Thermal Dynamics MERLIN 3000 Service Manual
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Thermal Dynamics MERLIN 3000 Service Manual

Thermal Dynamics MERLIN 3000 Service Manual

Plasma cutting power supply
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MERLIN 3000
Plasma Cutting Power Supply
A-00907
Service Manual
Manual No. 0-2533
October 6, 1999

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  • Page 1 MERLIN 3000 Plasma Cutting Power Supply A-00907 Service Manual Manual No. 0-2533 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 3000 Plasma Cutting Power Supply Service 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 6: PARTS LISTS ........................51 6.01 Introduction ....................51 6.02 Ordering Information ..................51 6.03 External Power Supply Replacement Parts List ........... 52 6.04 Access Panel Replacement Parts ..............53 6.05 Front Panel/Chassis Replacement Parts ............. 54 6.06 Rear Panel Replacement Parts ..............

  • 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

    1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc- tive’ (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.

  • Page 12: Statement Of Warranty

    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 stored, 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, correct such defects by suitable repair or replacement, at Thermal’s sole...

  • Page 13: Introduction

    This Manual provides Service Instructions for Thermal Maintenance work should be accomplished in a timely Dynamics Merlin 3000 Power Supply. manner. If problems are encountered, or the equipment does not function as specified, contact Technical Services Refer to Operating Manual (0-2532) for individual oper- Department at West Lebanon for assistance.
  • Page 14 INTRODUCTION Manual 0-2533...

  • Page 15: Introduction & Description

    • Power Supply with Running Gear and Handles SECTION 3: • Arc Starter Box INTRODUCTION & • Maximizer 300 Machine Torch with Mounting As- sembly and Leads DESCRIPTION • Torch Leads Extension • Maximizer 300 Spare Parts Kit 3.01 Scope of Manual •...

  • Page 16: Theory Of Operation

    5. Duty Cycle 3.04 Theory Of Operation 100% A. Plasma Arc Cutting and Gouging 6. Pilot Modes Plasma is a gas which is heated to an extremely high tem- perature and ionized so that it becomes electrically con- Auto-Restart, Pre-Flow Delay, Recycle ductive.

  • Page 17: Options And Accessories

    E. RF Shielding ply lead. At the torch, the coolant is circulated around the torch tip and electrode, where the extra cooling helps All machine torch systems are shielded to minimize ra- to prolong parts life. Coolant then circles back to the dio frequency (RF) interference which results from the power supply through the return lead.
  • Page 18 G. Hour/Counter Meters Meter assembly containing two meters. One meter indicates the total number of hours that the main cut- ting arc has been on. The second meter counts the number of times that the cutting arc has been started. Both meters display a maximum of 999999 hours or starts and cannot be reset.

  • Page 19: Service Troubleshooting Diagnostics

    NOTE The troubleshooting contained in this manual is Coolant Filter Assembly for the Merlin 3000 Power Supply only. Trouble- shooting other parts of the system is covered in the separate manuals for that product. 4.02 Periodic Inspection &...

  • Page 20: System Theory

    The Merlin 3000 system is designed for mechanized reservoir is more than 2 inches (50mm) from the cutting only and consists of the Merlin 3000 plasma top of the reservoir then add Torch Coolant. power supply, the Maximizer 300 Torch, Torch Leads Extension, and Arc Starter Box.
  • Page 21 C. Switch-Mode Power Supply Operation run, set, and purge modes by turning on the plasma and secondary solenoids. The Logic PC Board also Primary three-phase power is rectified by the three- controls pre-flow and post-flow durations, which are phase bridge diodes D1-D6. The resulting negative selectable by DIP switches on the board.

  • Page 22: Troubleshooting Guide

    The cable connected to J42 supplies con- trol signals between Power Supply and the Stand- A Merlin 3000 system may include the following: off Control. Refer to the individual Instruction Manuals supplied with the equipment for more •...
  • Page 23 Refer to Section 4.05-A, Voltage Selection PC surements. It is helpful for solving many of the common Board Check. Replace Voltage Selection PC problems that can arise with the Merlin 3000 Plasma Cut- Board if necessary ting System. B. AC indicator ON; Fan and pump not operating If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.
  • Page 24 E. Fuse blown at disconnect when primary power is 4. Faulty LED/Current Control PC Board connected a. Refer to Section 4.05-F, Thermal Sensing Circuit 1. Voltage selection busbars connected incorrectly Check. Replace LED/Current Control PC Board if necessary. a. Check and correct if necessary. H.
  • Page 25 3. Gas Control (GC3000) on wrong setting NOTE a. Select input that has gas connected. With a clogged internal coolant filter or Torch and leads the Coolant Pressure Gauge will be normal, 4. Gas supply turned off (or tank empty) but the Pressure LED, indicates flow, will be OFF.
  • Page 26 M. DC indicator off (after pre-flow); Main contactor 3. Broken conductor in torch lead comes on momentarily; No pilot arc; No main arc a. Check and replace if necessary transfer 4. Shorted torch lead 1. Switching transistor (Q1) not turning on a.

  • Page 27: Test Procedures

    U. Main arc transfers and pierces through the plate, 2. Check the AC voltage from J6-24 to both J6-17 and but cutting machine doesn’t move J6-18 for 16 - 22 VAC. 1. Incorrect or missing OK-To-Move signal. 3. If input voltages are correct, check output from J6- 24 to both J6-19 and J6-21 for 14 - 18 VAC.
  • Page 28 F2 to wire #10 and T1. Only one of the MC contactors should have voltage applied. If the red LED indicator (D18) on the volt- Merlin 3000, 6000 age selection board is lit, MC2 should be energized. or 6000GST RC6010 If D18 is not lit, MC1 should be energized.
  • Page 29 2. High frequency protection for the input rectifier 1. Check the voltage at J1-7 for less than 1 VDC with diodes (D1-6) is provided by capacitors C1 - C6 gases flowing and operating pressure greater than and MOV 1-3, which are located between each side 35 psi (2.4 BAR).
  • Page 30 2. If the coolant conductivity indicator is not lit with and the 120 VAC should go to W2 otherewise it goes the probe disconnected, measure between the to W1. The first step is to measure for 120 VAC from Logic PC Board common (TP1) and J3-1. If the Logic PC Board J2-9 to wire #110 (PCR coil, MC1 or voltage measures below +12 VDC, replace the LED MC2 coils).
  • Page 31 lem is in the Standoff Control (SC10) or the ribbon cable. Refer to Section 5, Customer/Operator Service, Transistor/Coil in the Standoff Control Instruction Manual. Switching Transistor Bracket If the Standoff Control (SC10) isn’t used or the Power Supply didn’t start with the ribbon cable disconnected, there are two approaches you can take.
  • Page 32 The PWM compares shunt amp output on J9-5 with shorted (pilot resistors will get very hot). If it is be- the current control signal (3.3 - 10 VDC) from the re- tween 100 and 200v PCR contactor is probably not mote (J7-18) or the panel control (J10-15).
  • Page 33 NOTE 1. Tip Drag Circuit Refer to Appendix XI for Corner Slowdown (CSD) The Merlin 3000 has a circuit that monitors the Circuit Diagram. torch tip voltage to reduce cutting current to 40- 50 amps reducing consumable parts wear if the...
  • Page 34 The display signal at J7-2 should be equal to the For the Standoff Control (SC11) used without the control pot wiper voltage at J7-18 measured in Step Remote Control (RC6010), the CNC input for CSD 3 above. is through J40-10 and J40-11 or J11-1 and J11-2 of the Standoff Control (SC11).
  • Page 35 Q. OK-To-Move Tests in J6-15 (24 VAC) measure for 24 VAC at J6-13 to J6-16. If OK, the problem is in the CNC cable con- 1. The Shunt Amp sends a voltage level to the Switch- nections to the cutting machine or the controller. ing Control PC Board that corresponds to the work 4.
  • Page 36 CAUTION Move the clamps only what is necessary for a steady pilot. Too much adjustment can cause increased parts wear. DO NOT move each clamp more than a total of 2 inches (50.8 mm). If a steady pilot cannot be achieved with the adjust- ment, then something else is wrong.

  • Page 37: Repairs & Replacement Procedures

    This Section describes parts replacement procedures and move the failed PC board. all repairs which may be performed on the Merlin 3000 Power Supply. 6. Carefully open the ESD protective bag and remove the replacement PC board.

  • Page 38: External Parts Replacement

    WARNING Left Side Panel Disconnect primary power from the source before opening or disassembling the power supply. Make sure AC indicator on the Power Supply front panel is OFF. Before disassembling any part of the Power Supply first read the procedure for the part to be replaced, then pro- ceed with the disassembly.

  • Page 39: Access Panel Parts Replacement

    2. Loosen the two screws of the Work Cable strain D. LED/Current Control PC Board Assembly relief securing the Work Cable at the Front Panel. Replacement 3. Remove the nut (under the Horizontal Chassis 1. Remove the Current Knob per paragraph 'A' above. Panel) securing the Work Cable connection to the 2.

  • Page 40: Rear Panel Parts Replacement

    3. Remove the Coolant Hose from the Internal Cool- 4. Carefully remove the Transformer Assembly from ant Filter Assembly. the unit. 4. Remove the Internal Coolant Filter from the fitting 5. Install the replacement Transformer Assembly by on the Radiator. reversing the above procedure.
  • Page 41 7. Locate and remove the four bolts and lock nuts 7. Install the replacement Solenoid Valve Assembly securing the Fan Assembly to the Rear Panel As- by reversing the above procedure and noting the sembly. following: 8. Carefully pull the Fan Assembly from the Rear •...
  • Page 42 G. Coolant Tank Replacement 12. Place the Deionizer Basket and Bag into the Cool- ant Tank filler hole and install the Coolant Tank 1. Remove the Left, Right, and Top Side Panels per Cap. Section 5.04-B. H. Flow Switch Assembly Replacement 2.

  • Page 43: Base Assembly Parts Replacement

    5.08 Base Assembly Parts CAUTION Replacement Handle and dispose of the used coolant per recom- NOTE mended procedures. Refer to Section 6.07, Base Assembly Replacement 3. Remove the two wires from the Conductivity Sen- Parts, for parts list and overall detail drawing. sor Assembly.

  • Page 44: Upper Chassis Parts Replacement

    6. Install the replacement Transformer Assembly by 4. Note the orientation of the Pump Assembly to the reversing the above procedure. Pump Mounting Plate. C. Main Contactor (W1 or W2) Replacement 5. Remove the three nuts securing the Pump Assem- bly to the Pump Mounting Plate.
  • Page 45 Transistor/Coil Switching Transistor Bracket Rear of Front Panel A-01083 Driver PC Board 5. Note and label the two wiring connectors that con- Large Blue nect to the Driver PC Board. A-01085 Capacitors 6. Disconnect the two wiring connectors from the Driver PC Board.
  • Page 46 Wire #84 PTC Resistor Assembly Wire #83 A-01086 Wire #82 Main Heatsink A-01089 Wire Connections (Q1 With E Terminal) 17. Remove the four screws securing the Switching Transistor module to the Main Heatsink. 18. Pry between the Main Heatsink and the faulty Wire #83 Switching Transistor Assembly until it slides eas- ily.
  • Page 47 C. Pressure Gauge Replacement E. Pressure Switch Replacement NOTE NOTE Both the Plasma and Secondary gauges are replaced Both the Plasma and Secondary Pressure Switches in the same manner are replaced in the same manner 1. Remove the Top Panel per Section 5.04-B. 1.
  • Page 48 3. Disconnect the gas Hose Assembly from the fitting 4. Disconnect the three connectors from the old Con- at the end of the Gas Input Fitting. trol Logic PC Board. 4. Remove the fitting screwed into the end of the Gas 5.

  • Page 49: Main Heatsink Assembly Parts Replacement

    A. 70 Amp STR. Diode Replacement Check Valve The Diode Replacement Kit (Cat # 8-1168) is a direct parts replacement for the failed Diode Assembly in Symbol the Power Supply. The following parts are supplied with each replace- ment assembly: •...
  • Page 50 d. Re-solder the wire lead to the replacement di- 6. Remove the nut securing the diode wire lead to the ode. PC Board. e. Apply a layer of RTV over the top of the Diode 7. Make sure the replacement diode is a direct re- Assembly to encapsulate the lead and top of placement for the old one.

  • Page 51: Hose Assembly Replacements

    7. Make sure the replacement diode is a direct re- 5. Install the replacement Hose Assembly by revers- placement for the old one. ing the above procedure. 8. Install the replacement diode by reversing the above B. Coolant Return Hose (RETURN Connector procedure and noting the following: to Radiator) Assembly Replacement a.
  • Page 52 NOTE 3. Disconnect the Other end of the Hose Assembly from the T-Fitting at the Plasma Pressure Gauge Refer to Subsection 6.08, Upper Chassis Replace- Assembly. ment Parts for part numbers and detail drawing. 4. Remove the Hose Assembly from the unit. 1.
  • Page 53 3. Remove the Hose Assembly from the unit. 5. Install the replacement Hose Assembly by revers- ing the above procedure. 4. Install the replacement Hose Assembly by revers- ing the above procedure. K. Plasma Gas Hose (Plasma Gas Solenoid to Plasma Gas Regulator) Assembly 5.
  • Page 54 REPLACEMENT PROCEDURES Manual 0-2533...

  • Page 55: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all basic replace- able parts. The parts lists are arranged as follows: Section 6.03: External Power Supply Replacement Parts List Section 6.04: Access Panel Replacement Parts Section 6.05: Front Panel/Chassis Replacement Parts Section 6.06: Rear Panel Replacement Parts...

  • Page 56: External Power Supply Replacement Parts List

    6.03 External Power Supply Replacement Parts List Item # Qty. Description Catalog # Complete Merlin 3000 Power Supply With Running Gear and Work Cable Without Gas Control GC3000 3-5100 With Gas Control GC3000 3-5101 Work Cable with Clamp - 25 ft (7.6 m)

  • Page 57: Access Panel Replacement Parts

    6.04 Access Panel Replacement Parts Item # Qty. Description Catalog # Access Panel Assembly Includes: 8-3257 Access Panel With Overlay 8-6302 Access Panel Overlay 8-3306 ON/OFF Rocker Switch, DPST 8-3258 Switch, Rocker, SPDT, Center Off 8-3259 LED/Current Control PC Board Assembly 9-5759 Knob, Inner Concentric 9-4146...

  • Page 58: Front Panel/Chassis Replacement Parts

    6.05 Front Panel/Chassis Replacement Parts Item # Qty. Description Catalog # Front Panel With Overlay 8-6304 Front Panel Overlay ------ Cord Grip 8-6307 Torch Leads Panel Boot 9-4210 Radiator 8-1347 #6 JIC x 3/8 NPT Male Union 8-6141 Coolant Filter 8-4276 Support, Inner Coolant Filter 8-3313...
  • Page 59 A-01217 Manual 0-2533 PARTS LISTS...

  • Page 60: Rear Panel Replacement Parts

    6.06 Rear Panel Replacement Parts Item # Qty. Description Catalog # Rear Panel 8-4505 Fan, 16" Axial 8-6312 Contactor, 25 amp, 2-pole, 120V Coil 8-5143 3 PH Contactor 8-1373 4 mfd, Capacitor 9-3210 Capacitor Mounting Bracket 8-6308 330k Ohms Resistor Assembly 9-5545 Voltage Selection PC Board 8-5144...
  • Page 61 A-01216 Manual 0-2533 PARTS LISTS...

  • Page 62: Base Assembly Replacement Parts

    6.07 Base Assembly Replacement Parts Item # Qty. Description Catalog # Base 8-5145 Caster, 5" Diameter 8-5578 Wheel, 8" Diameter 8-5579 Axle 9-1243 Retaining E-Ring, 1/2 Diameter Shaft 9-5539 Mat, Inductor Base 8-6143 DC Inductor Assembly 8-6145 29 KVA Transformer 8-6670 Main Contactor 9-1244...
  • Page 63 A-00894 Manual 0-2533 PARTS LISTS...

  • Page 64: Upper Chassis Replacement Parts

    6.08 Upper Chassis Replacement Parts Item # Qty. Description Catalog # Panel, Upper Chassis/Gauge 9-1302 Power Driver PC Board Assembly Includes: 7-3360 Thermstrate, Transistor (Refer to Section 6.09 Item # 7) 9-1406 Transistor, 300A, 550V Darlington (Refer to Section 6.09 Item # 8) 8-6154 Current Driver PC Board Assembly 9-4381...
  • Page 65 Item # Qty. Description Catalog # Check Valve, Male, 1/4 NPT, 5 PSI 8-4512 Hose Assembly, Secondary Water, Gauge To T-Fitting 8-4513 Hose Assembly, Secondary Gas/Water to Bulkhead 8-4514 Hose Assembly, Secondary Gas Inlet to Regulator 8-4515 Hose Assembly, Bulkhead to Coolant Pressure Gauge 8-4516 Hose Assembly, Secondary Water Inlet to Gauge 8-4517...

  • Page 66: Main Heatsink Assembly Replacement Parts

    6.09 Main Heatsink Assembly Replacement Parts Item # Qty. Description Catalog # Main Heatsink 9-1404 Capacitor, 550 mfd, 400VDC 9-1303 Bracket, Capacitor/Heatsink 8-4521 Support, Air Foil 8-2176 Capacitor Clamp 9-4212 Support, Heatsink Assembly 9-1304 Thermstrate, Transistor 9-1406 Transistor, 300A, 550V Darlington (Refer to Section 6.08 Item #2) 8-6154 Capacitor, 10 mfd, 400V Poly., Hi-Current 9-1305...
  • Page 67 A-00971 Manual 0-2533 PARTS LISTS...

  • Page 68: Power Supply Options And Accessories

    6.10 Power Supply Options And Accessories Item # Qty. Description Catalog # Remote Control (RC6010) 3-6106 Standoff Control (SC10) 3-6110 Gas Control (GC3000) 7-3411 Air Line Filter Assembly 7-3139 Replacement First Stage Filter Element 9-1021 Replacement Second Stage Filter Element 9-1022 Gas Regulators Nitrogen Regulator...
  • Page 69 FI ND P LA LI FT S TA 0. 2 0. 3 0. 1 P LY 0. 4 0. 5 0. 75 N TR 0. 25 PI ER 0. 5 (in ch T. H es ) 0. 1 .C . TI V IP M PI ER...
  • Page 70 PARTS LISTS Manual 0-2533...

  • Page 71: 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 tes) V o ltag e F r eq .

  • Page 72: 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 73: Appendix Iii: Typical Mechanized System Cable Connections

    APPENDIX III: TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS System With Remote Control RC6010, Standoff Control SC10 And Gas Control GC3000 GC3000 Gas Control Option Torch Lifter SC-10 Standoff Assembly Control RC6010 Remote Control CONTROL Workpiece Power Supply Earth Ground 3-Phase Input System With Standoff Control SC11 And Gas Control GC3000 Torch Lifter SC-11 Standoff...

  • Page 74: Appendix Iv: Interface Cables For Remote Control (Rc6010) And Standoff Control (Sc11)

    APPENDIX IV: INTERFACE CABLES FOR REMOTE CONTROL (RC6010) AND STANDOFF CONTROL (SC11) A-00983 APPENDIX Manual 0-2533...

  • Page 75: Appendix V: Cnc Interface

    APPENDIX V: CNC INTERFACE A-00982 Manual 0-2533 APPENDIX...

  • Page 76: Appendix Vi: 120 Vac Circuit Diagram

    APPENDIX VI: 120 VAC CIRCUIT DIAGRAM SWITCHING J28 TO OPTIONAL STANDOFF CONTROL CONTROL PCB F2 (9) (8) (110) (24) (10) SW1-A ON/OFF SOL3 SOL1 SOL2 (881) (22) (21) (89) (14) SW3-A (50) (75) (23) (15) VOLTAGE SELECTION PCB (24) LOGIC PCB A-01136 APPENDIX Manual 0-2533...

  • Page 77: Appendix Vii: Ladder Diagram - 15 Vdc

    APPENDIX VII: 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 J3-9 OXYGEN ENABLE WATER CONTACTOR DISABLE SENSE BRIDGE (Only after main con- VOLTAGE tactor initially closes) <60VDC...

  • Page 78: Appendix Viii: Signal Flow Block Diagram

    APPENDIX VIII: SIGNAL FLOW BLOCK DIAGRAM A-01139 APPENDIX Manual 0-2533...

  • Page 79: Appendix Ix: Start Circuit Diargram

    APPENDIX IX: START CIRCUIT DIARGRAM A-01079 Standoff Control SC11 PLASMA START FIND HT A-01080 START J8-17 J40-3 FIND J40-4 J8-18 J8-10 J42-3 OPTO- Merlin 3000 START J11-3 J15-24 Isolator Merlin 6000 J11-4 J42-4 START J15-25 Merlin 6000GST J8-11 Manual 0-2533 APPENDIX...

  • Page 80: Appendix X: Current Control / Display Circuit Diagram

    APPENDIX X: CURRENT CONTROL / DISPLAY CIRCUIT DIAGRAM A-01138 APPENDIX Manual 0-2533...

  • Page 81: Appendix Xi: Csd (Corner Slowdown) Circuit Diagram

    APPENDIX XI: CSD (CORNER SLOWDOWN) CIRCUIT DIAGRAM A-01140 Manual 0-2533 APPENDIX...

  • Page 82: Appendix Xii: Ok-To-Move Circuit Diagram

    APPENDIX XII: OK-TO-MOVE CIRCUIT DIAGRAM Merlin 3000 or Merlin 6000 or Merlin 6000GST with Remote Control RC6010 / Standoff Control SC10 OK-To-Move Circuit OFF = OK-To-Move PIERCE DELAY 0 - 3 seconds 24 VAC Source A-01081 Standoff Control SC11 OK OUT...

  • Page 83: Appendix Xiii: Hose Block Diagram

    Plasma Gas Hose Assembly Gas Connections Rear Panel To Regulator (Rear Panel) Plasma Gas Solenoid Plasma Gas (+) Regulator (Front Panel) Secondary Gas Check Valve Regulator Solenoid Secondary Gas (Front Panel) Secondary Gas/Water Hose Assembly Plasma Gas Pressure T-Fitting T-Connection To T-Connection Gauge (Front Panel) Check Valve Secondary Water...

  • Page 84: Appendix Xiv: System Schematic

    APPENDIX XIV: SYSTEM SCHEMATIC A-00981 APPENDIX Manual 0-2533...
  • Page 85 A-00981 Manual 0-2533 APPENDIX...

  • Page 86: Appendix Xv: Recommended Routine Maintenance Schedule For Liquid Cooled Plasma Cutting Systems

    APPENDIX XV: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS This 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...

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