminal
A-01536
Figure 3-16 Pilot Lead Connection at Slave Power
Supply
9. Connect the other end of the Power Lead to the
Slave Power Supply per the following procedure:
a. Feed the Power Lead through the large strain
relief at the front panel of the Slave Power Supply .
b. Remove the nut from the power connection
terminal inside the power supply.
Figure 3-15 Power Lead Connection - Slave
6. Connect the other end of the Pilot Lead, two wires,
to the Slave Power Supply per the following procedure:
a. Remove the right side panel from the Slave
Power Supply.
b. Feed the Pilot Lead, two wires, through the
small strain relief at the front panel of the Slave
Power Supply.
c. Remove the nut and star washer on the ground
terminal of the pilot connection inside the
power supply.
d. Secure the shield lead (black) to the ground
connection with the nut and star washer removed above.
e. Remove the nut and star washer from the other
pilot connection inside the power supply.
f. Secure the pilot lead (red) to the pilot connec-
tion with the nut and star washer removed
above.
c. Secure the power lead to the connection with
the nut removed above.
Power Lead
Terminal Bolt
Large
Strain Relief
A-01496
Power Lead
Nut
Figure 3-17 Power Lead Connection at Slave Power
Supply
INSTALLATION PROCEDURES 16 Manual 0-2572
Page 21
SECTION 4:
CUSTOMER/OPERATOR
SERVICE
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
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 required for the Arc Starter
Box is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.
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.
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed
first) then remedies. Repair as needed being sure to
verify that unit is fully operational after any repairs.
A. Start signal given to the Power Supply. Gas
flows for selected pre-flow 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 to
test the output of the Power Supply
B. 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 To rch 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.
4.03 T roubleshooting 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.
NOTE
Refer to Appendix I for the Interconnecting Diagram of 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.
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.
Manual 0-2572 17 SERVICE
Page 22
C. 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.
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.
4.04 Test Procedures
A. Fault Isolation
WARNING
High voltage may be present in the Arc Starter
Box.
The following two things are needed for the spark gap
to fire in the Arc Starter Box:
• 24 VAC bias voltage
The 24 V AC 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 200 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 (-).
• 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 Board 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, Ar c Starter PC Boar d
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 Arc Starter Box Control Cable from the
bulkhead connection, J14, 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.
The following procedure is to isolate the faulty assembly to the Arc Starter PC Board, Power Supply, Torch,
Torch Leads, or Torch Supply Leads Assembly
1. Remove the START signal from the power Supply to
disable the DC high voltage from the Ar c Starter Box.
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.
NOTE
Connector J1 must be connected to the Arc Starter
PC Board.
• If red LED is ON proceed to Step 15.
SERVICE 18 Manual 0-2572
• 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 VAC 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-To-Move 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.
Page 23
• If present, check for open in Torch Supply Leads
Assembly signal wires.
15. If the Arc Starter PC Board 24 VAC red LED was
ON from the test in Step 5 or 9, place RUN/SET/
PURGE to RUN position.
16. Press start and go through a start sequence. After
pre-flow the 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 Ar c Starter
PC Board.
WARNING
DO NOT accidently measure P1 and P2, studs
and brass nuts, where the CD Transformer (T1)
connects to 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.
• If voltage is less than 220 VDC, proceed to Step 18.
18. In the Power Supply measure the DC voltage between the negative power lead and the red pilot lead.
• If greater than 220 VDC, check for open connec-
tions through the Power Supply connections,
Torch Supply Leads 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.
Manual 0-2572 19 SERVICE
Page 24
SERVICE 20 Manual 0-2572
Page 25
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 - Base Assembly
Bulkhead Side
Section 5.05: Replacement Parts -Base Assembly
Signal Side
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 unit. Address all inquiries to your authorized Thermal Dynamics distributor.
Manual 0-2572 21 PARTS LISTS
Page 26
5.03 Replacement Parts - Box
Item # Qty Description Cat #
1 COMPLETE ARC STARTER BOX ASSEMBLY 3-6820
1 BASE ASSEMBLY
BULKHEAD SIDE - REFER TO SECTION 5.04 FOR PA RTS LIST
SIGNAL SIDE - REFER TO SECTION 5.05 FOR PARTS LIST
2 1 COVER, ARC STARTER BOX 9-6821
3 4 #10-32 X 3/8" PPH, SQ CONE WASHER See Note
NOTE: Item can be purchased locally.
PARTS LISTS 22 Manual 0-2572
Page 27
Units Before Revision Letter 'C'
1
3
2
3
Units Revision Letter 'C' or Later
A-01450
3
2
3
1
A-01979
Manual 0-2572 23 PARTS LISTS
Page 28
5.04 Replacement Parts - Bulkhead Side
Item # Qty Description Cat #
1 BASE ASSEMBLY
SIGNAL SIDE - REFER TO SECTION 5.05 FOR PARTS LIST
2 RUBBER GROMMET 9-6822
3 Units Before Revision Letter 'C' See Note 1
4 Units Revision Letter 'C' or Later See Note 1
3 2 TORCH LEADS PANEL BOOT (2 STEP) 9-6823
4 1 BODY, BULKHEAD, FUEL B MALE - FUEL B MALE 9-6824
5 1 ADAPTER, BULKHEAD, INERT B, RH - INERT B, LH (See Note 2) 9-6825
6 1 ADAPTER, BULKHEAD, INERT B, LH - INERT B, RH (See Note 2) 9-6826
7 1 BODY, BULKHEAD,O2B MALE - O2B MALE 9-6827
8 Panel Bulkhead, Insulated
1 Units Before Revision Letter 'C' 9-6828
1 Units Revision Letter 'C' or Later 9-6838
9 BUSS BAR
1 Units Before Revision Letter 'C' 9-6829
1 Units Revision Letter 'C' or Later 9-6839
10 4 NUT, 1"-14 BRASS HEX JAM NUT See Note 1
11 1 9/16-18 JAM NUT, BRASS 8-2149
12 2 NUT, JAM, 9/16-18, BRASS, LH 9-6830
13 1 ASSEMBLY, TORCH LEADS SHIELDS 2 1/4" 9-6831
14 1 INSULA T OR #2, ARC STARTER 9-6832
15 1 INSULA TOR, ARC ST ARTER, LCS3 9-6833
The following parts are not shown:
1 STAY STRAP CABLE TIES- 5 1/2" 9-4244
NOTES
1. Item can be purchased locally.
2. Replacement parts may have two locating pins. T o use the part on older style units, r emove one of the locating
pins.
PARTS LISTS 24 Manual 0-2572
Page 29
Units Before Revision Letter 'C'
15
14
13
12
11
10
10
9
Units Revision Letter 'C' or Later
10
12
3
1
2
2
2
4
3
6
A-01493
8
5
7
15
14
10
13
3
1
2
2
2
11
12
12
8
2
3
4
9
10
7
6
5
A-01978
Manual 0-2572 25 PARTS LISTS
Page 30
5.05 Replacement Parts - Signal Side
Item # Qty Description Cat #
1 1 ASSEMBLY, ARC STARTER BASE
Units Before Revision Letter 'C' 9-6820
Units Revision Letter 'C' or Later ---2 1 ASSEMBLY, CD TRANSFORMER, ARC STARTER BOX 9-6835
3 1 ASSEMBLY, ARC STARTER/RF FILTER PCB 9-6849
4 1 HARNESS, ARC STARTER 9-6836
5 1 LABEL, DATA 10-2359
6 5 SCREW, #6-32 X 3/8 PPH STL ZINC, SQU CONE WASHER See Note
NOTE: Item can be purchased locally.
PARTS LISTS 26 Manual 0-2572
Page 31
Units Before Revision Letter 'C'
3
6
6
4
6
A-01936
Units Revision Letter 'C' or Later
6
5
1
2
3
6
A-01935
6
4
6
5
6
1
2
Manual 0-2572 27 PARTS LISTS
Page 32
PARTS LISTS 28 Manual 0-2572
Page 33
APPENDIX I: INTERCONNECTING DIAGRAM
A-01575
Manual 0-2572 29 APPENDIX
Page 34
APPENDIX II: 24VAC WIRING BLOCK DIAGRAM
Merlin 6000 Power Supply
F3
(1A, 250V)
(108)
24 V AC
(109)
Torch Control
Connector
J14-5
J14-8
Arc Starter Box
Control Cable
(Part of Torch Supply Leads)
Panel Connector
J2-1
J2-2
(14)
(15)
Arc Starter Box
Arc Starter PC Board
J1-1
J1-3
24 V AC Present
(Red LED On)
A-01255
APPENDIX 30 Manual 0-2572
Page 35
Manual 0-2572 31 APPENDIX
4.253" (108.03 mm)
To End Edge of Arc Starter Box
3.760"
(95.5 mm)
Side Edge of Arc Starter Box
0.911"
(23.14 mm)
MOUNTING HOLE TEMPLATE
0.375" (9.53 mm)
Mounting Hole
4 Places
6.305"
(160.15 mm)
A-01439
Page 36
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