Thermal Dynamics MERLIN 6000 Operating Manual
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Thermal Dynamics MERLIN 6000 Operating Manual

Thermal Dynamics MERLIN 6000 Operating Manual

Plasma cutting master power supply
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MERLIN
6000
Plasma Cutting
Master Power Supply
A-01497
Operating Manual
Manual No. 0-2568
October 6, 1999

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  • Page 1 ® MERLIN 6000 Plasma Cutting Master Power Supply A-01497 Operating Manual Manual No. 0-2568 October 6, 1999...
  • Page 2 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 the MERLIN 6000 Plasma Cutting Master Power Supply Operating Manual, whether such error results from negligence, accident, or any other cause.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1 1.01 Notes, Cautions and Warnings ..............1 1.02 Important Safety Precautions ................ 1 1.03 Publications ....................2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes ............3 1.06 Documents De Reference ................
  • Page 4 TABLE OF CONTENTS (continued) SECTION 5: CUSTOMER/OPERATOR SERVICE .................. 43 5.01 Introduction ....................43 5.02 General Maintenance .................. 43 5.03 Common Operating Faults ................44 5.04 Troubleshooting ................... 44 5.05 Basic Parts Replacement ................47 SECTION 6: PARTS LISTS ........................49 6.01 Introduction ....................

  • Page 5: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 6: Publications

    • Install and maintain equipment according to NEC • To protect your eyes, always wear a welding hel- code, refer to item 9 in Subsection 1.03, Publica- met or shield. Also always wear safety glasses with tions. side shields, goggles or other protective eye wear. •...

  • Page 7: Note, Attention Et Avertissement

    8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- AVERTISSEMENT CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, Toute procédure pouvant provoquer des blessures obtainable from the National Fire Protection Asso- de l’opérateur ou des autres personnes se trouvant ciation, Batterymarch Park, Quincy, MA 02269...
  • Page 8 • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des INCENDIE ET EXPLOSION revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous Les incendies et les explosions peuvent résulter des scories coupez ou soudez tout métal pouvant contenir un chaudes, des étincelles ou de l’arc de plasma.

  • Page 9: Documents De Reference

    • Utilisez la nuance de lentille qui est suggèrée dans 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA le recommendation qui suivent ANSI/ASC Z49.1: PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro...
  • Page 10 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS 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.

  • Page 11: Declaration Of Conformity

    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.

  • Page 12: Statement Of Warranty

    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.

  • Page 13: Introduction & Description

    DESCRIPTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and basic maintenance procedures for the Merlin 6000 Plasma Cutting Master Power Supply. Service of this equipment is restricted to Thermal Dynamics trained per- sonnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

  • Page 14: Specifications & Design Features

    5. Duty Cycle 2.03 Specifications & Design Features 100% 6. Pilot Modes The following apply to the Master Power Supply only: Auto-Restart, Pre-Flow Delay, "Recycle Required" 1. Controls 7. CNC Signals ON/OFF Switch, Output Current Control, RUN/ SET/PURGE Switch, Secondary Gas Regulator, Enable, Start/Stop, OK-To-Move, Pilot Sensing Relay Plasma Gas Regulator, Secondary Mode Switch, Sec- (PSR), Full CNC Available with Remote...

  • Page 15: Theory Of Operation

    13. Power Supply Dimensions NOTE Enclosure Only - For the arc to restart automatically, AUTO RE- START must be enabled at switch settings inside Width: 24.12 in (0.61 m) the Power Supply (Refer to Section 4.07). Height: 38.38 in (0.98 m) D.

  • Page 16: Options And Accessories

    power to the main contactor. When the overheated C. Computer Control Cable Kits component cools down the switch will close again and For interfacing the power supply with a computer or allow operation of the system. auxiliary control device. Available in various cable G.

  • Page 17: Installation Procedures

    Review the safety precautions in the front of this manual SECTION 3: to be sure that the location meets all safety requirements. INSTALLATION 3.03 Unpacking PROCEDURES Each component of the system is packaged separately and protected with a carton and packing material to prevent 3.01 Introduction damage during shipping.

  • Page 18: Filling Master Power Supply Coolant

    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 cool- ant reservoir. Coolant Reservoir Filler Cap Deionizer Basket Shipping Brackets Shipping Pallet Three Bolts A-01498 (Each Side)

  • Page 19: Voltage Selection

    B. Input Voltage Selection 3.07 Voltage Selection Every Power Supply is factory-wired for 460V three-phase The Power Supply can be wired to use input voltages input. For any other input voltage, the Power Supply from 200 - 575 VAC. Power Supply is factory-wired for must be changed using the procedures in Section 3.07.

  • Page 20: Primary Power Cable Connections

    Input Voltage Terminal Board Busbar Connections For Input Voltages 200, 208, 380, 415, 220, or 230 or 460 500, or 575 Primary Power Busbars Cable Ground Connection Strain Relief A-00893 Fitting Figure 3-6 Input Voltage Connections A-00904 2. Connect the electrical ground wire to the ground lug on the base of the unit.

  • Page 21: Plasma And Secondary Gas Connections

    tem is designed with to help prevent this problem. To Plasma and secondary requirements vary depending on further minimize RF interference, follow these ground- the application. The plasma and secondary gases are ing procedures when installing mechanized systems: connected to the rear panel connections of the power sup- ply.
  • Page 22 NOTE Only one of these will be used depending on con- figuration of Power Supply. Air Filter Install the Two Stage Air Filter Kit as follows: Mounting Bracket NOTE Use these instructions only for Power Supplies that Hose Assembly DO NOT have the Gas Control Option installed. Filter to Plasma Gas Input 1.
  • Page 23 WARNING Shop Air Gas Input Do not stand in front of the valve outlet when open- ing. 2. Each cylinder must be equipped with an adjustable Secondary Air high-pressure regulator capable of pressures up to 125 Gas Fitting psi (8.6 BAR) maximum and flows of up to 700 scfh (328 lpm) for cutting or gouging.
  • Page 24 NOTE 4. Set the SECONDARY selector switch on the front panel of the Power Supply to the WATER posi- A typical 50 lb. CO2 cylinder can deliver a con- tion. tinuous flow rate of 35 scfh (16.5 lpm). To obtain the required flow rate for the torch, it may be nec- D.
  • Page 25 NOTE 9. Connect the air supply hose from a Y-Hose Assembly to the street elbow on the Air Line Filter input port Do Not use teflon tape as a thread sealer as small (IN). The Y-Hose Assembly should have already been particles of the tape may break off and cause the installed, if shop air was being used as the plasma small gas passage to be blocked in the torch.

  • Page 26: Connecting Torch Supply Leads

    13. Connect the Plasma Hose from the Plasma Gas Con- A-01342 trol Manifold to the Plasma (Air) Gas Input Fitting at the rear of the Power Supply. OU TP RO L CO NT MO DU MA GA MA GA PL AS PL AS AI R PL AS...
  • Page 27 2. Feed the four hose assemblies on the Torch Supply d. Secure the shield lead (black) to the ground con- Leads components through the boot on the front panel nection with the nut and star washer removed of the Master Power Supply. above.

  • Page 28: External Cable Connections

    NOTE B. Computer Control Interface (CNC) Refer to the Installation sections in the Maximizer NOTE 300 Torch Instruction Manual (0-2573) for more Used when Remote Control RC6010 or Standoff information on the Torch. Control SC11 are not used. The computer control interface allows a mechanized sys- 3.12 External Cable Connections tem to interface with a computer or other control device.
  • Page 29 Depending on the Standoff Control to be used connect the cable per one of the following: • Standoff Control SC10 used with the Remote T B 2 Control RC6010 D es c ri ption C onnec ti on Connect the internal ribbon cable to the Remote O ne S i de of E nable S ignal (C om m on) Control RC6010.

  • Page 30: Master/Slave Parallel Cable Connection

    A-01507 A-01508 OU TPU OU TPU TO TO CO NTR CO NTR MO DU MA GA MA GA PL AS PL AS OU TP RO L AIR AIR High Flow Water Shield CO NT PLA SM MO DU MO DU INP UT MA GA MA GA...

  • Page 31: Pilot Resistor Adjustment

    R22) which are on a bracket in front of the Slave Power Supplies: fan. • Merlin 6000 Master Power Supplies with the revi- sion letter 'C' or later at the end of the serial num- ber on the data tag •...
  • Page 32 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 Pilot Resistor the input AC line voltage at the time the Power Clamp Wire #99 Supply is turned ON.
  • Page 33 A-01852 Pulser Wire #99 Wire #96 R16 (4.5 ohms) R22 (2.2 ohms) Wire #150 Wire #96A R21 (2.2 ohms) Wire #74 Temp Switch 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.
  • Page 34 INSTALLATION PROCEDURES Manual 0-2568...

  • Page 35: Operation

    A. Lower Front Panel SECTION 4: OPERATION 4.01 Introduction 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 oper- ating 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.
  • Page 36 5. Power Lead Strain Relief 5. TEMP Indicator Strain relief to secure the power lead to the Power Green light indicates proper operating temperature. Supply after it is installed. Red light indicates overheating. Unit must be allowed to cool. 6. Secondary Water Flowmeter/Regulator 6.
  • Page 37 Selects secondary mode to gas, oxygen (no second- Inside the reservoir, in the filler neck, is a basket and ary), or water. This mode selector is disabled when a deionizer bag. The bag removes charged particles using the Remote Gas Control Option (GC 3000). from the coolant after it is returned to the reservoir.

  • Page 38: Operating Unit Without Gas Control Option

    A strain relief supplied to secure the customer sup- Plasma Gas plied primary input power cable to the power sup- Manifold ply. The input AC power cable is routed through the strain relief and is connected to the power input ter- OUTPUT minals inside the unit.
  • Page 39 A. Coolant Level NOTE Refer to the Torch Instruction Manual for proper Check the coolant level at the coolant reservoir at the secondary gas selection. rear of the Power Supply. If the coolant is down from the top of the reservoir more than 2 inches (50mm) G.

  • Page 40: Operating Unit With Gas Control Option

    J. Additional Gas Purging D. Input Power If additional purging of the plasma gas line is neces- Check the power source for proper input voltage. sary, move the RUN/SET/PURGE switch to PURGE Make sure that Power Supply is set for the proper position.

  • Page 41: System Operation

    • Turn the Enable switch to ON at the front panel of K. Ready for Operation the RC6010 Remote Control Return the RUN/SET/PURGE switch to RUN posi- • Signal supplied through the CNC control cable tion. • Signal supplied from a customer supplied switch The system is now ready for operation.

  • Page 42: Optional Power Supply Settings

    B. Using Corner Slowdown for Mechanized D. Fold Back Feature Cutting Should the torch tip contact the workpiece the output current will immediately drop to 50 amps (100 amps NOTE with Slave Power Supply connected) to minimize po- Corner Slowdown (CSD) is available only if the tential tip damage.
  • Page 43 the system is used to replace other units which do not restarts. In some shape-cutting applications, it may have auto-restart, or for use with motion control de- not be desirable to immediately restart the main arc vices. In many applications, torch parts life may be after the torch passes beyond the desired cutting line improved by disabling auto-restart to reduce exces- (or between cuts).
  • Page 44 factory-set at 2 seconds, but can be reset to 4, 7, or 10 seconds as desired. Extended torch leads may require P o s t-F l o w T i m e S W 4 -1 S W 4 -2 longer pre-flow durations.
  • Page 45 NOTE TB2-7 Switch SW5 must be in the UP position when us- External Voltage ing Remote Control RC6010 or Standoff Control Source Alternate SC11. TB2-8 Positions To use the contact closure for the OK-To-Move signal the switch should be in the up position (factory set- TB2-9 J15-10 ting).
  • Page 46 OPERATION Manual 0-2568...

  • Page 47: Customer/Operator Service

    SECTION 5: residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water CUSTOMER/OPERATOR before re-installing in the Coolant Filter Assembly. SERVICE Coolant Filter Assembly 5.01 Introduction This Section describes basic maintenance procedures per- formable by operating personnel.

  • Page 48: Common Operating Faults

    Supply and torch leads and replace with new cool- b. Current too low ant. Check the condition of the deionizer bag in c. Metal too thick the reservoir basket, if the bag is yellowish brown (straw color) replace the bag. d.
  • Page 49 NOTE 4. Blown fuse (F2) For major troubleshooting and parts replacement a. Check and replace fuse if necessary procedures refer to Power Supply Service Manual 5. Faulty power supply 0-2569. a. Isolate and replace component(s) per Service If major complex subassemblies are faulty, the unit must Manual.
  • Page 50 F. GAS indicator OFF, plasma and/or secondary gas 2. Coolant Level is low does not flow a. Check for proper coolant level at rear panel 1. RUN/SET/PURGE switch set to PURGE, secondary gauge mode switch set to GAS secondary J. Coolant CONDUCTIVITY Indicator OFF a.

  • Page 51: Basic Parts Replacement

    N. No pilot; PILOT indicator ON; Strong spark 5.05 Basic Parts Replacement visible at spark gap points in Arc Starter Box NOTE 1. Faulty torch parts For more detailed Parts Replacement Procedures a. Repair per Torch Manual and Replacement Parts refer to Power Supply Ser- vice Manual 0-2569.
  • Page 52 4. Reinstall the panels by reversing the above steps. 1. Remove the Left Side Panel from the Power Sup- ply per paragraph 'A' above. B. Fuse Replacement 2. Locate the In-Line Coolant Filter near the front of There are three fuses located on the Power Supply as fol- the unit.

  • Page 53: Parts Lists

    B. Returns If a Thermal Dynamics product must be returned for ser- vice, contact your Thermal Dynamics distributor. Mate- rials returned to Thermal Dynamics without proper au- thorization will not be accepted.

  • Page 54: Complete Power Supply Replacement Parts List

    6.03 Complete Power Supply Replacement Parts List Qty. Description Catalog # Merlin 6000 Master Power Supply (with Running Gear and Work Cable) Without Gas Control 3-6800 With Gas Control 3-6802 Work Cable with Ring Lug - 25 ft (7.6 m)

  • Page 55: Basic Component Replacement Parts List

    6.04 Basic Component Replacement Parts List Qty. Description Catalog # Coolant Filter 8-4276 Hose Assembly - Tank to Coolant Filter 8-4274 Coolant Reservoir Basket 8-4273 Deionizer Bag 8-3312 Coolant Filler Cap 8-5142 Coolant Filter 8-4276 Caster 8-5578 Wheel 8-5579 Axle 9-1243 Fuse (F2) - 5 amp, 250V (F2) 8-1025...

  • Page 56: Power Supply Options And Accessories

    6.05 Power Supply Options And Accessories Qty. Description Catalog # Merlin 6000 Slave Power Supply 3-6801 Remote Arc Starter Box 3-6820 Gas Regulators Nitrogen Regulator 9-2722 CO2 Regulator 9-2759 Argon/Hydrogen Regulator 9-3053 High Pressure Air Regulator 9-3022 Oxygen Regulator 9-4379...

  • Page 57: Appendix I: Input Wiring Requirements

    APPENDIX I: INPUT WIRING REQUIREMENTS In p u t P o w er In p u t C u r r en t S u g g ested S iz es (S ee N o te) V o ltag e F r eq .

  • Page 58: Appendix Ii: Sequence Of Operation Block Diagram

    APPENDIX II: SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION RUN/SET/PURGE RUN/SET/PURGE Enable ON at Remote Close external switch to SET switch to RUN or TB2 disconnect switch ON/OFF switch to ON RESULT RESULT RESULT • Gas solenoids open, •...

  • Page 59: Appendix Iii: Typical Mechanized System Work And Ground Cable Connections

    APPENDIX III: TYPICAL MECHANIZED SYSTEM WORK AND GROUND CABLE CONNECTIONS Remote Control CNC Control Earth Standoff Control Ground Master Power 3-Phase Supply Input Work Cable Earth Ground Workpiece Slave Earth Power Ground Supply 3-Phase Input Work Cable A-01512 NOTE Work Cable(s) must connect direct to workpiece. DO NOT connect Work Cable(s) to earth ground and then to workpiece.

  • Page 60: Appendix Iv: Typical Mechanized System Cable Interconnection Diagram

    APPENDIX IV: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM NOTE Refer to Appendix V for complete data on the Cables and Hoses. MASTER POWER SUPPLY RC 6010 Bulkhead RC 6010 Internal Ribbon Cable SC10 GAS CONTROL GC3000 3 Ø INPUT Parallel Cable SLAVE POWER SUPPLY 3 Ø...
  • Page 61 ARC STARTER BOX Arc Starter Control ARC STARTER PILOT CABLE SECONDARY GAS PLASMA GAS COOLANT COOLANT TORCH (-) CABLE SHIELD PILOT CABLE WORK CABLE WORKPIECE TORCH (-) CABLE WORK CABLE A-01517 Manual 0-2568 APPENDIX...

  • Page 62: Appendix V: Quick Reference To Interconnecting Cables And Hoses

    APPENDIX V: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES Cable/Hose Diameter Cable Description Catalog # Inches Power Supply CNC Cable 25 ft (7.6 m) 8-3380 50 ft (15.2 m) 8-3381 75 ft (22.9 m) 8-3382 100 ft (30.5 m) 8-3383 Remote Control Cable 25 ft (7.6 m) 9-5961...

  • Page 63: Appendix Vi: Interface Cable For Remote Control (Rc6010)

    APPENDIX VI: INTERFACE CABLE FOR REMOTE CONTROL (RC6010) Remote Control RC6010 RC6010 Remote Cable Merlin 6000 A-01513 Manual 0-2568 APPENDIX...

  • Page 64: Appendix Vii: Interface Cable For Standoff Control (Sc11)

    APPENDIX VII: INTERFACE CABLE FOR STANDOFF CONTROL (SC11) Standoff Control Remote Cable Merlin 3000 or SC11 Merlin 6000 Black +48 VDC White 48 VDC Green Common Orange OK-To-Move Blue Yellow START/STOP Brown Violet Torch Volts Signal Gray Shield Drain A-01433...

  • Page 65: Appendix Viii: Cnc Interface Cables

    Remote Control RC6010 A-01514 Cable Connections Used With Standoff Control SC11 Cutting Machine CNC Cable Merlin 6000 Contact * 24 VAC Source * * Selected on the Logic PC Board Source 15 VDC, 10 ma Source 15 VDC, 10 ma...

  • Page 66: Appendix Ix: Ladder Diagram - 120 Vac

    APPENDIX IX: LADDER DIAGRAM - 120 VAC SW1-A 5A, 250 VAC NEON IND1 VOLTAGE SELECTION BOARD SWITCHING CONTROL BOARD (Energized by Enable Switch) K4 (HV) K3 (LV) K3 (LV) K4 (HV) LOGIC BOARD K5 (LV) K5 (HV) SOL1 - PLASMA GAS SECONDARY SELECTION SWITCH SOL2 - SECONDARY GAS...

  • Page 67: Appendix X: Ladder Diagram - 15 Vdc

    APPENDIX X: LADDER DIAGRAM - 15 VDC LOGIC CONTROL BOARD PLASMA CONTROL CIRCUIT PURGE START/STOP (CNC) SECONDARY PRE-FLOW & POST-FLOW CIRCUIT START/STOP (Hand) SWITCH RECOGNITION START INDICATOR CONTACTOR CONTACTOR CONTROL W-ON J3-9 ENABLE CONTACTOR DISABLE SENSE BRIDGE (Only after main con- VOLTAGE tactor initially closes) <60VDC...

  • Page 68: Appendix Xi: Parallel Cable

    APPENDIX XI: PARALLEL CABLE Master Power Slave Power Cable Supply J54 Supply J15 DEMAND 3.3 - 10 VDC ENABLE START/STOP SLAVE IS ON SLAVE OUTPUT 0 - 10 VDC Signal Isolation PC Board Power Supply Shield Drain This Is Slave Remote Installed A-01516 APPENDIX...

  • Page 69: Appendix Xii: Recommended Routine Maintenance Schedule For Water Cooled Plasma Cutting Systems

    APPENDIX XII: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR WATER COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of water 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...

  • Page 70: Appendix Xiii: System Schematic - Rev 'B' Or Earlier

    APPENDIX XIII: SYSTEM SCHEMATIC - Rev 'B' or Earlier A-01573 APPENDIX Manual 0-2568...
  • Page 71 NOTE System Schematic for units with the letter 'B' or earlier at the end of the serial number on the data tag. A-01573 Manual 0-2568 APPENDIX...

  • Page 72: Appendix Xiv: System Schematic - Rev 'C' Or Later

    APPENDIX XIV: SYSTEM SCHEMATIC - Rev 'C' or Later A-01947 APPENDIX Manual 0-2568...
  • Page 73 NOTE System Schematic for units with the letter 'C' or later at the end of the serial number on the data tag. A-01947 Manual 0-2568 APPENDIX...
  • Page 74 APPENDIX Manual 0-2568...

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