Tweco 6000CE User Manual

Download

Page 1

Plasma Cutting

Master Power Supply

CE MERLIN ® 6000

A-01497

Operating Manual

August 19, 2005 Manual No. 0-2601

Page 2

Page 3

WARNINGS

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.

Plasma Cutting Master Power Supply CE Merlin 6000 Operating Manual No. 0-2601

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermadyne.com

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: August 19, 2005

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

Page 4

TABLE OF CONTENTS

SECTION 5:

CUSTOMER/OPERA T OR SER VICE.................................................................................. 5-1

5.01 Introduction ................................................................................................... 5-1

5.02 General Maintenance .................................................................................... 5-1

5.03 Common Operating Faults ............................................................................ 5-2

5.04 Troubleshooting ............................................................................................ 5-2

5.05 Basic Parts Replacement ............................................................................. 5-5

SECTION 6:

P AR TS LISTS .................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-1

6.02 Ordering Information...................................................................................... 6-1

6.03 Complete Power Supply Replacement Parts List .......................................... 6-2

6.04 Basic Component Replacement Parts List.................................................... 6-3

6.05 Power Supply Options And Accessories ....................................................... 6-4

APPENDIX 1: INPUT WIRING REQUIREMENTS....................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION

BLOCK DIAGRAM............................................................................................................. A-2

APPENDIX 3: TYPICAL MECHANIZED SYSTEM W ORK AND GROUND CABLE CONNECTIONSA-3

APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM ...... A-4

APPENDIX 5: QUICK REFERENCE T O INTERCONNECTING CABLES AND HOSES ..............A-6

APPENDIX 6: INTERF A CE CABLE FOR REMOTE CONTROL (RC6010) .................................. A-7

APPENDIX 7: INTERF A CE CABLE FOR ST ANDOFF CONTROL (SC11)................................... A-8

APPENDIX 8: CNC INTERF A CE CABLES................................................................................. A-9

APPENDIX 9: LADDER DIA GRAM - 120 VAC ......................................................................... A-10

APPENDIX 10-A: LADDER DIAGRAM - 15 vdc

(Rev AE or Earlier Logic Control PC Board)...................................................................... A-11

APPENDIX 10-B: LADDER DIAGRAM - 15 vdc

(Rev AF or Later Logic Control PC Board) ........................................................................ A-12

APPENDIX 11: PARALLEL CABLE ......................................................................................... A-13

APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE ..........................................................A-14

APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier .......................................................A-16

APPENDIX 14: SYSTEM SCHEMATIC - Rev 'AK' or Later .....................................................A-18

Page 5

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERA T OR SERVICE.................................................................................. 5-1

5.01 Introduction................................................................................................... 5-1

5.02 General Maintenance.................................................................................... 5-1

5.03 Common Operating F aults ............................................................................ 5-2

5.04 Troubleshooting............................................................................................. 5-2

5.0 5 Basic Parts Replacement ............................................................................. 5-5

SECTION 6:

PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction................................................................................................... 6-1

6.02 Ordering Information ..................................................................................... 6-1

6.0 3 Complete Pow er Supply Replacement Parts List .......................................... 6-2

6.0 4 Basic Component Replacement Parts List.................................................... 6- 3

6.0 5 Po wer Supply Options And Accessories....................................................... 6-4

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION BLOCK DIAGRAM .............................................A-2

APPENDIX 3: TYPICAL MECHANIZED SYSTEM WORK AND GROUND

CABLE CONNECTIONS....................................................................................................A-3

APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM ...A-4

APPENDIX 5: Q UICK REFERENCE T O INTERCONNECTING CABLES AND HOSES ............ A-6

APPENDIX 6: INTERF A CE CABLE FOR REMOTE CONTR OL (RC6010) .................................A-7

APPENDIX 7: INTERF A CE CABLE FOR STANDOFF CONTROL (SC11) .................................A-8

APPENDIX 8: CNC INTERFACE CABLES................................................................................ A-9

APPENDIX 9: LADDER DIA GRAM - 120 VAC ........................................................................ A-10

APPENDIX 10-A: LADDER DIAGRAM - 15 vdc (Rev AE or Earlier Logic Control PC Board) ..A-11

APPENDIX 10-B: LADDER DIAGRAM - 15 vdc (Rev AF or Later Logic Control PC Board)..... A-12

APPENDIX 11: PARALLEL CABLE......................................................................................... A-13

APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE......................................................... A-14

APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier...................................................... A-16

APPENDIX 14: SYSTEM SCHEMATIC - Rev 'C' or Later........................................................ A-18

Page 6

Page 7

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: January 27, 2004 1-1 GENERAL INFORMATION

Page 8

• 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. Yo u 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 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 1-2 Date: January 27, 2004

Page 9

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. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standar d 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 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.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

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: January 27, 2004 1-3 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 10

• 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 1-4 Date: January 27, 2004

Page 11

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 Y ork, 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: January 27, 2004 1-5 GENERAL INFORMATION

Page 12

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 1-6 Date: January 27, 2004

Page 13

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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this 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 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

associated accessories.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment

* For environments with increased hazard of electrical shock, Power Supplies bearing the

EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible repr esentative: Steve W ard

Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

mark conform to

Date: January 27, 2004 1-7 GENERAL INFORMATION

Page 14

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 W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE.

LIMIT A TION 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 PA RTS 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 Y ears 1 Year 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 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year SureLok T orches 1 Y ear 1 Y ear 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

GENERAL INFORMATION 1-8 Date: January 27, 2004

Page 15

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Merlin 6000 Plasma Cutting CE Master Power Supply . 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 W arranty .

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.

NOTE

This Manual may include references to the Power Supply revision letter(s). There are old style and new style data tags that may be encountered. The old style data tag has the revision letter(s) at the end of the serial number. The new style data tag has the revision letter(s) in an area marked 'Rev'.

2.02 General Description

The Master Power Supply contains all operator controls, electrical and gas inputs and outputs, and the torch leads receptacle. A Slave Power Supply may be connected in parallel to double the cutting capacity (amperage) of the Master Power Supply . All signal inputs/outputs, gas, and torch connections are still connected to the Master Power Supply when the Slave Power Supply is used. The Slave Power Supply has the same power circuits as the Master Power Supply . The Master Power Supply can also be connected to a second Master Power Supply and the equipment will automatically be configured when the parallel cable is installed. Many options and accessories can be added to further improve the versatility of the system.

A-01497

Figure 2-1 Power Supply

The 'Extra-CoolTM' Coolant supplied with the Power Supply can be used in ambient temperatures down to 10° F (-12° C). If the ambient temperature will be below 10° F (-12° C) use 'Ultra-CoolTM' Coolant. This coolant can be used in areas where the ambient temperature drops to -27° F (-33° C).

A typical system configuration will contain the following:

• One or two CE Power Supplies with Running Gear

• Arc Starter Box

• Maximizer 300 Machine Torch with Leads and Mounting Assembly

• T or ch Supply Leads

• Maximizer 300 Spare Parts Kit

• 25 ft (7.6 m) W ork Cable and Ring Lug

• Optional Air Line Filter Assembly (or) High Pressure Regulators

NOTES

Refer to the Merlin 6000 Plasma Cutting CE Slave Power Supply Operating Manual 0-2603 for more information on the Slave Power Supply.

The Merlin 6000 CE Slave Power Supply requires a Merlin 6000 CE Master Power Supply for proper operation and torch connections.

Manual 0-2601 2-1 INTRODUCTION & DESCRIPTION

Page 16

2.03 Specifications & Design

Temperature

Features

5. Duty Cycle (see NOTE)

NOTE

The following apply to the Master Power Supply only:

1. Controls

ON/OFF Switch, Output Current Control, RUN/SET/PURGE Switch, Secondary Gas Regulator , Plasma Gas Regulator, Secondary Mode Switch, Secondary W ater Flowmeter/ Regulator , Optional Arc Hour/Counter Meters

2. Control Indicators

LED Indicators: AC , TEMP , GAS, DC, PILOT, COOLANT PRES, and COOL-

ANT COND Gauges: Secondary , Plasma, and Coolant Pressure Gauges

3. Input Power

Voltage Frequency Phase Amperage

380 50 or 60 Hz 3 51 415 50 or 60 Hz 3 47

NOTE

Refer to Appendix 1 for recommended input wiring size, current ratings, and circuit pr otection requirements.

Amperage depends on input voltage (Refer to Appendix 1).

4. Output Power Master Power Supply:

Continuously adjustable by potentiometer from 50 to 150 amps

With Slave Power Supply:

Continuously adjustable by potentiometer from 100 to 300 amps

The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher than shown in the chart.

Power Supply Duty Cycle

Ambient

Duty Cy cle

Current

DC Vol ta g e

6. Pilot Modes

Auto-Restart, Pre-Flow Delay , "Recycle Required"

7. CNC Signals

Enable, Start/Stop, OK-T o-Move, Pilot Sensing Relay (PSR), Full CNC A vailable with Remote

8. Coolant Pressure

Internal Service-adjustable 130 psi (8.8 bar) at zero flow 120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.6 lpm)

9. Coolant Flow Rate

0.5 gpm (2.2 lpm) with 150 feet of total torch and torch leads at 70°F (21°C)

The flow rate varies with lead length, torch configuration, ambient temperature, amperage level, etc.

10. Cooling Capacity

4,000 to 10,000 BTU

Maximum value based on “free flow” condition.

104° F (40° C)

100%

150 Amps

140 vdc

NOTE

11. Coolant Reservoir Capacity

2 gallons Capable of handling a total of 150 feet of torch lead

length

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2601

Page 17

12. Secondary Water

C. Pilot Arc

T ap water can be used as a secondary gas and must be capable of delivering the following minimums:

• Water pr essure of 50 psi (3.5 bar)

• Flow of 8 gph (35.2 lph)

NOTES

Tap water should only be used as a secondary gas on machine torches.

The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.

13. Power Supply Dimensions Enclosure Only -

Width: 24.12 in (0.61 m) Height: 38.38 in (0.98 m) Depth: 34.25 in (0.87 m)

Fully Assembled -

Width: 28.50 in (0.72 m) Height: 43.38 in (1.10 m) Depth: 43.75 in (1.11 m)

14. W eight of Power Supply Only

When the torch is activated there is a two second gas pr e-flow, followed by a uninterrupted DC pilot arc established between the electrode and tip. The pilot arc is initiated by a momentary high frequency pulse from the Arc Starter Box. The pilot creates a path for the main arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated.

NOTE

For the arc to restart automatically, AUTO RESTART must be enabled at switch settings inside the Power Supply (Refer to Section 4.07).

D. Main Cutting Arc

The Power Supply accepts 50 or 60 Hz three-phase line input. The power supply converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead. The positive output is connected to the workpiece via the work cable and ring lug connection.

E. RF Shielding

All machine torch systems are shielded to minimize radio frequency (RF) interference which results from the high frequency arc initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads.

678 lbs (308 kg)

2.04 Theory Of Operation

A. Plasma Arc Cutting and Gouging

Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away by the flow of gas. Plasma arc gouging uses the same process to remove material to a controlled depth and width.

With a simple change of torch parts, the system can also be used for plasma arc gouging. Plasma arc gouging is used to remove material to a controlled depth and width.

. Input and Output Power

The Power Supply accepts input voltages of 380/415V, 50 or 60 Hz, three-phase. The unit converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead, and the positive output connects to the workpiece through the work cable.

F. Interlocks

The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the fault condition must be remedied and the system recycled using the applicable control device.

1. Parts-In-Place (PIP) Interlock

The Power Supply has a built-in parts-in-place interlock that prevents accidental torch starting when torch parts are not properly installed. A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly. If not satisfied, the switch interrupts power to the tip and electrode.

2. Gas Pressure Interlock

A pr essure switch acts as an interlock for the plasma gas supply. If the supply pressure falls below minimum requirements the pressure switch will open, shutting off the power to the contactors, and the GAS indicator will go out. When adequate supply pressure is available the pressure switch will close, allowing power to be resumed for cutting.

Manual 0-2601 2-3 INTRODUCTION & DESCRIPTION

Page 18

3. Thermal Interlock

C. Computer Control Cable Kits

Thermal overload sensors are located in the transformer , pilot resistors, and main heatsink in the power supply . If one of these components is overheated the appropriate switch will open, causing the temperature light to turn from green to red and shutting of f power to the main contactor. When the overheated component cools down the switch will close again and allow operation of the system.

G. Plasma Torches

Plasma torches are similar in design to the common automotive spark plug. They consist of negative and positive sections which are separated by a center insulator . Inside the torch, the pilot arc is initiated in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas flows through the small orifice in the torch tip, which is focused on the metal to be cut.

The Maximizer 300 T orch uses an internal closed-loop cooling system. Deionized coolant is distributed from a reservoir in the Power Supply through the coolant supply lead. At the tor ch, the coolant is circulated through the torch tip and electrode, where the extra cooling helps to prolong parts life. Coolant then circles back to the power supply through the return lead. The Maximizer 300 also can use secondary gases such as compressed air , nitrogen (N2), water , and carbon dioxide (CO

2.05 Options And Accessories

These items can be used to customize a standard system for a particular application or to further enhance performance. T orch accessories are listed in the separate T orch Instruction Manual.

For interfacing the power supply with a computer or auxiliary control device. A vailable in various cable lengths.

D. High Pressure Regulators

A vailable for air, oxygen, ar gon/hydrogen, nitrogen, CO2, and water .

E. High Flow Water Shield (HFWS) Assembly

Reduces arc glare, noise, and fumes during the cutting process.

F. Two Stage Air Line Filter

Removes damaging contaminants as small as 5 microns from the plasma stream when using compr essed air.

G. Hour/Counter Meters

Meter assembly containing two meters. One meter indicates the total number of hours and minutes that the main cutting arc has been on to a maximum of 99999-59 (hoursminutes). The second meter counts the number of times that the cutting arc has been started to a maximum of 99999999 starts. Both meters can be reset to zero.

H. Plasma/Secondary Gas Control (GC 3000)

A remote control to select one of various plasma and secondary gases that can be connected to the Power Supply . This allows one-time plumbing connections of various gas/ water supplies. The operator has complete flexibility to quickly select the best plasma and secondary gas combinations for the metal to be cut.

NOTE

Refer to Section 6, Parts Lists, for ordering information.

A. RC6010 Remote Control

For mechanized systems, this low profile unit provides full CNC capability and allows the operator to control all system functions from a remote location.

B. SC-10 or SC11 Standoff Controls

For machine torch systems, the Standoff Control automatically finds height and maintains torch standoff with a high speed torch lifter motor .

NOTES

Standoff Control SC10 must be used with the Remote Control RC6010.

Standoff Control SC11 can be used without Remote Control RC6010.

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2601

Page 19

SECTION 3:

3.03 Unpacking

INSTALLATION

3.01 Introduction

This Section describes installation of the Master Power Supply. These instructions apply to the Master Power Supply Assemblies only; installation procedur es for Slave Power Supply, Options and Accessories are given in Manuals specifically provided for those units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input power b. Internal power selection c. Work cable d. Gas connections e. Torch Installation

Each component of the system is packaged separately and protected with a carton and packing material to prevent damage during shipping. Components are packaged as follows:

A. Power Supply

The power supply is skid-mounted and protected with a carton and padding material to prevent damage during shipment. The power supply with work cable are factory-assembled and packaged together. Also packed with the system are:

• Tor ch and torch leads

• Tor ch Supply Leads

• Spare parts kit for the torch

• Coolant deionizing bag

• Arc Starter Box

• Operating Manual for Power Supply

B. Torches

T orches and leads are packaged with the Power Supply . Spare parts for new torches are packed in a spare parts box. Separate instruction manual is provided with each torch.

C. Options and Accessories

f. Connecting auxiliary devices

4. Grounding

5. Operator training

3.02 Site Location

Select a clean, dry location with good ventilation and adequate working space around all components.

CAUTION

Operation without proper air flow will inhibit proper cooling and reduce duty cycle.

The Master Power Supply is cooled by air flow through the front, rear, and side panels. Air flow must not be obstructed. At least 2 feet (0.61 m) of clearance should be provided on all sides.

NOTE

When using the Slave Power Supply in parallel with the Master Power Supply the supplies should be placed next to each other. Placing one Power Supply behind the other will cause heated air to be drawn into the rear Power Supply. This condition may lower the duty cycle of the system.

Options and Accessories are packaged separately fr om the Power Supply .

D. 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 before proceeding with installation.

3.04 Removing Skid

The Power Supply is mounted on the skid with two brackets. Remove the Power Supply from the skid as follows:

1. Remove the six bolts connecting the brackets to the base of the Power Supply .

Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.

Manual 0-2601 3-1 INSTALLA TION PROCEDURES

Page 20

)

Shipping Brackets

2. Remove the coolant filler cap from the reservoir at the top rear of the Power Supply .

3. Place the deionizer bag into the basket in the coolant reservoir .

Coolant Reservo

Filler Cap

Deionizer

Bag

Basket

A-01498

Shipping Pallet

Three Bolt (Each Side

Figure 3-1 Skid Removal From Power Supply

2. Roll the Power Supply off the skid backwards (rear wheels first).

3.05 Filling Master Power Supply

Coolant

NOTE

Only the Master Power Supply requires coolant. DO NOT install coolant in the Slave Power Supply or the second Master Power Supply if used.

The ambient temperature of the environment where the Power Supply will be located determines the coolant to be used. The Standard T or ch Coolant supplied with the system can be used in ambient temperatures down to 10° F (-12° C).

Optional Super T orch Coolant should be used in areas wher e the ambient temperature drops down to -27° F (-33° C)

CAUTION

A-00872

Coolant Level Indicato

Figure 3-2 Coolant Reservoir

4. Carefully pour enough of the supplied Thermal Arc T orch Coolant into the reservoir to fill it to the FULL mark on the rear panel.

NOTE

After operating the system more coolant may need to be added. Allow the pump to operate for ten minutes to properly purge any air from the coolant lines before using the system.

5. Reinstall the reservoir coolant filler cap.

3.06 Input Power Connections

The Power Supply accepts input voltages of 380/415V, 50 or 60 Hz, three-phase power.

Use only Thermal Arc Torch Coolant. Use of any other coolant can result in torch damage, insufficient thermal protection, and/or pilot arc interference.

A. Electrical Connections

The power source must conform to local electric code and the recommended circuit protection and wiring r equirements shown in Appendix 1.

1. Locate the coolant deionizer bag and remove from the plastic shipping bag.

INSTALLA TION PROCEDURES 3-2 Manual 0-2601

Page 21

B. Opening Power Supply Enclosure

Busbar Connections

For Input Voltage

Of 380/415 VAC

A-01090

The left side panel (viewed from the front) of the Power Supply must be removed to make electrical connections and to select the proper input voltage.

Extra Busbar

Storage Locatio

W ARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

1. Remove the ten screws which secure the left side panel (viewed from the front) to the Power Supply .

Left Side Panel

A-01091

Input Voltage

Terminal Board

Busbars

Figure 3-4 Input Voltage Terminal Board Location

NOTE

Extra busbars are attached (stored) to the top side of the power transformer assembly.

2. Check the busbar configuration on the input voltage terminal board . The busbar configuration must correspond with the available line voltage per the following figure and the label inside the unit:

2. Remove the left side panel from the Power Supply.

3.07 Checking Input Connections

The Power Supply is wired to use input voltages of 380/415 VAC. Internal busbars must be checked on the input voltage terminal board to verify proper installation .

1. Locate the input voltage terminal board on the

Manual 0-2601 3-3 INSTALLA TION PROCEDURES

Screws

(10 Places)

Figure 3-3 Opening Power Supply

left side of the power supply.

A-01535

Figure 3-5 Busbar Connections

If necessary , reposition the busbars to correspond to the available line voltage.

Page 22

3.08 Primary Power Cable

Connections

WARNING

2. Locate the four input connectors, flat washers, conical spring washers, and hex locking nuts supplied with the power supply .

3. Install the input connectors, supplied, onto each of the input power line leads of the power cable.

Disconnect primary power at the source before connecting the primary power cable to the power supply.

The primary power cable must be supplied by the end user and installed to the Power Supply assembly. Recommended cable sizes are specified in Appendix 1.

NOTE

Three-phase operation requires a 3-conductor cable with ground.

1. Route the primary power cable through the strain relief fitting in the rear panel of the Power Supply and tighten strain relief screws.

PC Board

Power Stud

Flat Washer

Conical Sprin

Washer

Hex Lockin

Input

onnector

A-00908

Slotted Screw

Input Power Cable

(One Line)

Nut

Figure 3-7 Input Voltage Connector Installation Detail

4. Connect the input power connectors to the EMI Input Power Filter PC Board input studs with the supplied hex locking nuts, conical spring washers, and flat washers as follows:

• Input ground wire to G1.

• LI input line to X1.

Input Power

Filter PC Board

and Bracket

• L2 input line to Y1.

• L3 input line to Z1.

5. Tighten the nuts being careful not to over-tighten. Refer to the following W ARNING.

Input Ground

Connection

W ARNING

rimary Power

Cable

Do Not over tighten the nuts securing the input power cable connectors as damage to the PC Board

Strain Relief

Fitting

A-00896

can occur.

Figure 3-6 Input Voltage Connections

INSTALLA TION PROCEDURES 3-4 Manual 0-2601

Page 23

3.09 Ground Connections For Mechanized Applications

NOTE

Refer to Appendix 3 for a block diagram of a typical mechanized system work and ground cable connections.

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. T o minimize RF interference, follow these grounding procedures when installing mechanized systems:

B. Grounding

1. The preferred gr ounding arrangement is a single point

or “Star” ground. The single point, usually on the cutting table, is connected with 1/0 AWG (50.0 mm European) or larger wire to a good earth ground (refer to paragraph ‘C’, Creating An Earth Ground). The ground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible. Long wires will have increased resistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better .

2. G rounding for components mounted on the cutting

table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations.

For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (6.00 mm2 European) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. The connection point must be clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used and may improve noise protection.

3. The cutting machine frame is then connected to the

“Star” point using 1/0 A WG (50.0 mm larger wire.

European) or

4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.

NOTE

Do Not connect the work cable directly to the ground rod.

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended.

6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.

When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the cutting table, if possible.

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interfer ence than with no shield at all.

C. Creating An Earth Ground

1. To create a solid, low resistance, earth gr ound, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (50.0 mm2 European) or greater, between the ground rod and the star ground point on the cutting table.

NOTE

Ideally, a properly installed ground r od will have a resistance of three ohms or less.

Manual 0-2601 3-5 INSTALLA TION PROCEDURES

Page 24

T o test for a proper earth ground, refer to the following

diagram. Ideally , the reading on the multimeter should be as follows:

3.10 Plasma And Secondary Gas

Connections

• For 115VAC: 3.0 VAC

• For 230VAC: 1.5 VAC

115VAC: 3.0 VAC 230VAC: 1.5 VAC

Meter set to VAC setting

WARNING

Use extreme caution. This

test uses live voltage.

Neutral

115 or 230VAC

Line (Hot)

rt # A-02971

100W

Light Bulb

VR COM A

Groun

Rod

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

The Master Power Supply provides the liquid cooling and gases to support operation of the Liquid Cooled Maximizer 300 Torch.

NOTE

Refer to the Liquid Cooled Maximizer 300 Torch Instruction Manual (Cat. No. 0-2573 for information on plasma and secondary gas selection and requirements.

The following are available gases that can be used with the Liquid Cooled Maximizer 300 Torch:

Plasma Gases: Compressed Air, Oxygen (O

), Nitro-

gen (N2), or Argon/Hydrogen (Ar/H2) Secondary Gases: Compressed Air, Nitrogen (N2),

Carbon Dioxide (CO

), or T ap Water (refer to follow-

ing note)

Plasma and secondary requirements vary depending on the application. The plasma and secondary gases are connected to the rear panel connections of the power supply. Depending on the options installed and the source of the gases will determine the installation of filters and regulators.

This sub-section includes information for connecting the gas supplies to the Power Supply. The information is grouped in paragraphs for different types of gases and options per the following:

A. Using Shop Air B. Using High-Pressure Gas Cylinders C. Using W ater Secondary D. Plasma and Secondary Gases With Gas Control

Option

Refer to the appropriate paragraph(s) for the desired application to be used.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference.

INSTALLA TION PROCEDURES 3-6 Manual 0-2601

Page 25

A. Using Shop Air

An inline pneumatic dryer/evaporator type air filter , capable of filtering particulates to at least 5 microns with a dew point of 35°F (1.7°C), is required when using air from a compr essor. This type filter will insure that moisture, oil, dirt, chips, rust particles, and other contminants from the supply hose do not enter the torch. For highly automated applications, a refrigerated drier plus a particulate filter may be used to chill the air to remove all moisture.

CAUTION

Excessive oil or moisture in compressed air will reduce torch parts life and cutting performance and may cause torch failure.

The optional Two Stage Air Line Filter is shipped with the following components:

NOTE

The Two Stage Air Line Filter Assembly is to be used when using shop air as the Plasma Gas.

• Installation Instructions - 1 each

• 10-32 Nylon Lock Nuts - 2 each

• Filter Mounting Bracket - 1 each

• Air Line Filter Assembly - 1 each

• 1/4 NPT Street Elbow - 1 each

• Thread Sealer - 1 each

• Filter To Plasma Gas Hose Assembly - 1 each (see NOTE)

• Filter to Gas Option Hose Assembly - 1 each (see NOTE)

NOTE

Only one of these will be used depending on configuration of Power Supply.

2. Locate the two mounting studs on the rear of the unit and secure the Air Filter Mounting Bracket to the panel using the two 10-32 Nylon Locking Nuts provided.

ounting

Studs

A-01336

Air Filter

Mounting Bracket

Mountin

Nuts

Figure 3-8 Air Filter Mounting Bracket Installation

3. Place thread sealer on the threads of the 1/4 NPT Street Elbow (see NOTE).

NOTE

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

4. Install the supplied 1/4 NPT Street Elbow into the input port (IN) of the Air Line Filter Assembly.

Install the Two Stage Air Filter Kit as follows:

NOTE

Use these instructions only for Power Supplies that DO NOT have the Gas Control Option installed.

1. Remove the air supply input hose from the Plasma Gas (Air) Input Fitting at the rear of the power supply, if already installed.

Manual 0-2601 3-7 INSTALLA TION PROCEDURES

Page 26

5. Slide the Air Line Filter Assembly into the mounting bracket.

The Filter Assembly will snap into place.

Air Filter

ounting Bracket

Hose Assemb Filter to Plasm

Gas Input

Shop Air

as Input

Secondary Air

Gas Fitting

Y-Hose

Assemb

Air Filter

Assembly

Plasma Gas

Input Fitting

A-01337

1/4 NPT

Elbow

Assembly

A-01338

From Supply

Filter

Figure 3-10 Supply Hose Connections Without Gas

Control Option

Figure 3-9 Two Stage Air Line Filter Installation

10 . Connect the elbow fitting to the SECONDARY (Air) 1/4

NPT fitting.

6. Using the Filter to Plasma Gas Hose Assembly connect the output port (OUT) of the Air Line Filter Assembly to the Plasma Gas Input Fitting.

7. Place thread sealer on the threads of the Street Elbow on a Y -Hose Assembly (see NOTES).

NOTES

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

The Y -Hose Assembly is customer supplied and is shown to illustrate one method of connecting the customer's air supply.

8. Connect the air supply hose from a Y -Hose Assembly to the street elbow on the Air Line Filter input port (IN). The Y -Hose Assembly should have alr eady been installed, if shop air was being used as the plasma and secondary gases.

11. Connect the supply line from the air supply source to the Y hose assembly . The supply hose must be 3/8 in (10 mm) minimum inside diameter to provide adequate air flow .

B. Using High-Pressure Gas Cylinders

NOTES

Refer to the regulator manufacturer’s specifications for installation and maintenance procedures. Refer to Section 6.05, System Options and Accessories, or a listing of available high-pressure regulators.

Do not use an air line filter with high pressure gas cylinders.

Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to blow out any dust which may be present.

9. Apply thread sealer (see NOTE) to the other elbow of the Y -Hose Assembly.

WARNING

NOTE

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the

Do not stand in front of the valve outlet when opening.

small gas passage to be blocked in the torch.

INSTALLA TION PROCEDURES 3-8 Manual 0-2601

Page 27

Each cylinder must be equipped with an adjustable high-pres-

OUTPUT

MODULE

INPUT

PLASMA GAS

INPUT

y ly

sure regulator capable of pressures up to 125 psi (8.6 bar) maximum and flows of up to 700 scfh (328 lpm) for cutting or gouging.

CAUTION

Maximum input pressure to the internal regulator on the Power Supply must not exceed 125 psi (8.6 bar).

Connect the gas supply to the Power Supply per the following:

1. Connect the black supply hose from the plasma gas regulator directly to the input fitting on the rear panel of the Power Supply marked PLASMA.

C. Using Water Secondary

NOTES

Tap water should only be used as a secondary gas on machine torches.

The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.

Tap water can be used instead of a secondary gas and is connected to the Power Supply as follows:

1. The tap water source must be capable of delivering a minimum water pressure of 50 psi (3.5 bar) and flow of 8 gph (35.2 lph).

2. Connect the tap water supply hose to the input of a Water Pressure Regulator.

A-01503

Secondary Ga

Fitting

Secondary Gas

Supply Hose

Plasma Gas

Fitting

Plasma Gas

Supply Hose

Figure 3-11 Gas Connections Using Gas Cylinders

3. Connect the output of the water regulator to the fitting marked SEC. WATER on the rear panel of the Power Supply.

NOTE

The water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.

A-01504

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

2. Connect the yellow supply hose from the secondary gas regulator directly to the input fitting on the rear panel of the Power Supply marked SECONDARY . Do not use the air line filter with high pressure cylinders.

A typical 50 lb. CO

NOTE

cylinder can deliver a con-

tinuous flow rate of 35 scfh (16.5 lpm). To obtain

4. Set the SECONDARY selector switch on the front

econdary Water

Fitting

Water Secondar

Hose From Supp

Figure 3-12 Secondary Water Connection

panel of the Power Supply to the WA TER position.

the required flow rate for the torch, it may be necessary to manifold several CO2 cylinders. Continuous flow requirements will depend on the specific application and duty cycle.

Manual 0-2601 3-9 INSTALLA TION PROCEDURES

Page 28

D. Plasma and Secondary Gases With

CONTROL

PLASMA

PLASMA GAS

Ar/H

PLASMA

Optional Gas Control

4. Install the supplied 1/4 NPT Street Elbow into the input port (IN) of the Air Line Filter Assembly .

The required plasma and secondary gases are connected to the rear of the Power Supply. The secondary selection switch on the front panel of the Power Supply must always be set to GAS for all secondary gases when the Gas Control Option is installed. The type of gas to be used will be selected at the Gas Control Option front panel.

NOTE

If compressor shop air is to be used as the plasma gas the line must be filtered.

If using shop air as one of the plasma gases then install the optional T wo Stage Air Line Filter as follows:

NOTE

Use these instructions only for Power Supplies that HAVE the Gas Control Option installed.

1. Remove the air supply input hose from the Plasma Gas (Air) Input Fitting at the rear of the power supply , if already installed.

2. Locate the two mounting studs on the rear of the unit and secure the Air Filter Mounting Bracket to the panel using the two 10-32 Nylon Locking Nuts provided.

5. Slide the Air Line Filter Assembly into the mounting bracket. The Filter Assembly will snap into place.

Gas Contr

Air Filter

Mounting

Bracket

OUTPUT TO CONTROL MODULE

PLASMA GAS

AIR

PLASMA INPUT

Ar/H

PLASMA INPUT

Plasma Ga

Input Fittin

Hose

Assembl

Filter to Plasma

Gas Inpu

1/4 NPT

Elbow

A-01339

Air Filter

Assembly

Figure 3-14 Supply Hose Connections With Gas Control

Option

6. Place thread sealer on the threads of the connectors at both ends of the Filter to Plasma Input Gas Hose Assembly (see NOTE).

NOTE

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

7. Connect the Filter to Plasma Input Gas Hose Assembly to the output port (OUT) of the Air Line Filter Assembly and to the Air Plasma Input Fitting on the

ounting Studs

Gas Control Manifold.

8. Place thread sealer on the threads of the Street Elbow on a Y-Hose Assembly (see NOTES).

Air Filter

A-01336

Mounting Bracket

Figure 3-13 Air Filter Mounting Bracket Installation

3. Place thread sealer on the threads of the 1/4 NPT Street Elbow (see NOTE).

Mountin

Nuts

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

The Y -Hose Assembly is customer supplied and is shown to illustrate one method of connecting the

NOTES

customer's air supply.

NOTE

9. Connect the air supply hose from a Y -Hose Assembly

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

to the street elbow on the Air Line Filter input port (IN). The Y -Hose Assembly should have alr eady been installed, if shop air was being used as the plasma and secondary gases.

INSTALLA TION PROCEDURES 3-10 Manual 0-2601

Page 29

Shop Air

OUTPUT

INPUT

PLASMA INPU

LASMA INPUT

PLASMA GAS

PUT

MODULE

OUTPUT C

ONTROL MODULE

PLASMA INPUT

PLASMA GAS

PLASMA INPUT

as Input

Air Filter

Assembly

OUTPUT

TO CONTROL MODULE

PLASMA GAS

AIR

PLASMA

INP

M PLAS INPUT

SMA PLA INPUT

Ar/H

PLASMA INPUT

Secondary A

Gas Fitting

Y-Hose

Assembly

as Control Option

Gas Manifold

Plasma Gas Output

From Gas Select Option

OUTPUT TO

ONTROL C MODULE

PLASMA GAS

AIR

PLASMA INPUT

Ar/H

PLASMA INPUT

To Plasma Gas

Input Fitting

A-01340

From Supply

A-01343

Figure 3-15 Supply Hose Connections Wit Gas Control

Option

10. Apply thread sealer (see NOTE) to the other elbow of the Y Hose Assembly .

NOTE

Do Not use teflon tape as a thread sealer as small particles of the tape may break off and cause the small gas passage to be blocked in the torch.

11. Connect the elbow fitting to the SECONDARY (Air) 1/4 NPT fitting.

12. Connect the other required plasma gases to the optional Gas Control gas manifold.

Figure 3-17 Plasma Hose Connection From Gas Control

14. Connect the required secondary gases the SECONDAR Y INPUT fittings marked OTHER, N2, and SECONDARY GAS (air).

NOTE

If air is to be used as the secondary gas it should be connected to the fitting marked SECONDARY GAS.

If using Secondary Water connect as described in paragraph 'C' above.

NOTE

DO NOT connect Secondary Water to the

Gas Control Plasma

Gas Manifold

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

A-01341

Figure 3-16 Plasma Gas Connections

13. Connect the Plasma Hose from the Plasma Gas Con-

Plasma Gas

Input Fittings

Air (Filtere

Ar/H2

'OTHER' secondary gas fitting.

trol Manifold to the Plasma (Air) Gas Input Fitting at the rear of the Power Supply.

Manual 0-2601 3-11 INSTALLA TION PROCEDURES

Page 30

OUTPUT

MODULE

PLASMA GAS

A-01342

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

2. Feed the four hose assemblies on the Tor ch Supply Leads components through the boot on the front panel of the Master Power Supply .

3. Connect the four hose assemblies onto the mating connec-

N2 Seconda

Gas Supply

tions at the internal bulkhead of the Master Power Supply per the following figure.

Master Power Supply

Control Cable

econdary

Gas Lead

Bulkhead

Plasma

Gas Lead

Coolant Retu

Lead

Coolant Supply

Lead

orch Supply Leads

A-01447

Figure 3-19 Leads Extension Hose Connections To

Master Power Supply

Supply Leads Boot

OTHER Secondary

Gas Supply

4. Connect the end of the Pilot Lead, two wires, to the Master Power Supply as follows:

Figure 3-18 Secondary Gas Connections

a. Remove the right side panel from the Master Power

Supply .

3.11 Connecting Torch Supply Leads

The T orch Supply Leads interfaces the Master Power Supply to the Arc Starter Box. The Torch Supply Leads is

b. Feed the Pilot Lead, two wires, through the small strain

relief at the front panel of the Master Power Supply .

c. Remove the nut and star washer on the ground termi-

nal of the pilot connection inside the power supply .

made up of individual hoses and cables that must be connected.

NOTE

Refer to the Arc Starter Box Instruction Manual 0-2572 for details on installation of the Arc Starter

Star Washer

Nut

mall Strain

Relief

Ground T erminal

Pilot T ermin

Box.

The Torch Supply Leads components connects directly to a bulkhead inside the Master Power Supply and to connections inside the right side panel. Connect the Torch Supply Leads components as follows:

W ARNING

Black Wire

of Pilot Lead

Red Wire

of Pilot Lead

A-01495

Figure 3-20 Pilot Lead Connection at Power Supply

Primary power should NOT BE APPLIED when working inside the power supply.

1. Open the front panel access panel to gain access to

the bulkhead.

INSTALLA TION PROCEDURES 3-12 Manual 0-2601

Page 31

d . Secure the shield lead (black) to the ground connec-

CONTROL

MODULE

INPUT

PLASMA

INPUT

PLASMA GAS

Ar/H

INPUT

tion 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 connection with

the nut and star washer removed above.

5. Connect the Power Lead to the Master Power Supply as

follows:

a. Feed the Power Lead through the large strain relief at

the front panel of the Master Power Supply .

b. Remove the lock nut from the power connection termi-

nal inside the power supply .

Power Lea

Terminal Bo

3.12 External Cable Connections

Depending on the options installed there are various cables to be connected the Power Supply .

A. Optional RC 6010 Remote Control

For mechanized systems, the optional RC 6010 Remote Control allows the operator to control all system functions from a remote location. The control cable to interface the RC 6010 to the Power Supply is available in various lengths (Refer to Section

6.04, Options and Accessories).

1. Connect the control cable to the receptacle marked REMOTE CONTROL (J15) on the rear panel of the Power Supply .

A-01505

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

REMOTE CONTRO

Connector (J15)

Large

Power Lea

Strain Relief

Nut

A-01496

Figure 3-21 Power Lead Connection at Master Power

Supply

c. Remove the power lead terminal bolt. d . Place the Power Lead ring lug over the existing lug. e. Secure the power lead to the connection with the bolt

and lock nut removed above.

6. Refer to the Arc Starter Box Manual and connect the other end of the T orch Supply Leads components to the Arc Starter Box.

7. Refer to the Arc Starter Box Manual and connect the liquid cooled Maximizer 300 torch to the Arc Starter Box.

Refer to the Installation sections in the Maximizer 300 Torch Instruction Manual (0-2573) for more

NOTE

information on the Torch.

Cable From

Remote Control

Figure 3-22 Remote Control Interface Connection

2. Connect the other end of the control cable to the receptacle marked PS (J37) on the rear panel of the remote control.

NOTE

Refer to the RC 6010 Remote Control Instruction Manual 0-2478 for more information on the RC6010 Remote Control including CNC.

Manual 0-2601 3-13 INSTALLA TION PROCEDURES

Page 32

B. Computer Control Interface (CNC)

O ne Si de of Pil ot Sens i ng R el ay ( PSR)

NOTE

Used when Remote Control RC6010 or Standoff Control SC1 1 are not used.

TB2

Connec tion

Description

The computer control interface allows a mechanized system to interface with a computer or other control device.

NOTE

Refer to Section 4.03-D for more information on the CNC connections.

CNC cables can be interfaced to the Power Supply using one of the following methods:

NOTE

Refer to Appendix 7 for CNC Interface Schematic.

• Connector (J15) at the rear of the Power Supply

• Internal terminal strip in the Power Supply

Depending on the equipment ordered and the cables supplied connect the CNC cable per one of the following:

1. Using supplied CNC cable

Connect the supplied Power Supply/CNC Cable to the Power Supply rear connector J15 labelled REMOTE CONTROL.

2. Using customer supplied CNC Cable

1 One Si de of Enabl e Sign al ( C om mon)

2 Other Side of Enable Signal (+15 vdc )

5Not Used

6Not Used

O ne Si de of START( Low ) /ST OP (Hi gh) Signa l ( +15 v dc)

O ther Side of S TAR T ( Low ) /STOP (Hi gh) Signa l ( C ommon)

- Dr y C ontacts O ther Side of P i l ot Sens i ng R e la y

(PSR) - Dry C ontacts O ne Si de of O K-To-Move Sig nal

(Refer to Sec tion 4.07) O ther Side of O K- T o -Move Si gna l

(Refer to Sec tion 4.07)

a. Remove the Left Side Panel from the Power

Supply as viewed from the front of the unit.

b. Locate the internal terminal strip (TB2) near

the heatsink.

c. Feed the CNC cable through the small strain

relief at the rear of the Power Supply.

d. Connect the CNC cable to the terminal strip

(TB) per the following chart:

NOTES

Connections to TB2 positions 1 through 4 are activated with a switch or contact closure.

If Remote Control is not used the Enable Signal circuit must be closed.

Connections TB2-7 and TB2-8 are normally open (NO) contacts.

Connections TB2-9 and TB2-10 are selectable for normally open (NO) contacts or 24 VAC.

e. Secure the CNC cable by tightening the two

screws on the strain relief.

f. Reinstall the Left Side Panel.

INSTALLA TION PROCEDURES 3-14 Manual 0-2601

Page 33

C. Optional SC-10 or SC11 Standoff Control

Ar/H

INPUT

PLASMA INPUT

PLASMA GAS

PLASMA INPUT

Cable

For mechanized systems, the Standoff Control automatically finds height and maintains torch standoff with a high speed torch lifter motor. The unit consists of a remote operator's control, torch lifter motor, and all cables required for installation. It is ordered and shipped separately. Refer to the SC-10 or SC11 Standoff Control Instruction Manual for more information.

Depending on the Standoff Control to be used connect the cable per one of the following:

• Standoff Control SC10 used with the Remote Control RC6010

Connect the internal ribbon cable to the Remote Control RC6010. Refer to the Standoff Control Instruction Manual for more details.

• Standoff SC11 only

1. Connect the high flow water shield interface cable to the receptacle marked HIGH FLOW W A TER SHIELD on the rear panel of the Power Supply . The receptacle is 115V AC.

A-01507

OUTPUT

TO CONTROL MODULE

PLASMA GAS

AIR

PLASMA

INPUT

High Flow Water Shield

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

Connector (J63)

Rotate Clockwis

To Lock

The standoff control remote cable connects to the receptacle marked REMOTE CONTROL (J15) on the rear panel of the Power Supply.

A-01506

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

Ar/H

PLASMA

INPUT

REMOTE CONTRO

Connector (J15)

Cable From

Standoff Control

High Flow Water Shield

Interface Cable

Figure 3-24 High Flow Water Shield Interface

Connection

2. Rotate the plug clockwise to lock the plug to the receptacle.

3. To shut off the high flow water shield r emove the interface cable or disconnect power to the High Flow W ater Shield (HFWS) accessory .

E. Optional Gas Control Connection

The optional GS3000 Gas Control allows the connection of various multiple plasma and secondary gases to be connected to the Power Supply . The proper plasma and secondary gas is selected with switches on the front panel of the Gas Control Option.

NOTE

The secondary selection switch on the front panel of the Power Supply must always be set to GAS for all secondary gases when the Gas Control Option is installed.

Figure 3-23 Standoff Control Interface Connection

D. Optional High-Flow Water Shield Cable

The High Flow W ater Shield surrounds the main cutting arc with a spray of water to reduce arc glare, noise, and fumes. Use of the water shield device reduces the system’s overall cutting capacity . Refer to the High-Flow Water Shield Instruction Manual for more information.

1. Connect the Gas Control control cable to the connector marked GAS CONTROL (J63) on the rear panel of the Power Supply.

2. Connect the other end of the cable to the Gas Control Option rear panel.

NOTE

Refer to the Gas Control Instruction Manual 02477 for more information on the GS3000 Gas Control Option.

Manual 0-2601 3-15 INSTALLA TION PROCEDURES

Page 34

A-01508

OUTPUT

CONTROL

MODULE

PLASMA GAS

AIR

PLASMA

INPUT

GAS CONTROL

PLASMA

INPUT

Connector (J63)

PLASMA

INPUT

Ar/H

PLASMA

INPUT

Cable From

Gas Select Optio

Figure 3-25 Optional Gas Control Interface Connection

3.13 Master/Slave Parallel Cable Connection

Approach From Front Or Re

Do Not Lift From Sides

The interface between the Master and Slave Power Supply is made through the Parallel Cable. Connect one end of the cable to the rear of the Master Power Supply at J54. The other end connects to the rear of the Slave Power Supply at J15.

3.14 Lifting Options

WARNING

Do not lift a power supply equipped with a cylinder rack running gear .

The recommended method for lifting the power supply is to use a forklift as follows:

1. Approach from the front or rear of the unit.

2. Place the forks between the rear wheels or the front casters.

3. Center the forks under the unit and carefully check for proper balance before lifting.

A-01499

Figure 3-26 Lifting the Power Supply

3.15 Pilot Resistor Adjustment

This Sub-Section applies only to the following Master and Slave Power Supplies:

• Merlin 6000 Master Power Supplies with the revision letter 'C' or later on the data tag

• Slave Power Supplies with the revision letter 'E' or later on the data tag

• Slave Power Supplies that have been retrofitted with Pilot Resistors

Master and Slave Power Supplies, as noted above, contain adjustable pilot resistor circuits. For output current below 250A, only the pilot circuit in the Master Power Supply is activated. For output current above 250A the Master and Slave Power Supply pilot circuits are activated.

INSTALLA TION PROCEDURES 3-16 Manual 0-2601

Page 35

Master and Slave Power Supply pilot resistors are initially set

at the factory and may need to be adjusted to the customer's input power (see Notes).

NOTES

The instructions in this Sub-Section apply to the Master Power Supply only.

To adjust the Slave Power Supply pilot resistor, refer to the Manual supplied with the Slave Power Supply.

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

The pilot current consists of two parts:

1) Minimum or “background” level

Pilot Resistor

R22

Wire

96A

Pilot Resistor

R21

Temp

Switch

Clamp

Wire #150

Wire #99

Pilot Resistor

R16

Wire

#74

Clamp

Wir

#96

A-01853

2) Pulse or peak level

Figure 4-4 Location Of Pilot Resistors (Viewed From

The background level has to be high enough that the pi-

The Front Of Power Supply)

lot will not sputter or go out, but not too high to cause excessive wear of the torch consumables. Adding pulses of current on top of the background current allows gr eater arc transfer distance without increasing the torch part wear. The amount of pilot current is determined by the value of the pilot resistors and the open circuit voltage which varies with the input line voltage. Both the Master and the Slave Power Supplies should be adjusted the same. Wire #99 tap sets the background level and wire #150 tap sets the pulse level. Set the pilot background and pulse levels as follows:

1. Remove the left and right side panels of the Master Power Supply .

2. Locate and identify the pilot resistors (R16, R21 and R22) which are on a bracket in front of the fan.

3. Check the busbar configuration on the input terminal board to determine which range the power transformer is set for .

4. Measure the level of the AC line voltage being supplied to the Power Supply .

5. To determine the r ecommended pilot resistor setting use the following table as follows:

a. Find the voltage that is nearest what was measured

above.

b. Note the ohms value for the voltage. Example: If

the measured voltage is 360, then the pilot resistor value is 6 ohms.

NOTE

V oltages that ar e fr om 410 to 420V requir e values from 8.5 or 9 to 4.5 ohms. If the voltage is near one of these points it is best to set for the lower ohms value.

Manual 0-2601 3-17 INSTALLA TION PROCEDURES

Page 36

The reason is because within each range the Power

Supply will automatically select a high or low tap on the transformer secondary. This is based on the input AC line voltage at the time the Power Supply is turned ON. If the line voltage is near one of these points the voltage might measure, for example, 410 VAC and the pilot resistor setting should be 9 ohms to have a good pilot. The next time the system is turned ON, the input AC line voltage may have gone up to 420V AC causing the pilot to sputter because 420V AC requires setting of 4.5 ohms.

Pilot Resistor Setting vs. Input Line Voltage

Inp u t (VAC) Ohms

340 5 350 5.5 360 6 370 6.75 380 7.25 390 8 400 8.5 410 9 420 4.5 430 5 440 5.5 450 6 460 6.5 470 7 480 7.5 490 8 500 8.5 510 9

6 . Wires are attached to the pilot resistors with metal

clamps or taps. Locate and loosen the screw that secures the wire #99 tap on resistor R16. Determine, from the Figure below, the correct position for the tap on R16 and tighten the screw.

Example:

5.0 ohms

4.4 ohms

1.9" (44 mm)

8.5 ohms

9.0 ohms

3.7" (90 mm)

Wire #74

A-01852

At End

Wire #96

Wire #150

Tap

2.5" (63 mm)

Wire #99

Tap

Wire

96A

At End

9.0 ohms

At End

4.4 ohms

8.0 ohms

8.5 ohms

12.8" (305 mm)

5.5 ohms

5.0 ohms

13.7" (344 mm)

7.5 ohms

7.0 ohms

6.5 ohms

9.6" (242 mm)

11.2" (279 mm)

12.3" (311 mm)

8.1" (203 mm)

R16 (4.5 ohms)

R22 (2.2 ohms)

6.0 ohms

6.5 ohms

7.0 ohms

9.4" (237 mm)

10.8" (255 mm)

R21 (2.2 ohms)

Temp Switch

Pulser

6.0 ohms

5.5 ohms

6.5" (164 mm)

5.0" (127 mm)

7.5 ohms

8.0 ohms

8.0" (203 mm)

6.5" (164 mm)

150

3.4" (87 mm)

5.1" (127 mm)

Figure 4-5 Resistance Value Diagram

7 . The pilot pulse value is set by positioning the wire

#150 tap on resistor R22. Locate and loosen the wire #150 tap. From the above Figure find the ohms value that corresponds to the value that the wire #99 tap was set to. Measure distance indicated from the right side of R22, where wire #96 attaches and secure the wire #150 tap there.

NOTE

The ohm value shown for the wire #150 tap does not represent the value of the R22 resistor but instead corresponds to the total resistance of R16, R22 and R22 set by the wire #99 tap.

8. Test the pilot, if it still sputters move the wire #99 tap to the right, toward wire #96, 1 inch (25.4 mm) at a time until the pilot no longer sputters.

9. Once there is a good steady pilot, test for the desired transfer height. If the transfer height is not high enough, between 3/8 inch (9.5 mm) to 1/2 inch (12.7 mm), move the wire #150 tap to the left on R22, 1 inch (25.4 mm) at a time, until the desired height is obtained.

To set for 6 ohms measure 5” from the right side of R16, where wire # 96 attaches, and secure the #99 tap at that position.

INSTALLA TION PROCEDURES 3-18 Manual 0-2601

Page 37

SECTION 4:

OPERATION

4.01 Introduction

A. Lower Front Panel

This Section provides a description of the Master Power Supply operating controls and procedures. Identification of the Front and Rear Panel Controls is followed by operating procedures.

4.02 Functional Overview

The system is a high performance 50 to 150 amp plasma cutting system which can cut most metals from gauge thickness up to two inches. With a quick change of torch parts, power supply can also be used for plasma arc gouging. In its simplest form, a system consists of one Master Power Supply, one Arc Starter Box and one Maximizer 300 Liquid Cooled Torch and leads connected.

With the addition of a Slave Power Supply or a second Master Power Supply the system becomes a 100 to 300 amp plasma cutting system which can cut most metals from gauge thickness up to three inches.

4.03 Front and Rear Panel Descriptions

This sub-section provides specific functional descriptions of the Power Supply front and rear panel operating controls, indicators and connections. The Power Supply has three main front panels and one rear panel. Each panel is described in this sub-section as to the functions of the connections, switches, and indicators.

Gauge Front Panel

Control Front Panel

A-01501

Figure 4-2 Lower Front Panel

1. Work Cable Strain Relief

Strain relief to secure the factory installed work cable with ring lug to the Power Supply.

2. Torch Supply Leads Boot

NOTE

The Torch cannot be connected directly to the TORCH connector as the High Frequency (HF) is generated in the Arc Starter Box.

Connection inside at the bulkhead for the T orch Supply Leads Assembly. The connections supply all the required signals, gases, and coolant to the torch Arc Control Box.

3. Optional Meters

a. Upper Meter - Hour and Minutes

The upper meter indicates the total number of

Lower Front Panel

4. Pilot Lead Strain Relief

A-01500

hours and minutes that the main cutting arc has been on. The meter will display a maximum of 99999-59 (hours-minutes). The meter can be reset by the use of the meter pushbutton.

b. Lower Meter - Counter

The lower meter counts the number of times that the cutting arc has been started. The meter will display a maximum of 99999999 starts. The meter can be reset by the use of the meter pushbutton.

Strain relief to secure the pilot lead to the Power Supply after it is installed.

Figure 4-1 Main Front Panels

Manual 0-2601 4-1 OPERA TION

Page 38

5. Power Lead Strain Relief

300

100

200

DUAL

150

250

5. TEMP Indicator

Strain relief to secure the power lead to the Power Supply after it is installed.

6. Secondary Water Flowmeter/Regulator

Used to adjust and monitor the flow of the secondary water from 0 - 10 gph (0 - 44 lph).

B. Control Front Panel

NOTE

This panel is the access cover to the Logic Control PC Board.

1. ON/OFF Switch

ON position activates all system control circuits when remote or CNC enable is ON.

OFF position deactivates control circuits.

2. RUN/SET/PURGE Switch

RUN position is used for torch operation. SET position is used for setting gas pressures. PURGE position is for purging the plasma gas line.

3. Current Control (Dual Scale)

Selects output current for the application on various materials and thicknesses. Current control is disabled when Remote Control is used.

Current is adjustable for the application as follows:

Green light indicates proper operating temperature. Red light indicates overheating. Unit must be allowed to cool.

6. GAS Indicator

In RUN or SET position, yellow light indicates gas pressure switches are satisfied when gas is flowing to the torch. Light goes out in PURGE mode. RUN/ SET/PURGE switch must be in the RUN position for proper cutting operation.

7. COOLANT PRES. (Coolant Pressure) Indicator

Yellow light indicates adequate coolant flow.

8. COOLANT COND. (Coolant Conductivity) Indicator)

Yellow light indicates proper coolant conductivity. Light out indicates excessive coolant conductivity (resistivity less than 0.1 megaohms per centimeter). Replace coolant and de-ionizer cartridge.

9. DC Indicator

Y ellow light indicates voltage is present at the power supply output and cutting current is available.

10. PILOT Indicator

Y ellow light indicates pilot arc contactor closure. Light goes out when cutting arc is established and comes back on if cutting arc is interrupted. Refer to Section

4.07-A and -B, Auto Restart Function.

• 50 to 150 amps for single power supply

C. Gauge Front Panel

• 100 to 300 amps for dual power supplies

COOLANT

PRES.

COND.

Figure 4-4 Upper Gauge Panel

PILOT

1. Secondary Pressure Control

Adjusts secondary gas pressure. Pull knob out and

A-01502

turn clockwise to increase secondary pressure to desired level.

1 2

OFF

AC TEMP

5 6

GAS

RUN

PURGE

SET

150

100

200

100

SINGLE

DUAL

AMPS

150

300

125

250

Figure 4-3 Front Control Panel

2. Secondary Pressure Gauge

4. AC Power Indicator

Green light indicates AC power is being supplied to the system when the ON/OFF switch is in ON position.

Displays secondary pressure from 0 - 100 psi (0 - 6.9 bar).

3. Secondary Mode Selector

Selects secondary mode to gas, oxygen (no secondary), or water. This mode selector is disabled when

OPERA TION 4-2 Manual 0-2601

using the Remote Gas Control Option (GC 3000).

Page 39

NOTE

6. Coolant Level Indicator

This switch must be in the gas (cylinder symbol) mode for all secondary gases when the Gas Control Option is installed.

4. Coolant Pressure Gauge

Displays coolant pressure from 0 - 160 psi (0 - 11.0 bar). Normal operation is 100 - 120 psi (6.9 - 8.3 bar)

5. Plasma Pressure Gauge

Displays plasma gas pressure from 0 - 100 psi (0 - 6.9 bar).

6. Plasma Pressure Control

Adjusts plasma gas pressure. Pull knob out and turn clockwise to increase plasma pressure to desir ed level.

D. Rear Panel

1. Fan Assembly

Fan used to move the air across the internal components for cooling purposes.

2. SECONDARY Gas Input Fitting

1/4 NPT female gas fitting used to supply the secondary gas to the system.

A slot pr ovided in the rear panel allows the operator a visual check of the coolant level. The coolant should be above the indicator mark on the slot.

3. PLASMA Gas Input Fitting

1/4 NPT female gas fitting used to supply the plasma gas to the system.

4. SECONDARY W ATER Fitting

1/4 NPT female fitting used for connection of tap water to the Power Supply. The water can be used as a secondary gas for the torch when the front panel SECONDARY switch is in the W A TER position or the Gas Control Option is installed.

5. Coolant Reservoir and Filler Cap

The coolant reservoir is located under the top panel cover . The coolant reservoir supplies the system with coolant to cool the torch parts during operation. The maximum capacity of the reservoir is two gallons of coolant.

Inside the reservoir , in the filler neck, is a basket and a deionizer bag. The bag removes charged particles from the coolant after it is returned to the reservoir. If the coolant in the reservoir breaks down because of these charged particles then a sensor on the reservoir will cause the COOLANT COND indicator to go OFF .

A-01509

Figure 4-5 Power Supply Rear Panel

7. Coolant Filter Assembly

The Coolant Filter Assembly on the rear panel is used to filter the coolant as it returns to the reservoir. The filter is a screen type which is easily cleaned or replaced.

8. Primary Input Power Cable Strain Relief

A strain relief supplied to secure the customer supplied primary input power cable to the power supply . The input AC power cable is routed through the strain relief and is connected to the EMC Filter PC Board inside the unit.

Manual 0-2601 4-3 OPERA TION

Page 40

9. Remote Control and CNC Interface Connector

OUTPUTOUTPUT

AIRAIR

PLASMA

INPUT

PLASMA

INPUT

PLASMA

INPUT

PLASMA GAS

Ar/HAr/H

PLASMA

INPUT

A-01011

Plasma Gas

Manifold

NOTE

For use with Remote Control RC6010 or Standoff Control SC11. Refer to the Remote Control (RC6010) Instruction Manual 0-2478 or the Standoff Control (SC11) Instruction Manual 02556 for more information.

REMOTE CONTROL connector (J15) used to interface remote controls with mechanized systems. The connector can be used to interface the Power Supply with one of the following:

• Optional Remote Control (RC 6010) which allows the operator to control all system functions from a remote location.

• Optional SC-11 Standoff Control or other standard control (CNC) which allows the operator to control various functions of the mechanized system from a remote location.

10. High Flow W ater Shield

Output connector to allow the use of the Optional High Flow Water Shield on the system.

11. CNC Cable Strain Relief

Used to secure a CNC cable to the Power Supply when the CNC cable does not have a connector installed. The CNC cable is fed through the strain relief and connected to an internal terminal strip (TB2).

12. Optional Gas Selection Interface Connector

Connector used to interface the Power Supply to the Optional Gas Control (GC3000) Accessory. The Gas Control Accessory connects to the connector marked GAS CONTROL (J63).

13. Optional PLASMA GAS Selection

Optional panel with multiple ports (manifolds) for connection to four plasma gases. The gas manifolds are controlled by the Gas Control Accessory. Each fitting is a 1/4 NPT type.

Figure 4-6 Optional PLASMA Gas Selection

14. Optional Gas Secondary (N2) Input Fitting

Optional 1/4 NPT female gas fitting used to supply the secondary gas (N2) to the system.

15. Optional Gas Secondary (OTHER) Input Fitting

Optional 1/4 NPT female gas fitting used to supply the secondary gas (OTHER) to the system.

16. Parallel Cable Connector

Connector J54 is used to interface the Master Power Supply to the Slave Power Supply.

4.04 Operating Unit Without Gas Control Option

NOTE

This Subsection describes the normal operation of the system without the Gas Control Option installed. Refer to Section 4.05 for systems with the Gas Control Option installed.

This procedure should be followed at the beginning of each shift:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and leads assemblies or adding coolant.

OPERA TION 4-4 Manual 0-2601

Page 41

A. Coolant Level

NOTE

Check the coolant level at the coolant reservoir at the rear of the Power Supply . If the coolant is down fr om the top of the reservoir more than 2 inches (50mm) add coolant.

B. Deionizer Bag

Check the condition of the deionizer bag in the reservoir basket. If the bag is a yellowish brown (straw color) then replace the bag.

C. Torch Parts

Check the torch for proper assembly. Install proper torch parts for the application (refer to Maximizer 300 Torch Instruction Manual, Catalog No. 0-2573).

D. Input Power

Check the power source for proper input voltage. Make sure that Power Supply is set for the proper voltage. Close main disconnect switch or plug unit in to supply primary power to the system.

E. Plasma Gas Supply

Connect desired plasma gas. Make sure gas sources meet requirements (refer to appr opriate T orch Instruction manual). Check connections and turn plasma gas supply on.

F. Secondary Gas Supply

Connect desired secondary gas. Make sure gas sources meet requirements (r efer to T orch Instruction Manual). Check connections and turn secondary supplies on.

Select the desired secondary gas per the following:

1. If gas secondary is desired, set secondary mode selector switch to gas cylinder symbol position.

Refer to the Torch Instruction Manual for proper secondary gas selection.

G. Plasma Gas Purge

Enable the system by doing one of the following:

• Turn the Enable switch to ON at the front panel of the RC6010 Remote Control

• Signal supplied through the CNC control cable

• Signal supplied from a customer supplied switch connected to the CNC terminal block (TB2) inside the Power Supply

Move the Power Supply ON/OFF switch to the ON position (see note). The Enable Signal must be turned ON either by a switch or contact closure.

NOTE

In systems using more than one Power Supply both front panel ON/OFF switches must be ON.

An automatic gas purge will remove any condensation that may have accumulated in the torch and leads while the system was shut down. The gas purge duration is 40 seconds. After the purge is complete, if the RUN/SET/PURGE switch is in SET position, gases will flow. If the switch is in PURGE position only plasma gas will flow. If the switch is in RUN position there will be no gas flow.

NOTE

RUN/SET/PURGE may be selected at the RC6010 Remote Control. Both switches must be in the RUN position for normal operation.

H. Current Output Level

Single Power Supply System:

NOTES

Tap water should only be used for secondary gas on machine torches.

To use tap water there must be a Water Regulator (Catalog No. 8-6118) installed between the water source and the Power Supply.

2. If tap water secondary is desired, set secondary mode selector switch to water tap symbol position and connect tap water to the Power Supply rear panel at the secondary water connection. It may take two or three minutes for the water to start flowing out the front of the torch.

3. If no secondary gas is desired, set secondary selector switch to O2 position.

Manual 0-2601 4-5 OPERA TION

I. Pressure Settings

Select the desired current output level from 50 to 150 amps.

Dual Power Supply System:

Select the desired current output level from 100 to 300 amps.

Move the RUN/SET/PURGE switch to SET position. Set plasma and secondary pressures (refer to Maximizer 300 Torch Instruction Manual 0-2573).

Page 42

J. Additional Gas Purging

D. Input Power

If additional purging of the plasma gas line is necessary , move the RUN/SET/PURGE switch to PURGE position. In PURGE mode, the GAS indicator will be OFF because only plasma gas flows and the secondary gas flow switch is not satisfied.

K. Ready for Operation

Return the RUN/SET/PURGE switch to RUN position.

The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram of the Sequence Of Operation.

4.05 Operating Unit With Gas Control Option

NOTE

This Subsection describes the normal operation of the system with the Gas Control Option installed. Refer to Section 4.04 for systems without the Gas Control Option installed.

This procedure should be followed at the beginning of each shift:

WARNING

Check the power source for proper input voltage. Make sure that Power Supply is set for the proper voltage. Close main disconnect switch or plug unit in to supply primary power to the system.

E. Plasma Gas Supply

NOTE

Refer to the Gas Control Option Instruction Manual 0-2477 for more information.

Connect the desired plasma gases to the gas manifold at the rear panel of the Power Supply. Make sure plasma gas sources meet requir ements (r efer to Torch Instruction Manual). Check connections and turn plasma gas supplies on.

Select the desired plasma gas at the Gas Control Option front panel PLASMA gas switch.

F. Secondary Gas Supply

NOTE

Refer to the Gas Control Option Instruction Manual 0-2477 for more information.

Connect the desired secondary gases to the gas connections at the rear of the Power Supply. Make sure gas sources meet requirements (r efer to T orch Instruction Manual). Check connections and turn secondary supplies on.

NOTE

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.

A. Coolant Level

Check the coolant level at the coolant reservoir at the rear of the Power Supply . If the coolant is down fr om the top of the reservoir more than 2 inches (50mm) add coolant.

B. Deionizer Bag

Check the condition of the deionizer bag in the reservoir basket. If the bag is a yellowish brown (straw color) then replace the bag.

C. Torch Parts

Check the torch for proper assembly. Install proper torch parts for the application (refer to Maximizer 300 Torch Instruction Manual, Catalog No. 0-2573).

For all secondary gases set the Power Supply front panel gas selector mode switch to the gas cylinder symbol position.

Select the desired secondary gas at the Gas Control Option front panel SECONDARY gas switch.

NOTE

To use tap water there must be a Water Regulator (Catalog No. 8-6118) installed between the water source and the Gas Control Option

When using water as the secondary it may take two or three minutes for the water to start flowing out the front of the torch.

NOTE

Refer to the Torch Instruction Manual for proper secondary gas selection.

G. Plasma Gas Purge

Enable the system by doing one of the following:

OPERA TION 4-6 Manual 0-2601

Page 43

• Turn the Enable switch to ON at the front panel of the RC6010 Remote Control

• Signal supplied through the CNC control cable

K. Ready for Operation

Return the RUN/SET/PURGE switch to RUN position.

• Signal supplied from a customer supplied switch connected to the CNC terminal block (TB2) inside the Power Supply

Move the Power Supply ON/OFF switch to the ON position (see note). The Enable Signal must be turned ON either by a switch or contact closure.

NOTE

In systems using more than one Power Supply both front panel ON/OFF switches must be ON.

NOTE

RUN/SET/PURGE may be selected at the RC6010 Remote Control. Both switches must be in the RUN position for normal operation.

H. Current Output Level

Single Power Supply System:

Select the desired current output level from 50 to 150 amps.

Dual Power Supply System:

Select the desired current output level from 100 to 300 amps.

I. Pressure Settings

Move the RUN/SET/PURGE switch to SET position. Set plasma and secondary pressures (refer to Maximizer 300 Torch Instruction Manual 0-2573).

J. Additional Gas Purging

NOTE

Additional gas purging should be done when switching to a new plasma gas. This will make sure that the old gas in the lines has been purged.

The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram of the Sequence Of Operation.

4.06 System Operation

NOTE

Frequently review the safety precautions at the fr ont of this manual.

This section contains operating information which is specific to the power supply. Detailed operating information for torches can be found in the appropriate Torch Instruction Manual.

WARNINGS

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.

It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.

A. Operational Suggestions

The suggestions below should be followed in all cutting and gouging operations:

1. Wait five minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run to dissipate operating heat from the power supply.

2. For maximum parts life, do not operate the pilot arc any longer than necessary.

3. Use care in handling torch leads and protect them fr om damage.

4. In continuous cutting applications using CO2, it is often necessary to manifold four to six cylinders together to maintain adequate flow at operating pressures.

Manual 0-2601 4-7 OPERA TION

Page 44

B. Using Corner Slowdown for Mechanized

PLASMA ENABLE

TRAVEL

SPEED

Cutting

NOTE

Corner Slowdown (CSD) is available only if the Remote Control RC6010 is used.

The corner slowdown (CSD) function provides a reduction in output current which corresponds with the reduced travel speed of a mechanized torch as it changes direction at a sharp corner. When activated (by CNC or other control device) corner slowdown eliminates excessive metal removal and bottom dross in corners.

Normally open (NO) contacts (supplied by the control device) close when the torch travel speed decreases through a corner. When the contacts close, power supply output drops to a preset current level.

C. Setting CSD Output

NOTE

Corner Slowdown (CSD) is set at the RC6010 Remote Control.

D. Fold Back Feature

Should the torch tip contact the workpiece the output current will immediately drop to 50 amps (100 amps with Slave Power Supply connected) to minimize potential tip damage.

NOTE

The torch is not designed for drag cutting.

4.07 Optional Power Supply

Settings

NOTE

The adjustments in this sub-section should be set in the Master Power Supply ONL Y.

The following functions can be used to tailor a system for special application requirements or unique user preferences. These functions are controlled by DIP switches located on the Logic Control PC board in the power supply. Locate the Logic Control PC Board under the front panel access cover and set the functions as required.

A. Auto-Restart Function (SW1)

Front Panel of

RC6010 Remote Control

START

PLASMA ENABLE

OUTPUT AMPS

REMOTE POWER SUPPLY CONTROL

CSD (%)

Adjustment

25 75

100

CSD

(%)

125+ IPM

0-125 IPM

TRAVEL SPEED

RUN PURGE SET

A-00997

Figure 4-7 Corner Slowdown (CSD) Adjustment

The corner slowdown adjustment is located on the front panel of the RC6010 Remote Control. The control sets corner slowdown output to any current level from the minimum (50 amps) to the maximum (150 amps) level of the system. The corner slowdown output level is a percentage of the main output level. T ypically the CSD output level should not be set lower than 70% of the main current level to insure full arc penetration during corner slowdown.

If the cutting machine controller activates CSD (three decimals on the display) during pierce starts it may not be desirable to set CSD below 100% as starting current will be reduced requiring longer pierce times.

NOTE

For electrical connections, refer to Appendix 6, CNC Interface Schematic

OFF

1 2

SW1

A-00991

Logic PC Board

Figure 4-8 Auto-Restart Enable Switch SW1

Location

Auto-restart provides an immediate pilot arc r estart during post-flow if the torch is brought within range of the workpiece. Auto-restart can be switched off so that the torch must be reactivated (via tor ch switch or control device) to restart the pilot arc each time the main arc is interrupted. This setting may be use-

OPERA TION 4-8 Manual 0-2601

Page 45

ful if the system is used to replace other units which do not have auto-restart, or for use with motion control devices. In many applications, torch parts life may be improved by disabling auto-restart to reduce excessive pilot arc time.

NOTE

Either pole set to 1 (on) disables auto-restart function.

restarts. In some shape-cutting applications, it may not be desirable to immediately restart the main arc after the torch passes beyond the desired cutting line (or between cuts).

NOTE

Either pole set to 1 (on) sets delayed auto-restart function.

Auto-Restart

Function

Enabled 0 (Off) 0 (Off)

Disabled 0 (Off) 1 (On)

Disabled 1 (On) 0 (Off)

Disabled * 1 (On) 1 (On)

SW 1-1

Pos ition

* = F acto ry Set ting

B. Auto-Restart Mode (SW2)

OFF

1 2

SW 1-2

Pos ition

SW2

Auto -Re sta r t

Mod e

Normal * 0 (Off) 0 (Off)

De laye d 0 (O f f) 1 (On )

Delayed 1 (On) 0 (Off) Delayed 1 (On) 1 (On)

SW 2-1

Pos itio n

* = Fact ory Setting

C. Gas Pre-Flow Delay (SW3)

SW3

OFF

1 2

SW 2-2

Pos itio n

A-00992

A-00993

Logic PC Board

Figure 4-10 Gas Pre-Flow Delay Switch SW3

Figure 4-9 Auto-Restart Mode Switch SW2 Location

Normal mode provides an immediate pilot restart whenever the main arc is interrupted and the AutoRestart switch SW1 is set to ENABLE. Delayed mode provides a gas pre-flow each time before the pilot ar c

The pre-flow delay allows time for gases to flow to the torch when the torch is activated. Pre-flow is immediately followed by pilot arc initiation Pre-flow durations are factory set but extended torch leads may

Location

require longer pre-flow durations.

Manual 0-2601 4-9 OPERA TION

Page 46

NOTE

Pre-flow timing depends on the Logic PC Board installed in the Power Supply.

Refer to one of the following descriptions for the Logic PC Board installed in the Power Supply:

• Power Supply Unit Rev AF or Earlier Using Logic PC Board 19x1247

Pre-flow is factory-set at 2 seconds, but can be reset to 4, 7, or 10 seconds as desired.

Logic PC Board 19x1247

Pre-Flow Time

(Seconds)

SW3-1

Position

SW3-2

Position

2 * 0 (Off) 0 (Off)

4 0 (Off) 1 (On)

7 1 (On) 0 (Off)

10 1 (On) 1 (On)

* = F a cto ry Se tti n g

D. Gas Post-Flow Delay (SW4)

Logic PC Board

OFF

SW4

A-00994

1 2

Figure 4-11 Gas Post-Flow Delay Switch SW4

Location

• Power Supply Unit Rev AG or Later Using Logic PC Board 19x1360

Pre-flow is factory-set at 2 seconds, but can be reset to 0.5, 3, or 4 seconds as desired.

Logic PC Board 19x1360

Pre-Flow Time

(Seconds)

SW3-1

Position

SW3-2

Position

0.5 0 (Off) 0 (Off)

2 * 0 (Off) 1 (On)

3 1 (On) 0 (Off)

4 1 (On) 1 (On)

* = F a cto ry Se tti n g

Post-flow delay allows gases to flow after the main cutting arc is interrupted. Post-flow is factory-set at 10 seconds, but can be reset to 5, 20, or 40 seconds.

Po s t-F lo w T i m e

(Seconds)

5 0 (Off ) 1 (O n )

10 * 0 (O ff) 0 (O ff)

20 1 (On) 0 (Off) 40 1 (On) 1 (On )

SW 4-1

Position

* = Factory Setting

Position

SW 4-2

OPERA TION 4-10 Manual 0-2601

Page 47

E. OK-To-Move Selection (SW5)

TB2-7

Logic

PC Board

SW5

A-00995

Figure 4-12 OK-To-Move Selection Switch SW5

Location

The OK-To-Move Selection Switch (SW5) selects either contact closure or 24 VAC for the OK-To-Move signal (motion start).

OK-To-Move Selecti on SW5

Logic PCB

OK-To-Move

SW5

PSR

J2-14

J2-16

J2-18

J2-19

TB2-8

TB2-9

J15-10

TB2-10

J15-11

24VAC

OK-To-Move

At Pilot

Initiation

A-01009

Figure 4-13 OK-To-Move Using PSR

An external voltage source up to 120V may be connected in series with the Pilot Sensing Relay (PSR) or OK-To-Move. This also works with the RC6010, refer to RC6010 Manual for 24 VAC or external voltage. RC6010 must have only contact closure from the Power Supply.

TB2-7

External Voltage

PSR

TB2-8

Source Alternate

Positions

Contact Closure * UP

24 Vac DOWN

* = F a cto ry Se tti n g

NOTE

Switch SW5 must be in the UP position when using Remote Control RC6010 or Standoff Control SC11.

T o use the contact closure for the OK-To-Move signal the switch should be in the up position (factory setting). To use 24 VAC for the OK-To-Move signal the switch should be in the down position.

T o get a motion start signal when starting off the edge of the workpiece, not a pierce start, jumper TB2-8 to TB2-9 and TB2-7 to TB2-10 to give an OK-To-Move contact closure when the pilot starts via pilot sensing relay (PSR). The switch, SW5, must be in the contact closure (up) position or the 24 VAC will be shorted out and blow the internal fuse (F3).

TB2-9

J15-10

TB2-10

J15-11

A-01010

Figure 4-14 OK-To-Move Using External Supply

Manual 0-2601 4-11 OPERATION

Page 48

OPERA TION 4-12 Manual 0-2601

Page 49

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.

For major troubleshooting and parts replacement procedures refer to the Master Power Supply Service Manual 0-2602.

5.02 General Maintenance

A. Routine Maintenance

NOTE

residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before re-installing in the Coolant Filter Assembly.

Coolant Filter Assembly

Refer to Appendix 12 for a recommended maintenance schedule for water cooled plasma cutting systems.

Routine maintenance for the Power Supply should include an occasional thorough cleaning and inspection. The frequency depends on the usage and the operating environment.

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

Remove both Side Panels of the Power Supply and blow out any accumulated dirt and dust with compressed air. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.

While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected.

B. Coolant Filter Assembly (Rear Panel)

The rear panel filter screen should be cleaned periodically. Remove the filter screen by unscrewing the filter holder from the Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soap

Filter Screen

A-01510

Filter Holder

Figure 5-1 Coolant Filter Assembly (Rear Panel)

C. In-Line Filter Assembly

The in-line filter screen should be cleaned periodically. T o gain access to the In-Line Filter Assembly remove the Left Side Panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing the filter holder from the In-Line Filter Assembly. Clean the filter screen by rinsing with hot soapy water . Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before re-installing in the In-Line Filter Assembly.

D. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50mm) from the top of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity LED on the front panel must be ON for normal operation. If the LED is OFF then drain the old coolant from the Power

Manual 0-2601 5-1 CUSTOMER/OPERATOR SER VICE

Page 50

Supply and torch leads and replace with new coolant. Check the condition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag.

E. Draining Coolant

Remove the old coolant from the Power Supply reservoir per the following procedure:

5.03 Common Operating Faults

Listed below are common cutting problems followed by probable causes of each. If the problems are caused by a torch problem, refer to the appropriate Torch Manual.

1. Insufficient Penetration

a. Cutting speed too high

1. Remove the right side and top panels from the Power Supply.

2. Disconnect the coolant hose input to the rear panel filter assembly.

3. Carefully lower the hose out the right side of the Power Supply and drain the coolant into an acceptable container .

CAUTION

Handle and dispose of the used coolant per recommended procedures.

A-01511

Coolant Hose

Connection

b. Current too low c. Metal too thick d. Worn or damaged tor ch parts

2. Main Arc Extinguishes

a. Cutting speed too low b. Standoff too high

3. Dross Formation

a. Improper gas pressure b. Improper cutting speed c. Worn or damaged torch parts.

4. Burned-Out Tips

a. Cutting current too high b. Damaged or loose cutting tip c. Tip in contact with work d. Heavy spatter e. Low plasma gas pressure

5. Poor Pilot Starting

a. High coolant conductivity

5.04 Troubleshooting

Figure 5-2 Draining Coolant From Reservoir

4. Reconnect the hose to the filter assembly.

5. Install new coolant and deionizer bag.

6. Reinstall the top and right side panels.

CUSTOMER/OPERATOR SER VICE 5-2 Man ual 0-2601

General

Troubleshooting and repairing the this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Page 51

Basic T roubleshooting

3. No primary power

This manual covers a basic level of troubleshooting that requires limited disassembly and measurements. It is helpful for solving many of the common problems that can arise with a plasma cutting system.

NOTE

For major troubleshooting and parts replacement procedures refer to Power Supply Service Manual 0-2602.

If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.

Follow all instructions as listed and complete each section of the troubleshooting guide in the order presented.

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 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.

Troubleshooting Specific Problems

A. Main disconnect fuse blows when primary power

is connected

a. Check for proper three-phase power at input

terminal board

4. Blown fuse (F2)

a. Check and replace fuse if necessary

5. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

C. AC power indicator ON; Fan and pump OFF

1. Remote Control or TB2 Enable switch not ON

a. Turn ON switch or enable signal at TB2

2. Primary power - missing phase

a. Check for proper three-phase power at input

terminal board

3. Blown fuse (F1 or F2)

a. Check and replace fuse if necessary

4. Power Supply Parallel Cable not installed and Fan in Slave Power Supply is not ON

a. Connect cable between Master and Slave

Power Supplies

5. Faulty power supply

a. Isolate and replace component(s) per Service

Manual

D. TEMP indicator ON (red).

1. Unit overheated

a. Clean radiator and check for obstruction

1. Voltage selection busbars connected incorrectly

a. Check and correct if necessary .

2. One leg of three-phase primary connected to chassis ground

a. Rewire input cable

3. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

B. AC Power Indicator on Front Panel not ON; Fan

and pump OFF

1. Customer’s main power disconnect is turned OFF

a. Turn ON main power disconnect

2. Front Panel ON/OFF switch is turned OFF

a. Turn ON front panel power switch

Manual 0-2601 5-3 CUSTOMER/OPERATOR SER VICE

b. Check for adequate air flow around unit

2. Faulty power supply

a. Isolate and replace component(s) per Service

Manual

E. GAS indicator OFF

1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary

a. Normal operation (purges plasma line only,

secondary flow switch is not satisfied)

2. Gas pressure set too low

a. Adjust pressure

3. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

Page 52

F. GAS indicator OFF, plasma and/or secondary gas

does not flow

1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary

a. Normal operation (purges plasma line only,

secondary does not flow)

2. Secondary mode set to O2

a. No secondary flow is normal operation in O2

mode (but GAS indicator should be ON)

3. Low plasma pressure

a. Check plasma pressure

4. Secondary supply turned OFF (or tank empty)

a. Check secondary supply

5. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

H. No coolant pressure at gauge; COOLANT Indica-

tor may be OFF or ON

I. COOLANT indicator flashing ON and OFF

1. Air in coolant lines

a. Run pump for ten minutes to purge air from

the coolant lines before using the system.

2. Coolant Level is low

a. Check for proper coolant level at rear panel

gauge

J. Coolant CONDUCTIVITY Indicator OFF

1. Coolant conductivity is excessive.

a. Drain and replace coolant. Also check the con-

dition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag.

2. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

K. Leaking torch connection

1. Loose torch connection

1. Coolant level is too low

a. Check coolant level in Coolant Reservoir and

add if necessary.

2. Clogged Coolant Filter Assembly (Rear Panel)

a. Remove screen from filter and clean or replace

as necessary.

3. Clogged In-Line Coolant Filter Assembly (Behind Side Panels)

a. Remove screen from filter and clean or replace

as necessary.

4. Plugged or damaged coolant hoses

a. Inspect all coolant hoses and clean or replace

as necessary.

5. Plugged or damaged torch head

a. Inspect all torch head parts and replace as nec-

essary.

6. Defective Coolant Flow Component(s)

a. Isolate and replace component(s) per Service

Manual.

a. Check connection making sure connector is

fully seated.

L. DC indicator OFF (after pre-flow); No main

contactor closure

1. RUN/SET/PURGE switch not set to RUN

a. Normal operation, set switch to RUN position

2. Faulty torch switch, remote control, or remote pendant

a. Isolate and replace component(s) per Service

Manual.

3. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

M. Weak or sputtering pilot; HF stays on during pilot

1. Plasma gas pressure too high

a. Adjust pressure

2. Low OCV (normal 290-350 vdc) caused by improper connection of voltage selection bus bars

a. Check input voltage connections

3. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

CUSTOMER/OPERATOR SER VICE 5-4 Man ual 0-2601

Page 53

N. No pilot; PILOT indicator ON; Strong spark

visible at spark gap points in Arc Starter Box

1. Faulty torch parts

a. Repair per Torch Manual

2. Faulty power supply

5.05 Basic Parts Replacement

NOTE

For more detailed Parts Replacement Procedures and Replacement Parts refer to Power Supply Service Manual 0-2602.

a. Isolate and replace component(s) per Service

Manual.

O. Pilot arc ON; No main arc transfer (torch brought

within range of work)

1. Work cable not connected

a. Connect work cable securely

2. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

P. System cuts at one-half expected current

1. Work cable not connected

a. Check work cable connection from Master

Power Supply. If using Slave Power Supply, work cable must also be connected.

2. Slave Power Supply not ON

a. Turn ON front panel ON/OFF power switch

3. Parallel Cable not connected

a. Install Parallel Cable between Master and Slave

Power Supplies

The parts replacement procedures described in this manual are for basic replacement of parts that requires limited disassembly of the Power Supply.

WARNING

Disconnect primary power from the source before disassembling the power supply.

A. Side Panel Removal

The replacement of the fuse and filter assemblies can be made through the left and right sides of the Power Supply. Remove the Right and Left Side Panels as follows:

1. Locate the removable Left and Right Side Panel of the Supply as viewed from the front of the unit.

Left Side Panel

Q. Slave Power Supply AC Power Indicator on Front

Panel not ON; Fan OFF

1. Customer’s main power disconnect is turned OFF

a. Turn ON main power disconnect

2. Front Panel ON/OFF switch is turned OFF

a. Turn ON front panel power switch

3. No primary power

a. Check for proper three-phase power at input

terminal board

4. Blown fuse (F2)

a. Check and replace fuse if necessary

5. Faulty power supply

a. Isolate and replace component(s) per Service

Manual.

Screws

(10 Places)

A-01535

Figure 5-3 Side Panel Screw Removal

Manual 0-2601 5-5 CUSTOMER/OPERATOR SER VICE

Page 54

2. Remove the ten screws that secure each side panel to the Power Supply.

3. Remove the side panels from the Power Supply .

4. Reinstall the panels by reversing the above steps.

B. Fuse Replacement

There are three fuses located on the Power Supply as follows:

• T wo fuses ar e located in the torch leads connection area under the hinged cover at the Front Panel. These fuses are in a typical fuse holder that requires removal of the fuse holder cap to replace the fuse.

• One fuse is located inside the Power Supply behind the Right Side Panel. The fuse is located above the Bias PC Board and to the right of the line filter.

Replace the fuse inside the Power Supply per the following:

1. Remove the Right Side Panel as described in paragraph “A” above.

2. Locate the internal fuse mounted above the Bias PC Board and to the right of the line filter near the center edge of the unit.

D. In-Line Filter Assembly Replacement

The In-Line Filter Assembly is located inside behind the Left Side Panel (viewed from the front of the unit). The filter is attached to the radiator inside of the Lower Front Panel.

1. Remove the Left Side Panel from the Power Supply per paragraph 'A' above.

2. Locate the In-Line Coolant Filter near the front of the unit.

3. Remove the two Coolant Hose connections to the In-Line Filter Assembly.

4. Clean the old thread sealer from the threads of the hoses and the fittings.

5. Apply a thin coating of liquid teflon thread sealer to the threads of the fittings.

6. Reconnect the two Coolant Hoses to the In-Line Filter Assembly making sure that the top hose goes to the Flow Switch Assembly. The bottom hose comes from the Radiator Assembly.

3. Remove the damaged Fuse for the snap type fuse holder.

4. Reinstall the replacement Fuse by reversing the above steps.

C. Coolant Filter Assembly Replacement

The Coolant Filter Assembly is located on a bracket on the Rear Panel Assembly of the unit.

1. Remove the two Coolant Hose connections to the Coolant Filter Assembly.

2. Remove the two elbow fitting on each side of the Coolant Filter Assembly and remove the damaged assembly from the bracket.

3. Clean the old thread sealer from the threads of the elbow fittings.

4. Apply a thin coating of liquid teflon thread sealer to the threads of the elbow fittings.

5. Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings.

6. Reconnect the two Coolant Hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly (left side as viewed from the back).

CUSTOMER/OPERATOR SER VICE 5-6 Man ual 0-2601

Page 55

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all basic replaceable parts. The parts lists are arranged as follows:

Section 6.03 Complete Power Supply Replacement

Parts List Section 6.04 Basic Component Replacement Parts List Section 6.05 Power Supply Options And Accessories

NOTE

Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers shown.

B. Returns

If a product must be returned for service, contact your authorized distributor . Materials returned without proper authorization will not be accepted.

6.02 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 machine as shown on the plate attached to the front panel of the unit. Address all inquiries to your authorized distributor .

Manual 0-2601 6-1 P A RTS LISTS

Page 56

6.03 Complete Power Supply Replacement Parts List

Qty. Description Catalog #

Merlin 6000 EMC Master Power Supply (with Running Gear and Work Cable) 1 Without Gas Control 3-6800-E 1 With Gas Contr ol 3-6802-E 1 Work Cable with Ring Lug - 25 ft (7.6 m) 9-6892

PARTS LISTS 6-2 Manual 0-2601

Page 57

6.04 Basic Component Replacement Parts List

Qty . Description Catalog #

1 Coolant Filter 8-4276 1 Hose Assembly - T ank to Coolant Filter 8-4274 1 Coolant Reservoir Basket 8-4273 1 Deionizer Bag 8-3312 1 Coolant Filler Cap 8-5142 1 Coolant Filter 8-4276 2 Caster 8-5578 2 Wheel 8-5579 1 Axle 9-1243 1 Fuse (F2) - 5 amp, 250V (F2) 8-1025 1 Fuse (F1) - 8 amp, 500V, Time Delay 9-3641 1 Spill Tray 8-6149

1 gal Torch Coolant

'Extra-Cool 'Ultra-Cool

' Coolant for Ambient T emperatur es to +10°F (-12°C) 7-3580

' Coolant for Ambient Temperatures to -27°F (-33°C) 7-3581

NOTE

For Cable and Hose Replacement Parts refer to Appendix 4 and 5.

Manual 0-2601 6-3 P A RTS LISTS

Page 58

6.05 Power Supply Options And Accessories

Qty. Description Catalog #

1 Merlin 6000 EMC Slave Power Supply 3-6801-E

Parallel Cable (For Dual System- Master to Slave) 1 8' / 2.4 m Length 9-6800 1 30' / 9.1 m Length 9-6997 1 Remote Ar c Starter Box 3-6820

Gas Regulators 1 Nitrogen Regulator 9-2722 1 CO2 Regulator 9-2759 1 Argon/Hydrogen Regulator 9-3053 1 High Pr essur e Air Regulator 9-3022 1 Oxygen Regulator 9-4379 1 Water Regulator 8-6118 1 Two Stage Air Line Filter Assembly 7-3139 1 Replacement First Stage Filter Element 9-1021 1 Replacement Second Stage Filter Element 9-1022 1 Plasma Gas Supply Line - 10 ft (3.0 m) 9-2146 1 Secondary Gas Supply Line - 10 ft (3.0 m) 9-2147 1 Remote Contr ol (RC6010) 3-6106 1 Standoff Control (SC10) 3-6110 1 High-Flow Water Shield

220V Version 7-3284-1 460V Version 7-324-2

Standoff Control Lifter Motor Control Cable 1 10 ft (308 m) 9-4535 1 15 ft (4.5 m) 9-4536 1 20 ft (6 m) 9-4537

PARTS LISTS 6-4 Manual 0-2601

Page 59

APPENDIX 1: INPUT WIRING REQUIREMENTS

Volt

Input Power Input Current Recommended Sizes (See Note)

Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) Wire (mm2)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph 3-Ph

380 50/60 34 51 60 6 6 14 415 50/60 34 47 60 8 6 9

Line Voltages with Recommended Circuit Protection and Wire Sizes

(Based on Table 310-16, 1987 National Electric Code) and Table 4, Canadian Electrical Code.

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. Cable size is de-rated based on the Duty Cycle of the equipment. The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations

refer to local or national codes. Cable conductor temperature used is 167° F (75° C). An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be

used to minimize damage to Plasma Cutting, Welding or power distribution equipment. NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2601 A-1 APPENDIX

Page 60

APPENDIX 2: SEQUENCE OF OPERATION

BLOCK DIAGRAM

ACTION

Close external

disconnect switch

RESULT

• Power to system

ACTION

Protect eyes and activate torch

Logic PC Board

Rev AE or Earlier

RESULT

• Gas indicator ON

• Gas pre-flow

• Main contactor closes

• DC indicator ON

• Pilot contactor closes

• PILOT indicator ON

• Pilot arc established

ACTION

Enable ON at Remote or TB2

ON/OFF switch to ON

RESULT

• AC indicator ON

• TEMP Indicator ON

• GAS indicator ON

• Fan and pump ON

• 40 second auto-purge

Logic PC Board

Rev AF or Later

RESULT

• Main contactor closes

• Gas indicator ON

• Gas pre-flow

• DC indicator ON

• Pilot contactor closes

• PILOT indicator ON

• Pilot arc established

ACTION

RUN/SET/PURGE

switch to SET

RESULT

• Gas solenoids open, gases flow to set pressures

• GAS indicator ON

PILOT ARC

ACTION

RUN/SET/PURGE

switch to RUN

RESULT

• Gas flow stops

• Power circuit ready

• GAS indicator OFF

ACTION

Torch removed from

work

RESULT

• Main arc stops

• Pilot arc auto-restart

• PILOT indicator ON

ACTION

Torch moved to within

1/8 - 3/8 inch of work

ACTION

Torch de-activated by torch switch

release or remote device

RESULT

• Main arc stops

• Main contactor opens (Logic PC Board Rev AE or Earlier Only

• DC indicator OFF

• Pilot and PILOT indicator OFF NOTE

If torch is activated during post-flow the pilot

arc will immediately restart. If within range

of work, main arc will transfer.

After post-flow:

• Main contactor opens

(Logic PC Board Rev AF or Later Only

• Gas solenoids close, gas flow stops

• GAS indicator OFF

ACTION

ON/OFF switch to OFF

RESULT

• AC indicator OFF

• TEMP Indicator OFF

• Fan and pump OFF

RESULT

• Main arc transfer

• PILOT indicator OFF

• Pilot arc OFF

ACTION

Open external disconnect

RESULT

• No power to system

A-03294

APPENDIX A-2 Man ual 0-2601

Page 61

APPENDIX 3: TYPICAL MECHANIZED SYSTEM WORK

AND GROUND CABLE CONNECTIONS

Remote Control

CNC Control

Earth

Ground

3-Phase

Input

Standoff Control

Master

Power

Supply

Work Cable

Earth

Ground

3-Phase

Input

Workpiece

Slave

Power

Supply

Work Cable

NOTE Work Cable(s) must connect direct to workpiece. DO NOT connect Work Cable(s) to earth ground and then to workpiece.

Earth

Ground

A-01512

Manual 0-2601 A-3 APPENDIX

Page 62

APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLE

INTERCONNECTION DIAGRAM

NOTE

CNC

J29

CNC

RC 6010

CNC

J37

MASTER POWER SUPPLY

Refer to Appendix 5 for complete data on the Cables and Hoses.

Bulkhead

J14

SC10

GAS CONTROL

GC3000

Internal

Ribbon Cable

PCR

J15

(-)

J63

J54

3 Ø AC INPUT

Parallel Cable

SLAVE POWER SUPPLY

(+)

J15

(-)

A-01517

3 Ø AC INPUT

(+)

APPENDIX A-4 Man ual 0-2601

Page 63

Arc Starter Control

ARC STARTER BOX

ARC STARTER PCB

PILOT CABLE

SECONDARY GAS

PLASMA GAS COOLANT

COOLANT

TORCH (-) CABLE

PILOT CABLE

SHIELD

WORK CABLE

WORKPIECE

TORCH (-) CABLE

WORK CABLE

A-01517

Manual 0-2601 A-5 APPENDIX

Page 64

APPENDIX 5: QUICK REFERENCE TO INTERCONNECTING

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

CABLES AND HOSES

Cable/Hose Diameter

Cable Description Catalog # Inches mm

A Power Supply CNC Cable

B R emote Control Cable

C Remote Gas Select Cable

D Arc Start er Cont rol Ca ble

E Positive Pilot Supply Cable

F Plasma or Secondary Gas Hose #4

G Coolant Hose #8

HTorch (-) Cabl e

I Wor k Cabl e

J Parallel Cable - 8ft

Parallel Cable - 30 ft

K CNC Cable

25 ft (7.6 m) 8-3380 3/8 9.5 50 ft (15.2 m) 8-3381 3/8 9.5 75 ft (22.9 m) 8-3382 3/8 9.5

100 ft (30.5 m) 8-3383 3/8 9.5

25 ft (7.6 m) 9-5961 1/2 13 50 ft (15.2 m) 9-5962 1/2 13 75 ft (22.9 m) 9-5963 1/2 13

100 ft (30.5 m) 9-5964 1/2 13

25 ft (7.6 m) 9-4579 1/2 13 50 ft (15.2 m) 9-4580 1/2 13 75 ft (22.9 m) 9-4581 1/2 13

100 ft (30.5 m) 9-4582 1/2 13

35 ft (10.7 m) 9-6901 1/4 6 50 ft (15.2 m) 9-6902 1/4 6 75 ft (22.9 m) 9-6903 1/4 6

100 ft (30.5 m) 9-6904 1/4 6 125 ft (38.1 m) 9-6905 1/4 6

35 ft (10.7 m) 9-6906 1/4 6 50 ft (15.2 m) 9-6907 1/4 6 75 ft (22.9 m) 9-6908 1/4 6

100 ft (30.5 m) 9-6886 1/4 6 115 ft (35.1 m) 9-6857 1/4 6 125 ft (38.1 m) 9-6909 1/4 6

10 ft (3.0 m) 9-6910 1/2 13

15 ft (4.6 m) 9-6911 1/2 13

20 ft (6.1 m) 9-6912 1/2 13

25 ft (7.6 m) 9-6913 1/2 13

30 ft (9.1 m) 9-6914 1/2 13 35 ft (10.7 m) 9-6915 1/2 13 40 ft (12.2 m) 9-6916 1/2 13 50 ft (15.2 m) 9-6917 1/2 13 75 ft (22.9 m) 9-6918 1/2 13

100 ft (30.5 m) 9-6919 1/2 13 125 ft (38.1 m) 9-6920 1/2 13

35 ft (10.7 m) 9-6921 7/8 22 50 ft (15.2 m) 9-6922 7/8 22 75 ft (22.9 m) 9-6923 7/8 22

100 ft (30.5 m) 9-6924 7/8 22 115 ft (35.1 m) 9-6858 7/8 22 125 ft (38.1 m) 9-6925 7/8 22

7.6 m

25 ft

10.7 m

35 ft 50 ft (15.2 m

22.9 m

75 ft

30.5 m

100 ft 115 ft (35.1 m

38.1 m

125 ft

7.6 m

25 ft

10.7 m

35 ft

15.2 m

50 ft 75 ft (22.9 m

30.5 m

100 ft

35.1 m

115 ft 125 ft (38.1 m

50 ft (15.2 m

5 ft (1.5 m

3.0 m

10 ft

4.6 m

15 ft 20 ft (6.1 m

7.6 m

25 ft

9.1 m

30 ft

2.4 m

9.1 m

9-6892 3/4 19 9-6926 3/4 19 9-6927 3/4 19 9-6928 3/4 19 9-6896 3/4 19 9-6856 3/4 19 9-6929 3/4 19

9-6892 3/4 19 9-6926 3/4 19 9-6927 3/4 19 9-6928 3/4 19 9-6896 3/4 19 9-6856 3/4 19 9-6929 3/4 19 9-6800 1/2 13 9-6997

9-4483 5/8 16 9-4484 5/8 16 9-4485 5/8 16

9-4486 5/8 16 9-4486-25 5/8 16 9-4486-30 5/8 16 9-4486-50 5/8 16

1/2 13

APPENDIX A-6 Man ual 0-2601

Page 65

APPENDIX 6: INTERFACE CABLE FOR REMOTE

CONTROL (RC6010)

Remote Control

RC6010

RC6010 Remote Cable Merlin 6000

A-01513

Manual 0-2601 A-7 APPENDIX

Page 66

APPENDIX 7: INTERFACE CABLE FOR STANDOFF

CONTROL (SC11)

J41

Merlin 3000 or

Merlin 6000

+48 VDC

48 VDC

Common

OK-To-Move

T orch Volts

Signal

J15

J42

Remote Cable

J15

6 8 7 9

10 11 24 25

28 29 19

Black

Red White Green

Orange

Blue Yellow Brown

Violet

Gray

Shield Drain

J41

Standoff Control

SC11

3 4 1 2

J42

12 14

START/STOP

4 5 6

A-01433

APPENDIX A-8 Man ual 0-2601

Page 67

APPENDIX 8: CNC INTERFACE CABLES

Cable Connections Used With Remote Control RC6010

Cutting Machine

* Refer to Remote Control RC6010

Manual for Station Select and CSD options

CNC Cable

Remote Control

RC6010

Contact **

24 V AC

Source **

** Selected inside the

Remote Control RC6010

Cable Connections Used With Standoff Control SC11

Cutting Machine CNC Cable

Merlin 6000

Contact *

Source 15 VDC, 10 ma

A-01514

24 VAC Source *

* Selected on the Logic PC Board

A-01515

Manual 0-2601 A-9 APPENDIX

Page 68

APPENDIX 9: LADDER DIAGRAM - 120 VAC

1415

LOGIC BOARD

NEON IND1

VOLTAGE SELECTION BOARD

10 9 8

5A, 250 VAC

K4 (HV)

K3 (LV)

K4 (HV)

K5 (LV)

K5 (HV)

SW1-AF2

SWITCHING CONTROL BOARD

MC1

MC2

SOL1 - PLASMA GAS

(Energized by Enable Switch)

110

K1-A

SECONDARY

SELECTION SWITCH

SW3-A

SEC 02 N/C

SOL2 - SECONDARY GAS

SOL3 - SECONDARY WATER

PCR

HFWS

110

A-01012

APPENDIX A-10 Manual 0-2601

Page 69

APPENDIX 10-A: LADDER DIAGRAM - 15 vdc

(Rev AE or Earlier Logic Control PC Board)

SECONDARY

INDICATOR

CONTACTOR

RUN

PLASMA

START

W-ON

LOGIC CONTROL BOARD

GAS

CONTROL

CIRCUIT

PRE-FLOW &

POST-FLOW

CIRCUIT

SWITCH

RECOGNITION

CONTACTOR

CONTROL

SW2

RUN

SET

PURGE

START/STOP (CNC)

START/STOP (Hand)

FS1

TS3

TS1 TS4

TS5

TS2

PWM

ENABLE

To disable this circuit for troubleshooting short test points together.

HF AND PILOT

CONTACTOR

J3-9

TP1

CONTACTOR DISABLE

(Only after main con-

TP4

tactor initially closes)

OK to Move

HFWS

REFERENCES J1 CONNECTOR

PILOT

CONTROL

CSR Indicator

D10

15 VDC SUPPLY

SENSE BRIDGE

VOLTAGE

<60VDC

SENSE BRIDGE

VOLTAGE

>60VDC

HF AND

PILOT

DISABLE

REFERENCES J3 CONNECTOR

PS1

OVER-CURRENT SHUTDOWN

(From Switching Control)

21 22

28 VAC

CENTER TAP

TORCH VOLTAGE/23

CSR (from Current

Control Board)

ALL PC BOARD INPUTS

ACTIVE LOW EXCEPT

J1-24 AND J1-21.

A-01557

Manual 0-2601 A-11 APPENDIX

Page 70

APPENDIX 10-B: LADDER DIAGRAM - 15 vdc

(Rev AF or Later Logic Control PC Board)

SECONDARY

CONTACTOR

INDICATOR

PWM

ENABLE

RUN

PLASMA

START

PWM-ON

J3-9

LOGIC CONTROL BOARD

GAS

CONTROL

CIRCUIT

PRE-FLOW &

POST-FLOW

CIRCUIT

SWITCH

RECOGNITION

PWM

CONTROL

SW2

RUN

SET

PURGE

START/STOP (CNC)

START/STOP (Hand)

FS1

TS3

TS1 TS4

PS1

TS5

TS2

TP1 TP4

To disable this circuit for troubleshooting short test points together.

HF AND PILOT

CONTACTOR

REFERENCES J1 CONNECTOR

PWM DISABLE (Only after main contactor initially closes)

PILOT

CONTROL

OK to Move

HFWS

CSR Indicator

D10

15 VDC SUPPLY

SENSE BRIDGE

VOLTAGE

<60VDC

SENSE BRIDGE

VOLTAGE

>60VDC

HF AND

PILOT

DISABLE

REFERENCES J3 CONNECTOR

OVER-CURRENT SHUTDOWN

(From Switching Control)

21 22

28 VAC

CENTER TAP

TORCH VOLTAGE/23

CSR (from Current

Control Board)

ALL PC BOARD INPUTS

ACTIVE LOW EXCEPT

J1-24 AND J1-21.

A-03295

APPENDIX A-12 Manual 0-2601

Page 71

APPENDIX 11: PARALLEL CABLE

Master Power

Supply J54

Slave Power

Supply J15

Cable

1 2 7

4 14 12

9 10

2 32 33 24 25 17 15

4 31 30

19 35 36 26 27

DEMAND

3.3 - 10 VDC

ENABLE

START/STOP

SLAVE IS ON

SLAVE OUTPUT

Signal

This Is Slave

Remote Installed

Shield Drain

A-01516

Isolation PC

Board Power

Supply

0 - 10 VDC

Manual 0-2601 A-13 APPENDIX

Page 72

APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE

This recommended schedule applies to all types of liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Arc Hours:

1. Check torch parts, replace if damaged.

2. Check plasma and secondary supply and pressure/flow.

3. Purge plasma gas line to remove any moisture build-up.

4. Check deionizer bag/cartridge, replace if color is predominantly yellow.

5. Check coolant pressure (100 - 120 psi).

Weekly or Every 30 Arc Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Arc Hours:

1. Remove and clean in-line filter screens.

2. Check cables and hoses for leaks or cracks, replace if necessary .

3. Check all contactor points for severe arcing or pits, replace if necessary.

4. Check all pillow blocks and bearings, clean and lubricate if necessary.

5. Check fan, pump and pulley belts for wear or cracking, replace if necessary .

Twelve Months or Every 1500 Arc Hours:

1. Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30 minutes.

WARNING

DO NOT energize the T or ch.

Drain distilled water and replace with Thermal Arc Coolant. Use 'Extra-CoolTM' Coolant (Catalog # 7-3580) or 'Ultra-CoolTM' Coolant (Catalog # 7-3581) for environments below +10° F (-12° C).

2. Check radiator fins, clean and comb out if necessary.

3. Repeat six month maintenance.

APPENDIX A-14 Manual 0-2601

Page 73

Manual 0-2601 A-15 APPENDIX

Page 74

APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier

A-01726

APPENDIX A-16 Manual 0-2601

Page 75

NOTE

System Schematic for units with the letter 'B' or earlier on the data tag.

A-01726

Manual 0-2601 A-17 APPENDIX

Page 76

APPENDIX 14: SYSTEM SCHEMATIC - Rev 'AK' or Later

Art # A-06020

APPENDIX A-18 Manual 0-2601

Page 77

NOTE

System Schematic for units with the letter 'AK' or later on the data tag.

Art # A-06020

Manual 0-2601 A-19 APPENDIX

Page 78

APPENDIX A-20 Manual 0-2601

Tweco 6000CE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.01 Scope of Manual

2.02 General Description

2.04 Theory Of Operation

2.05 Options And Accessories

3.03 Unpacking

3.01 Introduction

3.02 Site Location

3.04 Removing Skid

3.06 Input Power Connections

3.07 Checking Input Connections

3.09 Ground Connections For Mechanized Applications

3.11 Connecting Torch Supply Leads

3.12 External Cable Connections

3.13 Master/Slave Parallel Cable Connection

3.14 Lifting Options

3.15 Pilot Resistor Adjustment

4.01 Introduction

4.02 Functional Overview

4.03 Front and Rear Panel Descriptions

4.04 Operating Unit Without Gas Control Option

4.05 Operating Unit With Gas Control Option

4.06 System Operation

5.01 Introduction

5.02 General Maintenance

5.03 Common Operating Faults

5.04 Troubleshooting

5.05 Basic Parts Replacement

6.01 Introduction

6.02 Ordering Information

6.03 Complete Power Supply Replacement Parts List

6.04 Basic Component Replacement Parts List

6.05 Power Supply Options And Accessories

APPENDIX 1: INPUT WIRING REQUIREMENTS

APPENDIX 8: CNC INTERFACE CABLES

APPENDIX 9: LADDER DIAGRAM - 120 VAC

APPENDIX 11: PARALLEL CABLE

APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE

APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier