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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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Read and understand this entire Service Manual and your WARNING employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Service Manual repre- WARNING sents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. MERLIN 3000 Plasma Cutting Power Supply Service Manual Number 0-2533 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 Co
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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,
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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 ........................................
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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. are used to highlight important information. These high- • Use an air-supplied respirator if ventilation is not lights are categorized as follows: adequate to
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• 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. • Disconnect power source before performing any ser- • Wear welding gloves and suitable clothing to pro- vice or repairs. tect your skin from the arc rays and sparks. • Read and follow all the instructions in the Operat- • Keep helmet a
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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 dans la zone de travail en cas de non-respect de la proc
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• 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. Le procédé ou plusieurs des éléments suivants: à l’arc de plasma produit du métal, des étincelles, des antimoine cadm
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• 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 Numéro l’Institut Américain des Normes Nationales (Ameri- can National Standards Institute), 1430 Broadway, Moins de 300* 8 9 New York, NY 10018 300 - 400* 9 12 5. Norme ANSI Z41.1, NORMES POUR LES 400 - 800* 10
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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. Norme ANSI Z88.2, PRATIQUES DE PROTEC- TION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018 GENERAL INFORMATION 6 Date 6/22/99
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1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 USA 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. Serial numbers are unique with each individual piece of equipment and details descri
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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,
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2.03 Service Responsibilities SECTION 2: The Service Technician should be familiar with the equip- INTRODUCTION ment and its capabilities. He should be prepared to rec- ommend arrangements of components which will pro- vide the most efficient layout, utilizing the equipment to 2.01 Scope Of Manual its best possible advantage. This Manual provides Service Instructions for Thermal Maintenance work should be accomplished in a timely Dynamics Merlin 3000 Power Supply. manner. If problems are enc
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INTRODUCTION 10 Manual 0-2533
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• 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 • 25 ft (7.6 m) Work Cable and Clamp • Air Line Filter Assembly (or) High Pressure Regula- The information in this Section is the same information tors contained in Section 2 of the Operating Manual. It is sup- plied here to familiarize the Service
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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. The plasma arc cutting process uses this plasma 7. CNC Signals 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 Enable Start/Stop, OK-to-Move, Pilot Sensing Relay blown
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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. The Maximizer high frequency arc initiation. These shielded systems are 300 also can use secondary gases such as compressed air, designed with features such as
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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. H. Plasma/Secondary Gas Control A remote control to select one of various plasma and secondary gases, including secondary water, that can be connected to the Power Supply. INTRODUCTION & D
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To clean the unit, first make sure that the power is SECTION 4: disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air SERVICE especially from the radiator. The unit should also be wiped clean. If necessary, solvents that are recom- TROUBLESHOOTING mended for cleaning electrical apparatus may be used. DIAGNOSTICS While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected.
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hot soapy water. Remove soap residue by rinsing with 4. Reconnect the hose to the filter assembly. clean hot water. Be sure that all the soap has been 5. Install new coolant and deionizer bag. removed and the screen is dry of water before re-in- stalling in the Internal Filter Assembly. 6. Reinstall the top and right side panels. E. Coolant Level and Conductivity 4.03 System Theory 1. Coolant Level A. Circuit Description The coolant level should be checked every day at the rear panel co
