Tweco 6000CE User Manual
Plasma Cutting
Master Power Supply
CE MERLIN ® 6000
A-01497
Operating Manual
August 19, 2005 Manual No. 0-2601
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
©Copyright 1997 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: August 19, 2005
Record the following information for Warranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
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
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
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
• 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
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.
• 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
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
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
1.07 Declaration of Conformity
S
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
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
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
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
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
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.
B
. 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
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
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
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
s
)
Shipping Brackets
ir
r
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
B. Opening Power Supply Enclosure
n
11
12
L3
13
15
14
6
7
L2
8
10
9
1
2
L1
3
5
4
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.
L3
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
L2
A-01091
Input Voltage
Terminal Board
Busbars
L1
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.
3.08 Primary Power Cable
P
C
g
g
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
L3
L2
L1
Strain Relief
Fitting
A-00896
can occur.
Figure 3-6 Input Voltage Connections
INSTALLA TION PROCEDURES 3-4 Manual 0-2601
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.
2
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.
2
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
T o test for a proper earth ground, refer to the following
A
d
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
V
100W
Light Bulb
~
V
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-
2
gen (N2), or Argon/Hydrogen (Ar/H2)
Secondary Gases: Compressed Air, Nitrogen (N2),
Carbon Dioxide (CO
), or T ap Water (refer to follow-
2
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
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