Thermal Dynamics MERLIN 6000 Service Manual page 46

2. If using the Remote Control (RC6010), Logic PC Board
switch SW5 must be up for contact closure, indicator
D104, OK PS, on the Remote Control (RC 6010) inter-
nal PC Board should come ON with OK-To-Move. If
not check continuity between TB2-9 and J37-30, also
TB2-10 and J37-31. The Remote Control (RC6010) OK
relay is initially energized. The relay turns OFF to
send the OK-To-Move signal through the relay nor-
mally closed contact. As soon as indicator D104 turns
ON, or after the PIERCE DELAY if the Standoff Con-
trol (SC10) is also used, indicator D102 should go ON
indicating OK-ToMove is ON ( OK relay is OFF). If no
Standoff Control (SC10) is used and indicator D102
does not go ON, the Remote Control PC Board is
faulty. If the Standoff Control (SC10) is used, set the
torch to proper cutting height manually and discon-
nect the Standoff Control (SC10) by removing the rib-
bon cable from J5 or J7, and try again. If indicator
D102 goes ON now the Standoff Control PC Board is
faulty (or the ribbon cable is open, pin 11 or 15). If
indicator D102 does not go ON with the Standoff Con-
trol (SC10) disconnected, the Remote Control (RC6010)
is faulty.
3. If indicator D102 goes ON as it should and the E1
jumper is connected to J6-14 (contacts) measure for
contact closure at J6-13 to 16 or if E1 jumper is in J6-15
(24 VAC) measure for 24 VAC at J6-13 to J6-16. If OK,
the problem is in the CNC cable connections to the
cutting machine or the controller.
4. For the Standoff Control (SC11) refer to Section 5, Cus-
tomer/Operator Service, in the Standoff Control In-
struction Manual.
S. Pilot Resistor Adjustment
This Sub-Section applies only to the following Master and
Slave Power Supplies:
• 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
• Slave Power Supplies with the revision letter 'E' or
later at the end of the serial number on the data tag
• Slave Power Supplies that have been retrofitted with
Pilot Resistors
Master and Slave Power Supplies, as noted above, con-
tain 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 acti-
vated.
Master and Slave Power Supply pilot resistors are ini-
tially set at the factory and may need to be adjusted to
the customer's input power (see Notes).
SERVICE TROUBLESHOOTING
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.
Disconnect primary power at the source before as-
sembling or disassembling power supply, torch
parts, or torch and leads assemblies.
The pilot current consists of two parts:
1) Minimum or "background" level
2) Pulse or peak level
The background level has to be high enough that the pi-
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 greater
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 Mas-
ter 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. To set the pilot background
and pulse levels use the following procedure:
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.
40
NOTES
WARNING
Manual 0-2569