Thermal Dynamics MERLIN 6000 Service Manual
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Thermal Dynamics MERLIN 6000 Service Manual

Thermal Dynamics MERLIN 6000 Service Manual

Ce plasma cutting slave power supply
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®
MERLIN
6000
CE Plasma Cutting
Slave Power Supply
A-01526

Service Manual

September 29, 2005
Manual No. 0-2604

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Summary of Contents for Thermal Dynamics MERLIN 6000

  • Page 1: Service Manual

    ® MERLIN 6000 CE Plasma Cutting Slave Power Supply A-01526 Service Manual September 29, 2005 Manual No. 0-2604...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Merlin 6000 CE Plasma Cutting Slave Power Supply Service Manual No. 0-2604 Published by: Thermal Dynamics Corporation...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • Page 5 APPENDIX 3: PARALLEL CABLE ..................... A-3 APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE ............A-4 APPENDIX 5: MERLIN 6000 SLAVE POWER SUPPLY - 120 VAC CIRCUIT DIAGRAM ... A-5 APPENDIX 6: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM - For Merlin 6000 System ................. A-6 APPENDIX 7: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES - For Merlin 6000 System ................

  • Page 6: Table Of Contents (Continued)

    TABLE OF CONTENTS (Continued) APPENDIX 13: SYSTEM SCHEMATIC - Rev 'E' or Earlier ............A-18 APPENDIX 14: SYSTEM SCHEMATIC - Rev 'F' ..............A-20 APPENDIX 15: SYSTEM SCHEMATIC - Unit Rev 'AG' ............A-22 APPENDIX 16: SYSTEM SCHEMATIC - Unit Rev 'AH' or later ..........A-24...

  • Page 7: Section

    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 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection 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.

  • Page 13: 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 14: 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 15: Introduction

    This Manual provides Service Instructions for Thermal Maintenance work should be accomplished in a timely Dynamics Merlin 6000 CE Master Power Supply. Infor- manner. If problems are encountered, or the equipment mation in this manual is therefore particularly applicable...
  • Page 16 INTRODUCTION Manual 0-2604...

  • Page 17: Introduction & Description

    3.02 General Description A-01526 The Slave Power Supply may be connected in parallel to double the cutting current of the Merlin 6000 or Merlin 6000GST Master Power Supply. All signal inputs/out- puts, gas, and torch connections are still connected to the...

  • Page 18: Specifications & Design Features

    6. Power Supply Dimensions 3.03 Specifications & Design Features Enclosure Only - Width: 24.12 in (0.61 m) The following apply to the Slave Power Supply only: Height: 38.38 in (0.98 m) 1. Controls Depth: 34.25 in (0.87 m) ON/OFF Switch Fully Assembled - 2.

  • Page 19: Troubleshooting

    The Merlin 6000 Sys- tem uses the same Slave Power Supply as the Merlin The CE Merlin 6000 Slave Power Supply is used with ei- 6000GST System. A switch on the Switching Control PC ther the CE Merlin 6000 or CE Merlin 6000GST Master Board (PCB) configures the power supply for Merlin 6000 Power Supply.
  • Page 20 (L2A and L2B), resistor R13, and capacitor C23. A DIP-switch (SW1) configures the Switching Control PCB for no current ramping (Merlin 6000) or current D. Switching Control PC Board (PCB) ramping (Merlin 6000GST). The Switching Control PC Board compares the shunt amp...
  • Page 21 E. Logic PC Board (PCB) Functions removes the PWM enable signal. This 1/2 second delay allows time for the Switching Control PCB The Logic PC Board used in the Slave Power Supply is the to ramp the output current down until the arc goes same part as used in the Master Power Supply.

  • Page 22: Troubleshooting Guide

    Board Check. Replace Voltage Selection PC surements. It is helpful for solving many of the common Board if necessary problems that can arise with the Merlin 6000 Slave Power Supply. B. AC indicator ON; Fan not operating If major complex subassemblies are faulty, the unit must 1.
  • Page 23 C. Fuse blows at disconnect when primary power is 2. Faulty thermal sensor (TS1 to TS5) turned ON a. Refer to Section 4.05-F, Thermal Sensing Circuit 1. Voltage selection busbars connected incorrectly Check. Replace sensor(s) if necessary a. Check and correct if necessary. 3.
  • Page 24 G. Depending on the Logic Control PCB installed refer to I. Main arc starts but current is 1/2 what is expected; one of the following symptoms Main contactor (W1 or W2) goes off • For Logic Control PCB 19x1247 or 19x1360 rev AE or 1.

  • Page 25: Test Procedures

    4. If output is not present at J6-19 and J6-21, check 4.05 Test Procedures between J6-24 (-) and both J6-16 and J6-23 (+) for 12 - 16 vdc. If voltage is present at both points or The following tests are suggested for specific problems neither, replace the Voltage Selection PC Board.
  • Page 26 Check for +15 vdc from TP1 to TP2. • If voltage is incorrect, then the PCB may be faulty, Merlin 3000, 6000 or 6000GST proceed to next step RC6010 Switching • If voltage is correct, then reinstall the connec- Control PCB tors one at a time to isolate the problem.
  • Page 27 Only one of the two contactors should have voltage 3. Diodes can overheat if air flow over the heatsink is applied. If the red LED indicator (D18) on the volt- not adequate or if the diode is not properly fas- age selection board is lit, MC2 should be energized.
  • Page 28 G. Power Supply Start Circuit H. Switching Control Check (Q1) The following describes the flow of the START signal To produce DC output, the main switch (Q1) must be turned through the system. on and off rapidly. Power Supply output is controlled by the on-time.
  • Page 29 H-1. Switching Transistor H-2. IGBT There are two types of Switching Transistor / IBGT. The On units with Q1 without Suppressor PC Board: types can be identified by the top of the casing. Style With 3 Terminals Style With 2 Terminals Q1 without IGBT Suppressor PC Board: Q1 with E Terminal: Art # A-06055...
  • Page 30 If correct, measure from the gate terminal to emitter termi- If switching pulses are present at J8-1 and J8-3, check the nal. Normal reading is 2.2 ohms (digital meter on ohms Driver PC Board output between J27-3 and J27-2. not diode scale) a short (zero ohms) or an open indicates a The Driver PC Board output, J27-3 to J27-20, should mea- defective Q1.
  • Page 31 2. START LED on Logic PC Board is never ON, not b. If spark gap is not firing, check for 24 VAC (Arc even momentarily. Starter Box PC Board LED is ON) and DC greater than 250V at E1 & E2 fastons on Arc a.
  • Page 32 • If shutdown continues, the Logic PC Board is If PILOT indicator is ON and PCR is not closing, check for faulty. 120 VAC between wire #110 and J2-1 on the Logic PC Board. If output current is set for over 250A and the PILOT NOTE contactor stays ON, check for a logic low (near zero Refer to Appendix 5 for 120 V AC Circuit Diagram.
  • Page 33 K. Current Control, Display and CSD Checks 3. Remote AMPS Display NOTE NOTE Refer to Appendix 11 for Current Control and Dis- Refer to Appendix 11 for Current Control and Dis- play Circuit Diagram. play Circuit Diagram The Remote Control (RC 6010) AMPS displays the fol- 1.
  • Page 34 The Current Control potentiometer voltage of 3.3 to 10 L. Isolation PCB and Parallel Cable Checks vdc gives a display of 50 to 150A or 100 to 300A, if the The Slave Power Supply is controlled from the Master Slave supply is ON. The voltage comes from the Mas- Power Supply.
  • Page 35 M. Pilot Resistor Adjustment Pilot Resistor WARNING Clamp Wire #99 Wire #96A Pilot Resistor Disconnect primary power at the source before as- sembling or disassembling power supply, torch parts, or torch and leads assemblies. Wire This Sub-Section applies only to the following Slave Power Supplies: Pilot Resistor •...
  • Page 36 The reason is because within each range the Power Supply will automatically select a high or low tap on the transformer secondary. This is based on the input AC line voltage at the time the Power Supply is turned ON. If the line voltage is near one of these points the voltage might measure, for Wire #99 example, 410 VAC and the pilot resistor setting...

  • Page 37: Replacement Procedures

    B. Procedure SECTION 5: 1. Open the wrist strap and unwrap the first two folds REPLACEMENT of the band. Wrap the adhesive side firmly around PROCEDURES your wrist. 2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

  • Page 38: Parts Replacement - General Information

    5.03 Parts Replacement - General 5.04 External Parts Replacement Information NOTE The parts replacement procedures described in this Refer to Section 6.03, External Power Supply Re- manual, except for external Fuse(s) replacement, require placement Parts, for parts list and overall detail that the Power Supply be disassembled.

  • Page 39: Access Panel Parts Replacement

    B. Top Panel Replacement B. LED PC Board Assembly Replacement 1. Remove the Left and Right Side Panels per para- 1. Unlatch the Access Panel to gain access to the LED graph 'B' above. PC Board. 2. On the top of the unit remove the Coolant Tank 2.

  • Page 40: Rear Panel Parts Replacement

    B. Transformer (T2) Assembly Replacement 5.07 Rear Panel Parts Replacement The Transformer (T2) Assembly is mounted to the rear NOTE of the Horizontal Chassis Panel and has 25.2 VCT (Center Tap) output. Refer to Section 6.06, Rear Panel Parts Replace- ment, for parts list and overall detail drawing.

  • Page 41: Base Assembly Parts Replacement

    C. Main Contactor (W1 or W2) Replacement 5.08 Base Assembly Parts Replacement NOTE The Main Contactors, W1 and W2, are replaced in NOTE the same manner. Refer to Section 6.07, Base Assembly Replacement 1. Depending on which Main Contactor Assembly is Parts, for parts list and overall detail drawing.

  • Page 42: Upper Chassis Parts Replacement

    7. Carefully use a wrench to remove the Thermostat 5.09 Upper Chassis Parts Assembly. If resistance is felt, apply more heat (see Replacement NOTE). NOTE NOTE Using excessive force will cause the Thermostat As- Refer to Section 6.08, Upper Chassis Replacement sembly mounting stud to shear off.

  • Page 43: Installation Procedure

    The kit also includes: 4. Press in the securing tab knob on the PC Board Guide to release the PC Board from the PC Board Guides. • Installation Instructions There is a securing tab on both the upper and lower PC •...
  • Page 44 5. Remove the screw that secures the Transistor/Coil 12. Install the replacement Thermal pad, the IGBT Assem- Bracket to the Switching Transistor/IGBT Assembly. bly, IGBT Suppressor PC Board, and the replacement wire harness included in this kit in the sequence 6.
  • Page 45 4. Shunt Amp PCB Replacement 5. Loosen, but do not remove, the screws securing the Shunt Amp PCB to the Shunt. 1. Locate the Shunt Amp PCB, mounted to the Shunt on 6. Refer to the illustration. Remove the Shunt Amp PCB the main heatsink.

  • Page 46: Main Heatsink Assembly Parts Replacement

    B. Auxiliary Transformer (T2) Assembly E. Switching Control PC Board Assembly Replacement Replacement 1. Remove the Left Side Panel per Section 5.04-A. 1. Remove the Top and Right Side Panels per Section 5.04-B. 2. Disconnect the wiring connector from the wiring harness at the Auxiliary Transformer Assembly.
  • Page 47 4. Locate the old Diode Assembly inside the Power B. Relay Replacement (PSR and O Supply. The two Relay Assemblies are replaced in the same 5. Unsolder the wire lead from the old Diode As- manner. The PSR Relay is 110 vdc and the O Relay sembly.
  • Page 48 b. Position the thermal interface pad between the 8. Install the replacement diode by reversing the diode and contact surface where the diode will above procedure and noting the following: be installed. a. Wipe the surface clean where the replacement diode is to be installed.

  • Page 49: 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 Section 6.07 Base Assembly Replacement Parts...

  • Page 50: External Power Supply Replacement Parts List

    6.03 External Power Supply Replacement Parts List Item # Qty. Description Catalog # Complete CE Merlin 6000 Slave Power Supply w/Running Gear & Work Cable 3-6801-E Work Cable with Ring Lug - 25 ft (7.6 m) 9-6892 Panel, Top 9-7752 Panel, R.H.

  • Page 51: Access Panel Replacement Parts

    6.04 Access Panel Replacement Parts Item # Qty. Description Reference Catalog # Access Panel Assembly Includes: Access Panel With Overlay 9-9027 ON/OFF Rocker Switch, DPST 8-3258 LED PC Board Assembly 9-9028 A-02392 Manual 0-2604 PARTS LISTS...

  • Page 52: Front Panel/Chassis Replacement Parts

    6.05 Front Panel/Chassis Replacement Parts Item # Qty. Description Reference Catalog # Front Panel With Overlay 9-9029 Strain Relief 9-2179 Strain Relief 8-6307 Horizontal Chassis Panel 9-6655 Resistor, 8 ohm 9-3431 Resistor Mounting Bracket Kit 8-4234 A-02393 PARTS LISTS Manual 0-2604...

  • Page 53: Rear Panel Replacement Parts

    6.06 Rear Panel Replacement Parts Item # Qty. Description Reference Catalog # Rear Panel 9-9030 Fan, 16" Axial 8-6312 Relay, 25 amp, 120 AC MC1, MC2 8-3390 Voltage Selection PC Board 8-5144 P.C. Board Supoort 9-5333 Bracket, Heatsink Support 8-5576 Strain Relief, For #10 Stranded Wire 8-4249 3 PH Contactor (Rev 'F' units or later) - See Note...

  • Page 54: Base Assembly Replacement Parts

    6.07 Base Assembly Replacement Parts Item # Qty. Description Reference Catalog # Base 9-6657 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 9-6662 DC Inductor Assembly 8-6145 29 KVA Transformer 8-6670 Main Contactor W1, W2...
  • Page 55 A-02656 Manual 0-2604 PARTS LISTS...

  • Page 56: Upper Chassis Replacement Parts

    6.08 Upper Chassis Replacement Parts Item # Qty. Description Reference Catalog # Panel, Upper Chassis/Gauge 9-6658 Power Driver PC Board Assembly Includes: 7-3360 Thermstrate, Transistor* (Refer to Section 6.09 Item # 7) 9-1406 Switching Transistor,/IGBT* (Refer to Section 6.09 Item # 8) Power Driver PC Board Assembly* Not Available Separately PC Board Guide With 16mm Screw...
  • Page 57 2 (Part of 7-3360 Kit) 7-3360 Kit Driver IGBT Wire Harness PC Board Suppressor PC Board IGBT Shunt Amp PC Board Thermal Art # A-06796 NOTE Kit # 7-3360 includes several parts. If any of these parts fail, all must be replaced at the same time (along with additional parts in the kit).

  • Page 58: Main Heatsink Assembly Replacement Parts

    6.09 Main Heatsink Assembly Replacement Parts Item # Qty. Description Reference 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 9-6663 Thermstrate, Transistor* 9-1406 Transistor/IGBT* (Refer to Section 6.08 Item #2) Capacitor, 10 mfd, 400V Poly., Hi-Current 9-1305 Bracket, Capacitor Mounting...
  • Page 59 31 (Part of 7-3360 Kit) REPLACED BY: Art # A-06759 7-3360 Kit Driver IGBT Wire Harness PC Board Suppressor PC Board IGBT Shunt Amp PC Board Thermal NOTE Kit # 7-3360 includes several parts. If any of these parts fail, all must be replaced at the same time (along with additional parts in the kit).
  • Page 60 PARTS LISTS 6-12 Manual 0-2604...

  • Page 61: Appendix 1: Input Wiring Requirements

    APPENDIX 1: 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 est ed S iz es ( S ee N o t e) V o ltag e F r eq .

  • Page 62: Appendix 2: Typical Mechanized System Work And Ground Cable Connections

    APPENDIX 2: 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 63: Appendix 3: Parallel Cable

    APPENDIX 3: 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 Manual 0-2604...

  • Page 64: Appendix 4: Routine Maintenance Schedule

    APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE This recommended schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Cutting Hours: Check torch consumable parts, replace if damaged or worn.

  • Page 65: Appendix 5: Merlin 6000 Slave Power Supply - 120 Vac Circuit Diagram

    APPENDIX 5: MERLIN 6000 SLAVE POWER SUPPLY - 120 VAC CIRCUIT DIAGRAM SW1-A 5A, 250 VAC NEON IND1 VOLTAGE SELECTION PC BOARD SWITCHING CONTROL PC BOARD (Energized by Enable Switch) K4 (HV) K3 (LV) K3 (LV) K4 (HV) LOGIC PC BOARD...

  • Page 66: Appendix 6: Typical Mechanized System Cable Interconnection Diagram - For Merlin 6000 System

    APPENDIX 6: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM - For Merlin 6000 System NOTE Refer to Appendix 7 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...
  • Page 67 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 0-2604 APPENDIX...

  • Page 68: Appendix 7: Quick Reference To Interconnecting Cables And Hoses - For Merlin 6000 System

    APPENDIX 7: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES - For Merlin 6000 System C a b l e / H o s e D i a m e t e r C a b l e D e s c r i p t i o n...
  • Page 69 Manual 0-2604 APPENDIX...

  • Page 70: Appendix 8: Typical Mechanized System Cable Interconnection

    APPENDIX 8: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM - For Merlin 6000GST System NOTE Refer to Appendix 9 for complete data on the Cables and Hoses. Gas Control Cable Master Power Supply RC 6010 Secondary H Pre-Flow Gas RC 6010 Plasma Gas Internal Ribbon Cable...
  • Page 71 Gas Control Module Secondary Water Hose GCM6000 (Optional) Secondary Water Flow Control Module Secondary RAS Plasma RAS Pre-Flow RAS Arc Starter Control Cable Arc Starter Box Shield SOL2 SOL1 SOL3 SOL4 Arc Starter PCB Work Cable Workpiece Art # A-01790 Work Cable Manual 0-2604 A-11...

  • Page 72: Appendix 9: Quick Reference To Interconnecting Cables And Hoses - For Merlin 6000Gst System

    APPENDIX 9: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES - For Merlin 6000GST System Cable/Hose Diameter Cable/Hose Diameter Cable Description Catalog # Inches Cable Description Catalog # Inches Power Supply CNC Cable Work Cable 25 ft (7.6 m) 8-3380 25 ft (7.6 m) 9-6892 50 ft (15.2 m) 8-3381...

  • Page 73: Appendix 10-A: Ladder Diagram - 15 Vdc (Rev Ae Or Earlier Logic Control Pc Board

    APPENDIX 10-A: LADDER DIAGRAM - 15 vdc (Rev AE or Earlier Logic Control PC Board) LOGIC CONTROL BOARD START/STOP (CNC) 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 To disable this circuit for troubleshooting...

  • Page 74: Appendix 10-B: Ladder Diagram - 15 Vdc (Rev Af Or Later Logic Control Pc Board

    APPENDIX 10-B: LADDER DIAGRAM - 15 vdc (Rev AF or Later Logic Control PC Board) LOGIC CONTROL BOARD CONTACTOR START/STOP (CNC) CONTACTOR OFF DELAY SWITCH RECOGNITION START INDICATOR CONTROL PWM-ON J3-9 ENABLE PWM DISABLE SENSE BRIDGE (Only after main con- VOLTAGE tactor initially closes) <60VDC...

  • Page 75: Appendix 11: Current Control And Display Diagram

    APPENDIX 11: CURRENT CONTROL AND DISPLAY DIAGRAM Remote Control Cable Master Power Supply Switching Control PCB Remote Control (RC6010) Output AMPS Remote Pot High Adjustment 10 VDC (86) J37-5 J15-20 J50-8 Remote Demand 3.3 - 10 VDC (32) Demand Signal J37-21 J15-1 J7-17...

  • Page 76: Appendix 12: Parallel Interface Diagram

    APPENDIX 12: PARALLEL INTERFACE DIAGRAM Slave Power Supply Master Power Supply Logic PCB +15 V. (123) J4-7 J4-9 (120) J15-35 (124) J4-8 This is Slave J4-10 (119) J3-29 This is Slave J15-36 Isolation PCB +15 V. J54-14 J15-17 Slave is On (131) J1-20 J71-1...
  • Page 77 Logic PCB +15 V. (123) J4-7 J4-8 J4-9 (120) (124) This is Slave J15-35 J4-10 (119) J3-29 This is Slave J15-36 +15 V. Slave is On J15-17 Slave is On (129) J1-20 J70-24 J4-4 (45) High sets Remote to Display 300A J4-3 14 V / 1 V J70-22...

  • Page 78: Appendix 13: System Schematic - Rev 'E' Or Earlier

    APPENDIX 13: SYSTEM SCHEMATIC - Rev 'E' or Earlier A-01727 APPENDIX A-18 Manual 0-2604...
  • Page 79 NOTE System Schematic for units with the letter 'E' or earlier on the data tag. A-01727 Manual 0-2604 A-19 APPENDIX...

  • Page 80: Appendix 14: System Schematic - Rev 'F

    APPENDIX 14: SYSTEM SCHEMATIC - Rev 'F' Art # A-02657 APPENDIX A-20 Manual 0-2604...
  • Page 81 NOTE System Schematic for units with the letter 'F' on the data tag. Art # A-02657 Manual 0-2604 A-21 APPENDIX...

  • Page 82: Appendix 15: System Schematic - Unit Rev 'Ag

    APPENDIX 15: SYSTEM SCHEMATIC - Unit Rev 'AG' Art # A-04884 APPENDIX A-22 Manual 0-2604...
  • Page 83 NOTE System Schematic for units with 'AG' on the data tag. Art # A-04884 Manual 0-2604 A-23 APPENDIX...

  • Page 84: Appendix 16: System Schematic - Unit Rev 'Ah' Or Later

    APPENDIX 16: SYSTEM SCHEMATIC - Unit Rev 'AH' or later Art # A-06022 APPENDIX A-24 Manual 0-2604...
  • Page 85 Art # A-06022 Manual 0-2604 A-25 APPENDIX...
  • Page 86 APPENDIX A-26 Manual 0-2604...

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