Plasma Cutting Master Power Supply - Central Welding Supply 6000 Operating manual.pdf · 7. AWS Standard A6.0, WELDING AND CUTTING CON-TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-tainable

August 19, 2005 Manual No. 0-2568

MERLIN ®

6000Plasma Cutting

Master Power Supply

Operating Manual

A-01497

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, theManufacturer assumes no liability for its use.

Merlin 6000 Plasma Cutting Master Power SupplyOperating Manual No. 0-2568

Published by:Thermal Dynamics Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

© Copyright 1997 byThermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written per-mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability toany party for any loss or damage caused by any error or omission inthis Manual, whether such error results from negligence, accident, orany other cause.

Printed in the United States of America

Publication Date: August 19, 2005

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:_______________________________________

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-11.02 Important Safety Precautions ....................................................................... 1-11.03 Publications .................................................................................................. 1-21.04 Note, Attention et Avertissement .................................................................. 1-31.05 Precautions De Securite Importantes ........................................................... 1-31.06 Documents De Reference ............................................................................. 1-51.07 Declaration of Conformity ............................................................................. 1-71.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:INTRODUCTION & DESCRIPTION ................................................................................... 2-1

2.01 Scope of Manual .......................................................................................... 2-12.02 General Description ...................................................................................... 2-12.03 Specifications & Design Features ................................................................. 2-22.04 Theory Of Operation ..................................................................................... 2-32.05 Options And Accessories ............................................................................. 2-4

SECTION 3:INSTALLATION PROCEDURES ........................................................................................ 3-1

3.01 Introduction ................................................................................................... 3-13.02 Site Location ................................................................................................ 3-13.03 Unpacking .................................................................................................... 3-13.04 Removing Skid ............................................................................................. 3-13.05 Filling Master Power Supply Coolant ............................................................. 3-23.06 Input Power Connections .............................................................................. 3-23.07 Voltage Selection .......................................................................................... 3-33.08 Primary Power Cable Connections ................................................................ 3-43.09 Ground Connections For Mechanized Applications ....................................... 3-43.10 Plasma And Secondary Gas Connections .................................................... 3-63.11 Connecting Torch Supply Leads ................................................................... 3-123.12 External Cable Connections ......................................................................... 3-133.13 Master/Slave Parallel Cable Connection ...................................................... 3-163.14 Lifting Options ............................................................................................. 3-163.15 Pilot Resistor Adjustment ............................................................................ 3-16

SECTION 4:OPERATION...................................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-14.02 Functional Overview ..................................................................................... 4-14.03 Front and Rear Panel Descriptions ................................................................ 4-14.04 Operating Unit Without Gas Control Option ................................................... 4-44.05 Operating Unit With Gas Control Option ........................................................ 4-64.06 System Operation ......................................................................................... 4-74.07 Optional Power Supply Settings .................................................................... 4-8

TABLE OF CONTENTS (continued)

SECTION 5:CUSTOMER/OPERATOR SERVICE .................................................................................. 5-1

5.01 Introduction................................................................................................... 5-15.02 General Maintenance .................................................................................... 5-15.03 Common Operating Faults ............................................................................ 5-25.04 Troubleshooting ............................................................................................. 5-25.05 Basic Parts Replacement ............................................................................. 5-5

SECTION 6:PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction................................................................................................... 6-16.02 Ordering Information ..................................................................................... 6-16.03 Complete Power Supply Replacement Parts List .......................................... 6-26.04 Basic Component Replacement Parts List .................................................... 6-36.05 Power Supply Options And Accessories ....................................................... 6-4

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION BLOCK DIAGRAM ............................................. A-2

APPENDIX 3: TYPICAL MECHANIZED SYSTEM WORK AND GROUNDCABLE CONNECTIONS.................................................................................................... A-3

APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM ... A-4

APPENDIX 5: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES ............ A-6

APPENDIX 6: INTERFACE CABLE FOR REMOTE CONTROL (RC6010) ................................. A-7

APPENDIX 7: INTERFACE CABLE FOR STANDOFF CONTROL (SC11) ................................. A-8

APPENDIX 8: CNC INTERFACE CABLES................................................................................ A-9

APPENDIX 9: LADDER DIAGRAM - 120 VAC ........................................................................ A-10

APPENDIX 10-A: LADDER DIAGRAM - 15 vdc (Rev AE or Earlier Logic Control PC Board) .. A-11

APPENDIX 10-B: LADDER DIAGRAM - 15 vdc (Rev AF or Later Logic Control PC Board) ..... A-12

APPENDIX 11: PARALLEL CABLE ......................................................................................... A-13

APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE......................................................... A-14

APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier ...................................................... A-16

APPENDIX 14: SYSTEM SCHEMATIC - Rev 'AK' or Later ..................................................... A-18

Date: January 27, 2004 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warningsare used to highlight important information. These high-lights are categorized as follows:

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, maycause damage to the equipment.

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in the oper-ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO YOURHEALTH.

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with theproper function of cardiac pacemakers, hearingaids, or other electronic health equipment. Per-sons who work near plasma arc cutting applica-tions should consult their medical health profes-sional and the manufacturer of the healthequipment to determine whether a hazard exists.

To prevent possible injury, read, understand andfollow all warnings, safety precautions and in-structions before using the equipment. Call 1-603-298-5711 or your local distributor if you have anyquestions.

GASES AND FUMES

Gases and fumes produced during the plasma cuttingprocess can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is notadequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arcdepend on the kind of metal being used, coatingson the metal, and the different processes. You mustbe very careful when cutting or welding any met-als which may contain one or more of the follow-ing:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

• Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

• For information on how to test for fumes and gasesin your workplace, refer to item 1 in Subsection 1.03,Publications in this manual.

• Use special equipment, such as water or down draftcutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vaporsof chlorinated solvents and cleansers. Remove allsources of these vapors.

• This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects and, in some cases, cancer. (California Health& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc processuses and produces high voltage electrical energy. Thiselectric energy can cause severe or fatal shock to the op-erator or others in the workplace.

• Never touch any parts that are electrically “live”or “hot.”

GENERAL INFORMATION 1-2 Date: January 27, 2004

• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace ismoist or damp.

• Install and maintain equipment according to NECcode, refer to item 9 in Subsection 1.03, Publica-tions.

• Disconnect power source before performing anyservice or repairs.

• Read and follow all the instructions in the Operat-ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, orthe plasma arc.

• Be sure there is no combustible or flammable ma-terial in the workplace. Any material that cannotbe removed must be protected.

• Ventilate all flammable or explosive vapors fromthe workplace.

• Do not cut or weld on containers that may haveheld combustibles.

• Provide a fire watch when working in an area wherefire hazards may exist.

• Hydrogen gas may be formed and trapped underaluminum workpieces when they are cut under-water or while using a water table. DO NOT cutaluminum alloys underwater or on a water tableunless the hydrogen gas can be eliminated or dis-sipated. Trapped hydrogen gas that is ignited willcause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-cesses can cause noise levels to exceed safe limits. Youmust protect your ears from loud noise to prevent per-manent loss of hearing.

• To protect your hearing from loud noise, wear pro-tective ear plugs and/or ear muffs. Protect othersin the workplace.

• Noise levels should be measured to be sure the deci-bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.The plasma arc process produces very bright ultra violetand infra red light. These arc rays will damage youreyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-met or shield. Also always wear safety glasses withside shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.Use protective booths, screens or shields.

• Use the shade of lens as suggested in the followingper ANSI/ASC Z49.1:

Minimum Protective SuggestedArc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearlyseen. Experience has shown that lighter filtersmay be used when the arc is hidden by the work-piece.

1.03 Publications

Refer to the following standards or their latest revisionsfor more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR1910, obtainable from the Superintendent of Docu-ments, U.S. Government Printing Office, Washington,D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable from the American Welding So-ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDINGAND GAS WELDING AND CUTTING, obtainablefrom the Superintendent of Documents, U.S. Govern-ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-PATION AND EDUCATIONAL EYE AND FACE PRO-TECTION, obtainable from American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’SSAFETY-TOE FOOTWEAR, obtainable from the Ameri-can National Standards Institute, 1430 Broadway, NewYork, NY 10018


6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from American National Standards Institute, 1430Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-tainable from American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,obtainable from the National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN CYLINDERS, obtainable from theCompressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-ING AND CUTTING, obtainable from the CanadianStandards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHYobtainable from the National Welding Supply Associa-tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARA-TION FOR WELDING AND CUTTING OF CONTAIN-ERS AND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots “note,” “attention,” et“avertissement” sont utilisés pour mettre en relief desinformations à caractère important. Ces mises en reliefsont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignementgénéral sur lequel il importe d’insister davantageou qui contribue à l’efficacité de fonctionnementdu système.

ATTENTION

Toute procédure pouvant résulterl’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessuresde l’opérateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de laprocédure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC AU JETDE PLASMA PEUVENT PRÉSENTER DESRISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergieélectrique haute tension et des émissionsmagnétique qui peuvent interférer la fonctionpropre d’un “pacemaker” cardiaque, les appareilsauditif, ou autre matériel de santé electronique.Ceux qui travail près d’une application à l’arc aujet de plasma devrait consulter leur membreprofessionel de médication et le manufacturier dematériel de santé pour déterminer s’il existe desrisques de santé.

Il faut communiquer aux opérateurs et au person-nel TOUS les dangers possibles. Afin d’éviter lesblessures possibles, lisez, comprenez et suivez tousles avertissements, toutes les précautions de sécuritéet toutes les consignes avant d’utiliser le matériel.Composez le + 603-298-5711 ou votre distributeurlocal si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet deplasma peuvent présenter des risques et des dangers desanté.


• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fuméeprovenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en airsi l’aération fournie ne permet pas d’éliminer la fuméeet les gaz.

• Les sortes de gaz et de fumée provenant de l’arc deplasma dépendent du genre de métal utilisé, desrevêtements se trouvant sur le métal et des différentsprocédés. Vous devez prendre soin lorsque vouscoupez ou soudez tout métal pouvant contenir un ouplusieurs des éléments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécuritédes matières (sigle américain “MSDS”); celles-cidevraient être fournies avec le matériel que vousutilisez. Les MSDS contiennent des renseignementsquant à la quantité et la nature de la fumée et des gazpouvant poser des dangers de santé.

• Pour des informations sur la manière de tester lafumée et les gaz de votre lieu de travail, consultezl’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables decoupe à débit d’eau ou à courant descendant pourcapter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans unezone où se trouvent des matières ou des gaz combus-tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fuméeprovenant des solvants et des produits de nettoyagechlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,produit de la fumée ou des gaz pouvant contenir deséléments reconnu dans L’état de la Californie, quipeuvent causer des défauts de naissance et le cancer.(La sécurité de santé en Californie et la code sécuritéSec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Leprocédé au jet de plasma requiert et produit de l’énergieélectrique haute tension. Cette énergie électrique peutproduire des chocs graves, voire mortels, pour l’opérateuret les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”;portez des gants et des vêtements secs. Isolez-vousde la pièce de travail ou des autres parties du circuitde soudage.

• Réparez ou remplacez toute pièce usée ouendommagée.

• Prenez des soins particuliers lorsque la zone de tra-vail est humide ou moite.

• Montez et maintenez le matériel conformément auCode électrique national des Etats-Unis. (Voir la page5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel deconsignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scorieschaudes, des étincelles ou de l’arc de plasma. Le procédéà l’arc de plasma produit du métal, des étincelles, desscories chaudes pouvant mettre le feu aux matières com-bustibles ou provoquer l’explosion de fuméesinflammables.

• Soyez certain qu’aucune matière combustible ou in-flammable ne se trouve sur le lieu de travail. Protégeztoute telle matière qu’il est impossible de retirer de lazone de travail.

• Procurez une bonne aération de toutes les fuméesinflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayantpu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dansune zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sousles pièces de travail en aluminium lorsqu’elles sontcoupées sous l’eau ou sur une table d’eau. NE PAScouper les alliages en aluminium sous l’eau ou surune table d’eau à moins que le gas hydrogène peuts’échapper ou se dissiper. Le gas hydrogène accumuléexplosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesservos yeux et brûler votre peau. Le procédé à l’arc deplasma produit une lumière infra-rouge et des rayons


ultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous protégezpas correctement.

• Pour protéger vos yeux, portez toujours un casque ouun écran de soudeur. Portez toujours des lunettes desécurité munies de parois latérales ou des lunettes deprotection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteurapproprié pour protéger votre peau contre lesétincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protectionen bon état. Remplacez toute lentille sale oucomportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zonede travail contre les rayons de l’arc en fournissant descabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans lerecommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggeréeCourant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observéclairement. L’experience a démontrer que les filtresmoins foncés peuvent être utilisés quand l’arc estcaché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.Les procédés de soudage à l’arc de plasma peuventprovoquer des niveaux sonores supérieurs aux limitesnormalement acceptables. Vous dú4ez vous protéger lesoreilles contre les bruits forts afin d’éviter une pertepermanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protégez également les autres personnesse trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer queles décibels (le bruit) ne dépassent pas les niveauxsûrs.

• Pour des renseignements sur la manière de tester lebruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plusrécentes ayant été faites à celles-ci pour de plus amplesrenseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DEPROTECTION DE LA SANTÉ, 29CFR 1910,disponible auprès du Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DESOPÉRATIONS DE COUPE ET DE SOUDAGE,disponible auprès de la Société Américaine deSoudage (American Welding Society), 550 N.W.LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DESOPÉRATIONS DE COUPE ET DE SOUDAGE ÀL’ARC ET AU GAZ, disponible auprès du Superin-tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AU TRA-VAIL ET DANS LES ECOLES, disponible de l’InstitutAméricain des Normes Nationales (American Na-tional Standards Institute), 1430 Broadway, New York,NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponible auprèsde l’American National Standards Institute, 1430Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIESLORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ETDE SOUDAGE, disponible auprès de l’American Na-tional Standards Institute, 1430 Broadway, New York,NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage(AWS), LE SOUDAGE ET LA COUPE DECONTENEURS AYANT RENFERMÉ DES PRODUITSCOMBUSTIBLES, disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

8. Norme 51 de l’Association Américaine pour la Pro-tection contre les Incendies (NFPA), LES SYSTEMESÀ GAZ AVEC ALIMENTATION EN OXYGENEPOUR LE SOUDAGE, LA COUPE ET LESPROCÉDÉS ASSOCIÉS, disponible auprès de la Na-tional Fire Protection Association, Batterymarch Park,Quincy, MA 02269


9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection Association, Batterymarch Park, Quincy, MA02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DECOUPE ET DE SOUDAGE, disponible auprès de laNational Fire Protection Association, BatterymarchPark, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE DES GAZ COMPRIMÉS EN CYLINDRES,disponible auprès de l’Association des GazComprimés (Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POURLE SOUDAGE ET LA COUPE, disponible auprèsde l’Association des Normes Canadiennes, Stan-dards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ DU SOUDAGE, disponible auprès del’Association Nationale de Fournitures de Soudage(National Welding Supply Association), 1900 ArchStreet, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine deSoudage, RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRÉPARATION À LA COUPE ETAU SOUDAGE DE CONTENEURS ET TUYAUXAYANT RENFERMÉ DES PRODUITSDANGEREUX , disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTIONRESPIRATOIRE, disponible auprès de l’AmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018


1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation forthe enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unitand date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment andassociated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design andmanufacturing process. This is to ensure the product is safe, when used according to instructions in this manual andrelated industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturingprocess 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 ourarea of manufacture.

Manufacturers responsible representative: Steve WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX


1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects inworkmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermalproducts 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 soleoption, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but notlimited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for serviceinterruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, oranything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use ofany goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THESAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougarand DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years fromdate of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from dateof sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, andwith the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to anauthorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the furtherlimitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts PartsPAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 YearBut Not Limited To, Starting Circuit,Contactors, Relays, Solenoids, Pumps,Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 YearExchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repairfacility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation chargesto send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at thecustomer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

Manual 0-2568 2-1 INTRODUCTION & DESCRIPTION

SECTION 2:INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructionsand basic maintenance procedures for the Merlin 6000Plasma Cutting Master Power Supply. Service of thisequipment is restricted to Thermal Dynamics trained per-sonnel; unqualified personnel are strictly cautionedagainst attempting repairs or adjustments not covered inthis manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understand-ing of the characteristics and capabilities of this equip-ment will assure the dependable operation for which itwas designed.

NOTE

This Manual may include references to the PowerSupply revision letter(s). There are old style andnew style data tags that may be encounted. Theold style data tag has the revision letter(s) at theend of the serial number. The new style data taghas the revision letter(s) in an area marked 'Rev'.

2.02 General Description

The Master Power Supply contains all operator controls,electrical and gas inputs and outputs, and the torch leadsreceptacle. A Slave Power Supply may be connected inparallel to double the the cutting capacity (amperage) ofthe Master Power Supply. All signal inputs/outputs, gas,and torch connections are still connected to the MasterPower Supply when the Slave Power Supply is used. TheSlave Power Supply has the same power circuits as theMaster Power Supply. The Master Power Supply can alsobe connected to a second Master Power Supply and theequipment will automatically be configured when theparallel cable is installed. Many options and accessoriescan be added to further improve the versatility of thesystem.

NOTES

Refer to the Merlin 6000 Plasma Cutting SlavePower Supply Operating Manual 0-2570 for moreinformation on the Slave Power Supply.

The Merlin 6000 Slave Power Supply requires aMerlin 6000 Master Power Supply for proper op-eration and torch connections.

A-01497

Figure 2-1 Power Supply

The Standard Coolant supplied with the Power Supplycan be used in ambient temperatures down to 10° F(-12° C). If the ambient temperature will be below 10° F(-12° C) then Super Coolant should be used. This coolantcan be used in areas where the ambient temperature dropsto -34° F (-36° C).

A typical system configuration will contain the follow-ing:

• One or two Power Supplies with Running Gear

• Arc Starter Box

• Maximizer 300 Machine Torch with Leads andMounting Assembly

• Torch Supply Leads

• Maximizer 300 Spare Parts Kit

• 25 ft (7.6 m) Work Cable and Ring Lug

• Optional Air Line Filter Assembly (or) High Pres-sure Regulators

NOTE

Refer to Section 2.05 for complete list of PowerSupply Options and Accessories.

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2568

2.03 Specifications & DesignFeatures

The following apply to the Master Power Supply only:

1. Controls

ON/OFF Switch, Output Current Control, RUN/SET/PURGE Switch, Secondary Gas Regulator,Plasma Gas Regulator, Secondary Mode Switch, Sec-ondary Water Flowmeter/Regulator, Optional ArcHour/Counter Meters

2. Control Indicators

LED Indicators:

AC , TEMP, GAS, DC, PILOT, COOLANT PRES, andCOOLANT COND

Gauges:

Secondary, Plasma, and Coolant Pressure Gauges

3. Input Power

Vo ltag e F req ue ncy Pha se Am pe rag e

20 0 50 o r 6 0 H z 3 98

22 0 50 o r 6 0 H z 3 89

23 0 50 o r 6 0 H z 3 85

38 0 50 o r 6 0 H z 3 51

41 5 50 o r 6 0 H z 3 47

46 0 50 o r 6 0 H z 3 42

50 0 50 o r 6 0 H z 3 40

57 5 50 o r 6 0 H z 3 34

NOTE

Refer to Appendix 1 for recommended input wir-ing size, current ratings, and circuit protection re-quirements.

Amps depends on input voltage (Refer to Appendix1).

4. Output Power

Master Power Supply:

Continuously adjustable by potentiometer from 50to 150 amps

With Slave Power Supply:

Continuously adjustable by potentiometer from100 to 300 amps

5. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary in-put voltage (AC) is low or the DC voltage is higherthan shown in the chart.

Ambient Temperature

104° F (40° C)

Duty Cycle 100%

Current 150 Amps

DC Voltage 140 vdc

Power Supply Duty Cycle

6. Pilot Modes

Auto-Restart, Pre-Flow Delay, "Recycle Required"

7. CNC Signals

Enable, Start/Stop, OK-To-Move, Pilot Sensing Re-lay (PSR), Full CNC Available with Remote

8. Coolant Pressure

Internal Service-adjustable

130 psi (8.8 bar) at zero flow

120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.6 lpm)

9. Coolant Flow Rate

0.5 gpm (2.2 lpm) with 150 feet of total torch and torchleads at 70°F (21°C)

NOTE

The flow rate varies with lead length, torch con-figuration, ambient temperature, amperage level,etc.

10. Cooling Capacity

4,000 to 10,000 BTU

NOTE

Maximum value based on “free flow” condition.

11. Coolant Reservoir Capacity

2 gallons

Capable of handling a total of 150 feet of torch leadlength

Manual 0-2568 2-3 INTRODUCTION & DESCRIPTION

12. Secondary Water

Tap water can be used as a secondary gas and mustbe capable of delivering the following minimums:

• Water pressure of 50 psi (3.5 bar)

• Flow of 8 gph (35.2 lph)

NOTES

Tap water should only be used as a secondary gason machine torches.

The tap water source does not need to be deionized,but in water systems with extremely high mineralcontent a water softener is recommended.

13. Power Supply Dimensions

Enclosure Only -

Width: 24.12 in (0.61 m)

Height: 38.38 in (0.98 m)

Depth: 34.25 in (0.87 m)

Fully Assembled -

Width: 28.50 in (0.72 m)

Height: 43.38 in (1.10 m)

Depth: 43.75 in (1.11 m)

14. Weight of Power Supply Only

678 lbs (308 kg)

2.04 Theory Of Operation

A. Plasma Arc Cutting and Gouging

Plasma is a gas which is heated to an extremely high tem-perature and ionized so that it becomes electrically con-ductive. The plasma arc cutting process uses this plasmagas to transfer an electric arc to a workpiece. The metalto be cut is melted by the intense heat of the arc and thenblown away by the flow of gas. Plasma arc gouging usesthe same process to remove material to a controlled depthand width.

With a simple change of torch parts, the system can alsobe used for plasma arc gouging. Plasma arc gouging isused to remove material to a controlled depth and width.

B. Input and Output Power

The Power Supply accepts input voltages from 200 to575V, 50 or 60 Hz, three-phase. Input voltages are set byan internal changeover in the unit. The unit converts ACinput power to DC power for the main cutting arc. The

negative output is connected to the torch electrodethrough the negative torch lead, and the positive outputconnects to the workpiece through the work cable.

C. Pilot Arc

When the torch is activated there is a two second gas pre-flow, followed by a uninterrupted DC pilot arc establishedbetween the electrode and tip. The pilot arc is initiatedby a momentary high voltage pulse from the Arc StarterBox. The pilot creates a path for the main arc to transferto the work. When the main arc is established, the pilotarc shuts off. The pilot automatically restarts when themain arc stops, as long as the torch remains activated.

NOTE

For the arc to restart automatically, AUTO RE-START must be enabled at switch settings insidethe Power Supply (Refer to Section 4.07).

D. Main Cutting Arc

The Power Supply accepts 50 or 60 Hz three-phase lineinput. An internal changeover switches input line volt-ages in three ranges, for 200/220/230V, 380/415/460V,or 500/575V operation. The power supply converts ACinput power to DC power for the main cutting arc. Thenegative output is connected to the torch electrodethrough the negative torch lead. The positive output isconnected to the workpiece via the work cable and ringlug connection.

E. RF Shielding

All machine torch systems are shielded to minimize ra-dio frequency (RF) interference which results from thehigh frequency arc initiation. These shielded systems aredesigned with features such as a wire for establishing anearth ground and shielded torch and control leads.

F. Interlocks

The system has several built-in interlocks to provide safeand efficient operation. When an interlock shuts downthe system, the fault condition must be remedied and thesystem recycled using the applicable control device.

1. Parts-In-Place (PIP) Interlock

The Power Supply has a built-in parts-in-place inter-lock that prevents accidental torch starting whentorch parts are not properly installed. A flow switchon the coolant return lead detects reduced coolantflow caused by improper torch assembly. If not sat-isfied, the switch interrupts power to the tip and elec-trode.

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2568

2. Gas Pressure Interlock

A pressure switch acts as an interlock for the plasmagas supply. If the supply pressure falls below mini-mum requirements the pressure switch will open,shutting off the power to the contactors, and the GASindicator will go out. When adequate supply pres-sure is available the pressure switch will close, al-lowing power to be resumed for cutting.

3. Thermal Interlock

Thermal overload sensors are located in the trans-former, pilot resistors, and main heatsink in the powersupply. If one of these components is overheated theappropriate switch will open, causing the tempera-ture light to turn from green to red and shutting offpower to the main contactor. When the overheatedcomponent cools down the switch will close againand allow operation of the system.

G. Plasma Torches

Plasma torches are similar in design to the common au-tomotive spark plug. They consist of negative and posi-tive sections which are separated by a center insulator.Inside the torch, the pilot arc is initiated in the gap be-tween the negatively charged electrode and the positivelycharged tip. Once the pilot arc has ionized the plasmagas, the superheated column of gas flows through thesmall orifice in the torch tip, which is focused on the metalto be cut.

The Maximizer 300 Torch uses an internal closed-loopcooling system. Deionized coolant is distributed from areservoir in the Power Supply through the coolant sup-ply lead. At the torch, the coolant is circulated throughthe torch tip and electrode, where the extra cooling helpsto prolong parts life. Coolant then circles back to thepower supply through the return lead. The Maximizer300 also can use secondary gases such as compressed air,nitrogen (N2), water, and carbon dioxide (CO2).

2.05 Options And Accessories

These items can be used to customize a standard systemfor a particular application or to further enhance perfor-mance. Torch accessories are listed in the separate TorchInstruction Manual.

NOTE

Refer to Section 6, Parts Lists, for ordering infor-mation.

A. RC6010 Remote Control

For mechanized systems, this low profile unit pro-vides full CNC capability and allows the operator tocontrol all system functions from a remote location.

B. SC-10 or SC11 Standoff Controls

For machine torch systems, the Standoff Control auto-matically finds height and maintains torch standoffwith a high speed torch lifter motor.

NOTES

Standoff Control SC10 must be used with the Re-mote Control RC6010.

Standoff Control SC11 can be used without Re-mote Control RC6010.

C. Computer Control Cable Kits

For interfacing the power supply with a computer orauxiliary control device. Available in various cablelengths.

D. High Pressure Regulators

Available for air, oxygen, argon/hydrogen, nitrogen,CO2, and water.

E. High Flow Water Shield (HFWS) Assembly

Reduces arc glare, noise, and fumes during the cut-ting process.

F. Two Stage Air Line Filter

Removes damaging contaminants as small as 5 mi-crons from the plasma stream when using com-pressed air.

G. Hour/Counter Meters

Meter assembly containing two meters. One meterindicates the total number of hours and minutes thatthe main cutting arc has been on to a maximum of99999-59 (hours-minutes). The second meter countsthe number of times that the cutting arc has beenstarted to a maximum of 99999999 starts. Both meterscan be reset to zero.

H. Plasma/Secondary Gas Control (GC 3000)

A remote control to select one of various plasma andsecondary gases that can be connected to the PowerSupply. This allows one-time plumbing connectionsof various gas/water supplies. The operator has com-plete flexibility to quickly select the best plasma andsecondary gas combinations for the metal to be cut.

Manual 0-2568 3-1 INSTALLATION PROCEDURES

SECTION 3:INSTALLATIONPROCEDURES

3.01Introduction

This Section describes installation of the Master PowerSupply. These instructions apply to the Master PowerSupply Assemblies only; installation procedures for SlavePower Supply, Options and Accessories are given inManuals specifically provided for those units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input power

b. Internal power selection

c. Work cable

d. Gas connections

e. Torch Installation

f. Connecting auxiliary devices

4. Grounding

5. Operator training

3.02 Site Location

Select a clean, dry location with good ventilation and ad-equate working space around all components.

CAUTION

Operation without proper air flow will inhibitproper cooling and reduce duty cycle.

The Master Power Supply is cooled by air flow throughthe front, rear, and side panels. Air flow must not be ob-structed. At least 2 feet (0.61 m) of clearance should beprovided on all sides.

NOTE

When using the Slave Power Supply in parallelwith the Master Power Supply the supplies shouldbe placed next to each other. Placing one PowerSupply behind the other will cause heated air to bedrawn into the rear Power Supply. This conditionmay lower the duty cycle of the system.

Review the safety precautions in the front of this manualto be sure that the location meets all safety requirements.

3.03 Unpacking

Each component of the system is packaged separately andprotected with a carton and packing material to preventdamage during shipping. Components are packaged asfollows:

A. Power Supply

The power supply is skid-mounted and protected with acarton and padding material to prevent damage duringshipment. The power supply with work cable are fac-tory-assembled and packaged together. Also packed withthe system are:

• Torch and torch leads

• Torch Supply Leads

• Spare parts kit for the torch

• Coolant deionizing bag

• Arc Starter Box

• Operating Manual for Power Supply

B. Torches

Torches and leads are packaged with the Power Supply.Spare parts for new torches are packed in a spare partsbox. Separate instruction manual is provided with eachtorch.

C. Options and Accessories

Options and Accessories are packaged separately fromthe Power Supply.

D. Unpacking Procedure

1. Unpack each item and remove all packing mate-rial.

2. Locate the packing list(s) and use the list to iden-tify and account for each item.

3. Inspect each item for possible shipping damage.If damage is evident, contact your distributor be-fore proceeding with installation.

3.04 Removing Skid

The Power Supply is mounted on the skid with two brack-ets. Remove the Power Supply from the skid per the fol-lowing procedure:

1. Remove the six bolts connecting the brackets to thebase of the Power Supply.

INSTALLATION PROCEDURES 3-2 Manual 0-2568

A-01498Three Bolts(Each Side)

Shipping Brackets

Shipping Pallet

Figure 3-1 Skid Removal From Power Supply

2. Roll the Power Supply off the skid backwards (rear wheelsfirst).

3.05 Filling Master Power SupplyCoolant

NOTE

Only the Master Power Supply requires coolant.DO NOT install coolant in the Slave Power Sup-ply or the second Master Power Supply if used.

The ambient temperature of the environment where thePower Supply will be located determines the coolant tobe used. The Standard Torch Coolant supplied with thesystem can be used in ambient temperatures down to 10° F(-12° C).

Optional Super Torch Coolant should be used in areaswhere the ambient temperature drops down to -27° F (-33° C).

CAUTION

Use only Thermal Arc Torch Coolant. Use of anyother coolant can result in torch damage, insuffi-cient thermal protection, and/or pilot arc interfer-ence.

1. Locate the coolant deionizer bag and remove fromthe plastic shipping bag.

2. Remove the coolant filler cap from the reservoir at thetop rear of the Power Supply.

3. Place the deionizer bag into the basket in the coolantreservoir.

Coolant ReservoirFiller Cap

DeionizerBag

Basket

Coolant Level IndicatorA-00872

Figure 3-2 Coolant Reservoir

4. Carefully pour enough of the supplied Thermal ArcTorch Coolant into the reservoir to fill it to the FULLmark on the rear panel.

NOTE

After operating the system more coolant may needto be added. Allow the pump to operate for tenminutes to properly purge any air from the coolantlines before using the system.

5. Reinstall the reservoir coolant filler cap.

3.06 Input Power Connections

The Power Supply accepts input voltages from 200V to575V, 50 or 60 Hz, three-phase power. Every Power Sup-ply is factory wired for 460V input. For any other inputvoltage, the Power Supply must be reset.

NOTE

Refer to Section 3.07, Voltage Selection.

A. Electrical Connections

The power source must conform to local electric code andthe recommended circuit protection and wiring require-ments shown in Appendix 1.


B. Input Voltage Selection

Every Power Supply is factory-wired for 460V three-phaseinput. For any other input voltage, the Power Supplymust be changed using the procedures in Section 3.07.

C. Opening Power Supply Enclosure

The left side panel (viewed from the front) of the PowerSupply must be removed to make electrical connectionsand to select the proper input voltage.

WARNING

Disconnect primary power at the source before as-sembling or disassembling power supply, torchparts, or torch and leads assemblies.

1. Remove the ten screws which secure the left side panel(viewed from the front) to the Power Supply .

Left Side Panel

Screws(10 Places)

A-01535

Figure 3-3 Opening Power Supply

2. Remove the left side panel from the Power Supply.

3.07 Voltage Selection

The Power Supply can be wired to use input voltagesfrom 200 - 575 VAC. Power Supply is factory-wired for460 VAC, three-phase input. Voltage selection is accom-plished by switching busbar connections on the inputvoltage terminal board inside the Power Supply.

1. Locate the input voltage terminal board on theleft side of the power supply.

Input VoltageTerminal Board

L1

L2

L3

Busbars

A-00985

Extra BusbarStorage Location

Figure 3-4 Input Voltage Terminal Board Location

NOTE

Extra busbars are attached (stored) to the top sideof the power transformer assembly.

2. Check the busbar configuration on the input volt-age terminal board . The busbar configurationmust correspond with the available line voltageper the following figure and the label inside theunit:


200, 208,220, or 230

11 12

L3 13

15 14

6 7

L2 8

10 9

1 2

L1 3

5 4

380, 415,or 460

11 12

L3 13

15 14

6 7

L2 8

10 9

1 2

L1 3

5 4

500, or 575

11 12

L3 13

15 14

6 7

L2 8

10 9

1 2

L1 3

5 4

Busbar Connections For Input Voltages

A-00904

Figure 3-5 Busbar Connections

If necessary, reposition the busbars to correspond tothe available line voltage.

3.08 Primary Power CableConnections

WARNING

Disconnect primary power at the source before con-necting the primary power cable to the power sup-ply.

The primary power cable must be supplied by the enduser and installed to the Power Supply assembly. Rec-ommended cable sizes are specified in Appendix 1.

NOTE

Three-phase operation requires a 3-conductor cablewith ground.

1. Route the primary power cable through the strainrelief fitting in the rear panel of the Power Sup-ply and tighten strain relief screws.

Input VoltageTerminal Board

L1

L2

L3

Primary PowerCable

Strain ReliefFitting

GroundConnection

Busbars

A-00893

Figure 3-6 Input Voltage Connections

2. Connect the electrical ground wire to the groundlug on the base of the unit.

WARNING

The electrical ground wire must be connected tothe ground lug in the base of the unit for propergrounding.

3. Connect the three line leads to the input voltageterminal board per the following:

• Line 1 to terminal L1.



4. Tighten all nuts.

3.09 Ground Connections ForMechanized Applications

NOTE

Refer to Appendix 3 for a block diagram of a typi-cal mechanized system work and ground cable con-nections.

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electro-magnetic interference (EMI), commonly called RF noise.This RF noise may interfere with other electronic equip-ment such as CNC controllers, remote controls, height


controllers, etc. To minimize RF interference, follow thesegrounding procedures when installing mechanized sys-tems:

B. Grounding

1. The preferred grounding arrangement is a single pointor “Star” ground. The single point, usually on thecutting table, is connected with 1/0 AWG (50.0 mm2

European) or larger wire to a good earth ground (re-fer to paragraph ‘C’, Creating An Earth Ground). Theground rod must be placed as close as possible to thecutting table, ideally less than 10 ft (3.0 m), but nomore than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible.Long wires will have increased resistance to RFfrequencies. Smaller diameter wire has increasedresistance to RF frequencies, so using a larger di-ameter wire is better.

2. Grounding for components mounted on the cuttingtable (CNC controllers, height controllers, plasma re-mote controls, etc.) should follow the manufacturer’srecommendations for wire size, type, and connectionpoint locations.

For Thermal Dynamics components it is recom-mended to use a minimum of 10 AWG (6.00 mm2 Eu-ropean) wire or flat copper braid with cross sectionequal to or greater than 10 AWG connected to the cut-ting table frame. The connection point must be cleanbare metal; rust and paint make poor connections. Forall components, wires larger than the recommendedminimum can be used and may improve noise pro-tection.

3. The cutting machine frame is then connected to the“Star” point using 1/0 AWG (50.0 mm2 European) orlarger wire.

4. The plasma power supply work cable (see NOTE) isconnected to the cutting table at the single point “Star”ground.

NOTE

Do Not connect the work cable directly to theground rod.

5. Make sure work cable and ground cables are prop-erly connected. The work cable must have a solidconnection to the cutting table. The work and groundconnections must be free from rust, dirt, grease, oiland paint. If necessary grind or sand down to baremetal. Use lock washers to keep the connections tight.Using electrical joint compound to prevent corrosionis also recommended.

6. The plasma power supply chassis is connected to thepower distribution system ground as required by elec-trical codes. If the plasma supply is close to the cut-ting table (see NOTE) a second ground rod is not usu-ally needed, in fact it could be detrimental as it canset up ground loop currents that cause interference.

When the plasma power supply is far away from theground rod and interference is experienced, it mayhelp to install a second earth ground rod next to theplasma power supply. The plasma power supplychassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supplybe within 20 - 30 ft (6.1 – 9.1 m) of the cuttingtable, if possible.

7. The plasma control cable should be shielded with theshield connected only at the cutting machine end.Connecting the shield at both ends will allow groundloop currents which may cause more interference thanwith no shield at all.

C. Creating An Earth Ground

1. To create a solid, low resistance, earth ground, drive a1/2 in (12 mm) or greater diameter copper clad groundrod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so thatthe rod contacts moist soil over most of its length.Depending on location, a greater depth may be re-quired to obtain a low resistance ground (see NOTE).Ground rods, typically 10 ft (3.0 m) long, may bewelded end to end for greater lengths. Locate the rodas close as possible to the work table. Install a groundwire, 1/0 AWG (50.0 mm2 European) or greater, be-tween the ground rod and the star ground point onthe cutting table.

NOTE

Ideally, a properly installed ground rod will have aresistance of three ohms or less.

To test for a proper earth ground, refer to the follow-ing diagram. Ideally, the reading on the multimetershould be as follows:

• For 115VAC: 3.0 VAC

• For 230VAC: 1.5 VAC


A-02971

+ _

Meter set toVAC setting

MachineEarth Ground

Neutral

Line (Hot)

100WLight Bulb115 or 230VAC

WARNING

Use extreme caution. Thistest uses live voltage.

115VAC: 3.0 VAC230VAC: 1.5 VAC

V~V~

VR COM A

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft(6.1 – 9.1 m) does not generally increase the effective-ness of the ground rod. A larger diameter rod whichhas more surface area may help. Sometimes keepingthe soil around the ground rod moist by continuouslyrunning a small amount of water into it will work.Adding salt to the soil by soaking it in salt water mayalso reduce its resistance. When these methods areused, periodic checking of the ground resistance is re-quired to make sure the ground is still good.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads asfar as possible from any CNC components, drive mo-tors, control cables, or primary power lines. If cableshave to pass over torch leads, do so at an angle. Donot run the plasma control or other control cables inparallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleedoff energy, which causes difficult starting and in-creased chance of RF interference.

3.10 Plasma And Secondary GasConnections

The Master Power Supply provides the liquid cooling andgases to support operation of the Liquid Cooled Maxi-mizer 300 Torch.

NOTE

Refer to the Liquid Cooled Maximizer 300 TorchInstruction Manual (Cat. No. 0-2573 for informa-tion on plasma and secondary gas selection andrequirements.

The following are available gases that can be used withthe Liquid Cooled Maximizer 300 Torch:

Plasma Gases: Compressed Air, Oxygen (O2), Nitro-gen (N2), or Argon/Hydrogen (Ar/H2)

Secondary Gases: Compressed Air, Nitrogen (N2),Carbon Dioxide (CO2), or Tap Water (refer to follow-ing note)

Plasma and secondary requirements vary depending onthe application. The plasma and secondary gases areconnected to the rear panel connections of the power sup-ply. Depending on the options installed and the sourceof the gases will determine the installation of filters andregulators.

This sub-section includes information for connecting thegas supplies to the Power Supply. The information isgrouped in paragraphs for different types of gases andoptions per the following:

A. Using Shop Air

B. Using High-Pressure Gas Cylinders

C. Using Water Secondary

D. Plasma and Secondary Gases With Gas ControlOption

Refer to the appropriate paragraph(s) for the desired ap-plication to be used.

A. Using Shop Air

An inline pneumatic dryer/evaporator type air filter, ca-pable of filtering particulates to at least 5 microns with adew point of 35°F (1.7°C), is required when using air froma compressor. This type filter will insure that moisture,oil, dirt, chips, rust particles, and other contminants fromthe supply hose do not enter the torch. For highly auto-mated applications, a refrigerated drier plus a particu-late filter may be used to chill the air to remove all mois-ture.


CAUTION

Excessive oil or moisture in compressed air willreduce torch parts life and cutting performance andmay cause torch failure.

The optional Two Stage Air Line Filter is shipped withthe following components:

NOTE

The Two Stage Air Line Filter Assembly is to beused when using shop air as the Plasma Gas.

• Installation Instructions - 1 each

• 10-32 Nylon Lock Nuts - 2 each

• Filter Mounting Bracket - 1 each

• Air Line Filter Assembly - 1 each

• 1/4 NPT Sreet Elbow - 1 each

• Thread Sealer - 1 each

• Filter To Plasma Gas Hose Assembly - 1 each (seeNOTE)

• Filter to Gas Option Hose Assembly - 1 each (seeNOTE)

NOTE

Only one of these will be used depending on con-figuration of Power Supply.

Install the Two Stage Air Filter Kit as follows:

NOTE

Use these instructions only for Power Supplies thatDO NOT have the Gas Control Option installed.

1. Remove the air supply input hose from the PlasmaGas (Air) Input Fitting at the rear of the power sup-ply, if already installed.

2. Locate the two mounting studs on the rear of the unitand secure the Air Filter Mounting Bracket to the panelusing the two 10-32 Nylon Locking Nuts provided.

Air FilterMounting Bracket Mounting

Nuts

MountingStuds

A-01336

Figure 3-7 Air Filter Mounting Bracket Installation

3. Place thread sealer on the threads of the 1/4 NPTStreet Elbow (see NOTE).

NOTE

Do Not use teflon tape as a thread sealer as smallparticles of the tape may break off and cause thesmall gas passage to be blocked in the torch.

4. Install the supplied 1/4 NPT Street Elbow into theinput port (IN) of the Air Line Filter Assembly.

5. Slide the Air Line Filter Assembly into the mountingbracket. The Filter Assembly will snap into place.


A-01337

Hose AssemblyFilter to Plasma

Gas Input

1/4 NPTElbow

FilterAssembly

Air FilterMounting Bracket

Plasma GasInput Fitting

Figure 3-8 Two Stage Air Line Filter Installation

6. Using the Filter to Plasma Gas Hose Assembly con-nect the output port (OUT) of the Air Line Filter As-sembly to the Plasma Gas Input Fitting.

7. Place thread sealer on the threads of the Street Elbowon a Y-Hose Assembly (see NOTES).

NOTES


The Y-Hose Assembly is customer supplied and isshown to illustrate one method of connecting thecustomer's air supply.

8. Connect the air supply hose from a Y-Hose Assemblyto the street elbow on the Air Line Filter input port(IN). The Y-Hose Assembly should have already beeninstalled, if shop air was being used as the plasmaand secondary gases.

A-01338

Shop AirGas Input

Air FilterAssembly

Secondary Air Gas Fitting

Y-HoseAssembly

From Supply

Figure 3-9 Supply Hose Connections Witout GasControl Option

9. Apply thread sealer (see NOTE) to the other elbow ofthe Y-Hose Assembly.

NOTE


10. Connect the elbow fitting to the SECONDARY (Air)1/4 NPT fitting.

11. Connect the supply line from the air supply source tothe Y-hose assembly. The supply hose must be 3/8 in(10 mm) minimum inside diameter to provide ad-equate air flow.

B. Using High-Pressure Gas Cylinders

NOTES

Refer to the regulator manufacturer’s specificationsfor installation and maintenance procedures. Re-fer to Section 6.05, System Options and Accesso-ries, or a listing of available high-pressure regula-tors.

Do not use an air line filter with high pressure gascylinders.

Examine the cylinder valves to be sure they are clean andfree of oil, grease or any foreign material. Momentarilyopen each cylinder valve to blow out any dust which maybe present.


WARNING

Do not stand in front of the valve outlet when open-ing.

Each cylinder must be equipped with an adjustable high-pressure regulator capable of pressures up to 125 psi (8.6bar) maximum and flows of up to 700 scfh (328 lpm) forcutting or gouging.

CAUTION

Maximum input pressure to the internal regula-tor on the Power Supply must not exceed 125 psi(8.6 bar).

Connect the gas supply to the Power Supply per the fol-lowing:

1. Connect the black supply hose from the plasma gasregulator directly to the input fitting on the rear panelof the Power Supply marked PLASMA.

Plasma GasSupply Hose

Secondary GasSupply Hose

Secondary GasFitting

Plasma GasFitting

A-01503

Figure 3-10 Gas Connections Using Gas Cylinders

2. Connect the yellow supply hose from the secondarygas regulator directly to the input fitting on the rearpanel of the Power Supply marked SECONDARY. Donot use the air line filter with high pressure cylinders.

NOTE

A typical 50 lb. CO2 cylinder can deliver a con-tinuous flow rate of 35 scfh (16.5 lpm). To obtainthe required flow rate for the torch, it may be nec-essary to manifold several CO2 cylinders. Con-tinuous flow requirements will depend on the spe-cific application and duty cycle.

C. Using Water Secondary

NOTES

Tap water should only be used as a secondary gason machine torches.

The tap water source does not need to be deionized,but in water systems with extremely high mineralcontent a water softener is recommended.

Tap water can be used instead of a secondary gas and isconnected to the Power Supply as follows:

1. The tap water source must be capable of delivering aminimum water pressure of 50 psi (3.5 bar) and flowof 8 gph (35.2 lph).

2. Connect the tap water supply hose to the input of aWater Pressure Regulator.

3. Connect the output of the water regulator to the fit-ting marked SEC. WATER on the rear panel of thePower Supply.

NOTE

The water source does not need to be deionized,but in water systems with extremely high mineralcontent a water softener is recommended.

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT

PLASMA GASPLASMA GAS

Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

Water SecondaryHose From Supply

Secondary WaterFitting

A-01504

Figure 3-11 Secondary Water Connection


4. Set the SECONDARY selector switch on the frontpanel of the Power Supply to the WATER position.

D. Plasma and Secondary Gases WithOptional Gas Control

The required plasma and secondary gases are connectedto the rear of the Power Supply. The secondary selectionswitch on the front panel of the Power Supply must al-ways be set to GAS for all secondary gases when the GasControl Option is installed. The type of gas to be usedwill be selected at the Gas Control Option front panel.

NOTE

If compressor shop air is to be used as the plasmagas the line must be filtered.

If using shop air as one of the plasma gases then installthe optional Two Stage Air Line Filter per the followingprocedure:

NOTE

Use these instructions only for Power Supplies thatHAVE the Gas Control Option installed.

1. Remove the air supply input hose from the PlasmaGas (Air) Input Fitting at the rear of the power sup-ply, if already installed.

2. Locate the two mounting studs on the rear of the unitand secure the Air Filter Mounting Bracket to the panelusing the two 10-32 Nylon Locking Nuts provided.

Air FilterMounting Bracket Mounting

Nuts

MountingStuds

A-01336

Figure 3-12 Air Filter Mounting Bracket Installation

3. Place thread sealer on the threads of the 1/4 NPTStreet Elbow (see NOTE).

NOTE


4. Install the supplied 1/4 NPT Street Elbow into theinput port (IN) of the Air Line Filter Assembly.

5. Slide the Air Line Filter Assembly into the mountingbracket. The Filter Assembly will snap into place.

A-01339

1/4 NPTElbow

Air FilterAssembly

Air FilterMountingBracket

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

HoseAssemblyFilter toPlasma

Gas Input

Gas ControlPlasma GasInput Fitting

Figure 3-13 Supply Hose Connections With GasControl Option

6. Place thread sealer on the threads of the connectors atboth ends of the Filter to Plasma Input Gas Hose As-sembly (see NOTE).

NOTE


7. Connect the Filter to Plasma Input Gas Hose Assem-bly to the output port (OUT) of the Air Line FilterAssembly and to the Air Plasma Input Fitting on theGas Control Manifold.

8. Place thread sealer on the threads of the Street Elbowon a Y-Hose Assembly (see NOTES).

NOTES


The Y-Hose Assembly is customer supplied and isshown to illustrate one method of connecting thecustomer's air supply.


9. Connect the air supply hose from a Y-Hose Assemblyto the street elbow on the Air Line Filter input port(IN). The Y-Hose Assembly should have already beeninstalled, if shop air was being used as the plasmaand secondary gases.

A-01340

Air FilterAssembly

Shop AirGas Input

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

Secondary AirGas Fitting

Y-HoseAssembly

From Supply

Figure 3-14 Supply Hose Connections Wit GasControl Option

10. Apply thread sealer (see NOTE) to the other elbow ofthe Y-Hose Assembly.

NOTE


11. Connect the elbow fitting to the SECONDARY (Air)1/4 NPT fitting.

12. Connect the other required plasma gases to the op-tional Gas Control gas manifold.

A-01341

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT N2

Gas Control PlasmaGas Manifold

Air (Filtered)

O2

Ar/H2

Plasma GasInput Fittings

Figure 3-15 Plasma Gas Connections

13. Connect the Plasma Hose from the Plasma Gas Con-trol Manifold to the Plasma (Air) Gas Input Fitting atthe rear of the Power Supply.

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

To Plasma GasInput Fitting

Plasma Gas OutputFrom Gas Select Option

A-01343

Gas Control OptionGas Manifold

Figure 3-16 Plasma Hose Connection From GasControl

14. Connect the required secondary gases the SECOND-ARY INPUT fittings marked OTHER, N2, and SEC-ONDARY GAS (air).

NOTE

If air is to be used as the secondary gas it should beconnected to the fitting marked SECONDARYGAS.

If using Secondary Water connect as described inparagraph 'C' above.

NOTE

DO NOT connect Secondary Water to the'OTHER' secondary gas fitting.


OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

OTHER SecondaryGas Supply

N2 SecondaryGas Supply

A-01342

Figure 3-17 Secondary Gas Connections

3.11 Connecting Torch SupplyLeads

The Torch Supply Leads interfaces the Master Power Sup-ply to the Arc Starter Box. The Torch Supply Leads ismade up of individual hoses and cables that must be con-nected.

NOTE

Refer to the Arc Starter Box Instruction Manual0-2572 for details on installation of the Arc StarterBox.

The Torch Supply Leads components connects directlyto a bulkhead inside the Master Power Supply and to con-nections inside the right side panel. Connect the TorchSupply Leads components per the following procedure:

WARNING

Primary power should NOT BE APPLIED whenworking inside the power supply.

1. Open the front panel access panel to gain access tothe bulkhead.

2. Feed the four hose assemblies on the Torch SupplyLeads components through the boot on the front panelof the Master Power Supply.

3. Connect the four hose assemblies onto the mating con-nections at the internal bulkhead of the Master PowerSupply per the following figure.

Secondary Gas Lead

Torch Supply LeadsSupply Leads Boot

Coolant ReturnLead

Coolant SupplyLead

PlasmaGas Lead

A-01447

Control Cable

Master Power SupplyBulkhead

Figure 3-18 Leads Extension Hose Connections ToMaster Power Supply

4. Connect the end of the Pilot Lead, two wires, to theMaster Power Supply per the following procedure:

a. Remove the right side panel from the MasterPower Supply.

b. Feed the Pilot Lead, two wires, through the smallstrain relief at the front panel of the Master PowerSupply.

c. Remove the nut and star washer on the groundterminal of the pilot connection inside the powersupply.


Small StrainRelief

Black Wireof Pilot Lead

Ground Terminal

NutStar Washer

Pilot Terminal

Red Wireof Pilot Lead A-01495

Figure 3-19 Pilot Lead Connection at Power Supply

d. Secure the shield lead (black) to the ground con-nection with the nut and star washer removedabove.

e. Remove the nut and star washer from the otherpilot connection inside the power supply.

f. Secure the pilot lead (red) to the pilot connectionwith the nut and star washer removed above.

5. Connect the Power Lead to the Master Power Supplyper the following procedure:

a. Feed the Power Lead through the large strain re-lief at the front panel of the Master Power Sup-ply.

b. Remove the lock nut from the power connectionterminal inside the power supply.

LargeStrain Relief

Power Lead

Nut

Power LeadTerminal Bolt

A-01496

Figure 3-20 Power Lead Connection at MasterPower Supply

c. Remove the power lead terminal bolt.

d. Place the Power Lead ring lug over the existinglug.

e. Secure the power lead to the connection with thebolt and lock nut removed above.

6. Refer to the Arc Starter Box Manual and connect theother end of the Torch Supply Leads components tothe Arc Starter Box.

7. Refer to the Arc Starter Box Manual and connect theliquid cooled Maximizer 300 torch to the Arc StarterBox.

NOTE

Refer to the Installation sections in the Maximizer300 Torch Instruction Manual (0-2573) for moreinformation on the Torch.

3.12 External Cable Connections

Depending on the options installed there are variouscables to be connected the Power Supply.

A. Optional RC 6010 Remote Control

For mechanized systems, the optional RC 6010 RemoteControl allows the operator to control all system func-tions from a remote location. The control cable to inter-face the RC 6010 to the Power Supply is available in vari-ous lengths (Refer to Section 6.04, Options andAccessories).

1. Connect the control cable to the receptacle markedREMOTE CONTROL (J15) on the rear panel ofthe Power Supply.

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

A-01505

Cable FromRemote Control

REMOTE CONTROLConnector (J15)

Figure 3-21 Remote Control Interface Connection


2. Connect the other end of the control cable to thereceptacle marked PS (J37) on the rear panel ofthe remote control.

NOTE

Refer to the RC 6010 Remote Control InstructionManual 0-2478 for more information on theRC6010 Remote Control including CNC.

B. Computer Control Interface (CNC)

NOTE

Used when Remote Control RC6010 or StandoffControl SC11 are not used.

The computer control interface allows a mechanized sys-tem to interface with a computer or other control device.

NOTE

Refer to Section 4.03-D for more information onthe CNC connections.

CNC cables can be interfaced to the Power Supply usingone of the following methods:

NOTE

Refer to Appendix 7 for CNC Interface Schematic.

• Connector (J15) at the rear of the Power Supply

• Internal terminal strip in the Power Supply

Depending on the equipment ordered and the cables sup-plied connect the CNC cable per one of the following:

1. Using supplied CNC cable

Connect the supplied Power Supply/CNC Cableto the Power Supply rear connector J15 labelledREMOTE CONTROL.

2. Using customer supplied CNC Cable

a. Remove the Left Side Panel from the PowerSupply as viewed from the front of the unit.

b. Locate the internal terminal strip (TB2) nearthe heatsink.

c. Feed the CNC cable through the small strainrelief at the rear of the Power Supply.

d. Connect the CNC cable to the terminal strip(TB) per the following chart:

TB 2 Connec tion

Desc ription

1 O ne S ide of E nable S ignal (Com m on)

2 O ther S ide of E nable S ignal (+ 15 v dc )

3O ne S ide of S TA RT(Low)/S TO P (H igh) S ignal (+ 15 v dc )

4O ther S ide of S T A RT (Low)/S T O P (H igh) S ignal (Com m on)

5 Not Us ed

6 Not Us ed

7O ne S ide of P i lot S ens ing Relay (P S R) - D ry Contac ts

8O ther S ide of P i lot S ens ing Relay (P S R) - D ry Contac ts

9O ne S ide of O K -To-M ov e S ignal (Refer to S ec tion 4.07)

10O ther S ide of O K -T o-M ov e S ignal (Refer to S ec tion 4.07)

NOTES

Connections to TB2 positions 1 through 4 are acti-vated with a switch or contact closure.

If Remote Control is not used the Enable Signalcircuit must be closed.

Connections TB2-7 and TB2-8 are normally open(NO) contacts.

Connections TB2-9 and TB2-10 are selectable fornormally open (NO) contacts or 24 VAC.

e. Secure the CNC cable by tightening the twoscrews on the strain relief.

f. Reinstall the Left Side Panel.

C. Optional SC-10 or SC11 Standoff ControlCable

For mechanized systems, the Standoff Control automati-cally finds height and maintains torch standoff with a highspeed torch lifter motor. The unit consists of a remoteoperator's control, torch lifter motor, and all cables re-quired for installation. It is ordered and shipped sepa-rately. Refer to the SC-10 or SC11 Standoff Control In-struction Manual for more information.

Depending on the Standoff Control to be used connectthe cable per one of the following:


• Standoff Control SC10 used with the RemoteControl RC6010

Connect the internal ribbon cable to the RemoteControl RC6010. Refer to the Standoff Control In-struction Manual for more details.

• Standoff SC11 only

The standoff control remote cable connects to thereceptacle marked REMOTE CONTROL (J15) onthe rear panel of the Power Supply.

A-01506

Cable FromStandoff Control

REMOTE CONTROLConnector (J15)

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

Figure 3-22 Standoff Control Interface Connection

D. Optional High-Flow Water Shield Cable

The High Flow Water Shield surrounds the main cuttingarc with a spray of water to reduce arc glare, noise, andfumes. Use of the water shield device reduces thesystem’s overall cutting capacity. Refer to the High-FlowWater Shield Instruction Manual for more information.

1. Connect the high flow water shield interface cableto the receptacle marked HIGH FLOW WATERSHIELD on the rear panel of the Power Supply.The receptacle is 115VAC.

High Flow Water ShieldInterface Cable

High Flow Water ShieldConnector (J63)

Rotate ClockwiseTo Lock

A-01507

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

Figure 3-23 High Flow Water Shield InterfaceConnection

2. Rotate the plug clockwise to lock the plug to thereceptacle.

3. To shut off the high flow water shield remove theinterface cable or disconnect power to the HighFlow Water Shield (HFWS) accessory.

E. Optional Gas Control Connection

The optional GS3000 Gas Control allows the connectionof various multiple plasma and secondary gases to beconnected to the Power Supply. The proper plasma andsecondary gas is selected with switches on the front panelof the Gas Control Option.

NOTE

The secondary selection switch on the front panelof the Power Supply must always be set to GASfor all secondary gases when the Gas Control Op-tion is installed.

1. Connect the Gas Control control cable to the con-nector marked GAS CONTROL (J63) on the rearpanel of the Power Supply.


2. Connect the other end of the cable to the Gas Con-trol Option rear panel.

NOTE

Refer to the Gas Control Instruction Manual 0-2477 for more information on the GS3000 GasControl Option.

Cable FromGas Select Option

GAS CONTROLConnector (J63)

A-01508

OUTPUTOUTPUT

TOTO

CONTROLCONTROL

MODULEMODULE

AIRAIRPLASMAPLASMA

INPUTINPUT

N2

PLASMAPLASMA

INPUTINPUT

O2

PLASMAPLASMA

INPUTINPUT


Ar/HAr/H2

PLASMAPLASMA

INPUTINPUT

Figure 3-24 Optional Gas Control InterfaceConnection

3.13 Master/Slave Parallel CableConnection

The interface between the Master and Slave Power Sup-ply is made through the Parallel Cable. Connect one endof the cable to the rear of the Master Power Supply at J54.The other end connects to the rear of the Slave PowerSupply at J15.

3.14 Lifting Options

WARNING

Do not lift a power supply equipped with a cylin-der rack running gear.

The recommended method for lifting the power supplyis to use a forklift per the following procedure:

1. Approach from the front or rear of the unit.

2. Place the forks between the rear wheels or thefront casters.

3. Center the forks under the unit and carefullycheck for proper balance before lifting.

Approach From Front Or Rear

Do Not Lift From Sides

A-01499

Figure 3-25 Lifting the Power Supply

3.15 Pilot Resistor Adjustment

This Sub-Section applies only to the following Master andSlave Power Supplies:

• Merlin 6000 Master Power Supplies with the revi-sion letter 'C' or later on the data tag

• Slave Power Supplies with the revision letter 'E' orlater on the data tag

• Slave Power Supplies that have been retrofitted withPilot Resistors

Master and Slave Power Supplies, as noted above, con-tain adjustable pilot resistor circuits. For output currentbelow 250A, only the pilot circuit in the Master PowerSupply is activated. For output current above 250A theMaster 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 tothe customer's input power (see Notes).

NOTES

The instructions in this Sub-Section apply to theMaster Power Supply only.

To adjust the Slave Power Supply pilot resistor,refer to the Manual supplied with the Slave PowerSupply.

WARNING


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 causeexcessive wear of the torch consumables. Adding pulsesof current on top of the background current allows greaterarc transfer distance without increasing the torch partwear. The amount of pilot current is determined by thevalue of the pilot resistors and the open circuit voltagewhich varies with the input line voltage. Both the Mas-ter and the Slave Power Supplies should be adjusted thesame. Wire #99 tap sets the background level and wire#150 tap sets the pulse level. To set the pilot backgroundand pulse levels use the following procedure:

1. Remove the left and right side panels of the Mas-ter Power Supply.

2. Locate and identify the pilot resistors (R16, R21and R22) which are on a bracket in front of thefan.

Wire#96A Pilot Resistor

R16 Clamp

Clamp

A-01853

Wire#150

Pilot ResistorR21

Pilot ResistorR22

Wire#74

Wire #99

Wire#96

TempSwitch

Figure 4-4 Location Of Pilot Resistors (ViewedFrom The Front Of Power Supply)

3. Check the busbar configuration on the input ter-minal board to determine which range the powertransformer is set for.

4. Measure the level of the AC line voltage beingsupplied to the Power Supply.

5. To determine the recommended pilot resistor set-ting use the following table as follows:

a. Locate the transformer voltage range (200-230V, 380-460V or 500-575V)

b. Find the voltage that is nearest what was mea-sured above.

c. Note the ohms value for the voltage. Example:If the transformer range is 380-460, and themeasured voltage is 455, then the pilot resis-tor value is 6 ohms.

NOTE

Voltages that are from 200 to 210V, 410 to 420Vand 510 to 520V required values from 8.5 or 9 to4.5 ohms. If the voltage is near one of these pointsit is best to set for the lower ohms value.


The reason is because within each range the PowerSupply will automatically select a high or low tapon the transformer secondary. This is based onthe input AC line voltage at the time the PowerSupply is turned ON. If the line voltage is nearone of these points the voltage might measure, forexample, 410 VAC and the pilot resistor settingshould be 9 ohms to have a good pilot. The nexttime the system is turned ON, the input AC linevoltage may have gone up to 420VAC causing thepilot to sputter because 420VAC requires settingof 4.5 ohms.

Pilot Resistor Setting vs. Input Line Voltage

Transformer Voltage Range

200-230 VAC 380-460 VAC 500-575 VACInput(VAC)

OhmsInput(VAC)

OhmsInput(VAC)

Ohms

180 6.5 340 5 450 5.5

190 7.5 350 5.5 460 6

200 8.5 360 6 470 6.5

210 4.5 370 6.75 480 7

220 5.5 380 7.25 490 7.5

230 6.5 390 8 500 8

240 7.5 400 8.5 510 8.5

250 9 410 9 520 4.5

420 4.5 530 5

430 5 540 5.5

440 5.5 550 6

450 6 560 6.5

460 6.5 570 7

470 7 580 7.25

480 7.5 590 7.5

490 8 600 8

500 8.5 610 8.25

510 9 620 8.5

630 9

6. Wires are attached to the pilot resistors with metalclamps or taps. Locate and loosen the screw thatsecures the wire #99 tap on resistor R16. Deter-mine, from the Figure below, the correct positionfor the tap on R16 and tighten the screw.

Example:

To set for 6 ohms measure 5” from the right sideof R16, where wire # 96 attaches, and secure the#99 tap at that position.

Pulser99 150

Wire #99Tap

9.0

ohm

sA

t End

R16 (4.5 ohms)

R22 (2.2 ohms)

R21 (2.2 ohms)

Temp Switch

Wire#96A

Wire #150Tap

Wire #74

8.5

ohm

s12

.8"

(305

mm

)

8.0

ohm

s11

.2"

(279

mm

)

7.5

ohm

s9.

6" (

242

mm

)

7.0

ohm

s8.

1" (

203

mm

)

6.5

ohm

s6.

5" (

164

mm

)

6.0

ohm

s5.

0" (

127

mm

)

5.5

ohm

s3.

4" (

87 m

m)

5.0

ohm

s1.

9" (

44 m

m)

4.4

ohm

sA

t End

Wire #96

4.4

ohm

sA

t End

5.0

ohm

s13

.7"

(344

mm

)

5.5

ohm

s12

.3"

(311

mm

)

6.0

ohm

s10

.8"

(255

mm

)

6.5

ohm

s9.

4" (

237

mm

)

7.0

ohm

s8.

0" (

203

mm

)

7.5

ohm

s6.

5" (

164

mm

)

8.0

ohm

s5.

1" (

127

mm

)

8.5

ohm

s3.

7" (

90 m

m)

9.0

ohm

s2.

5" (

63 m

m)

A-01852

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 thewire #150 tap. From the above Figure find theohms value that corresponds to the value that thewire #99 tap was set to. Measure distance indi-cated from the right side of R22, where wire #96attaches and secure the wire #150 tap there.

NOTE

The ohm value shown for the wire #150 tap doesnot represent the value of the R22 resistor but in-stead corresponds to the total resistance of R16,R22 and R22 set by the wire #99 tap.

8. Test the pilot, if it still sputters move the wire #99tap to the right, toward wire #96, 1 inch (25.4 mm)at a time until the pilot no longer sputters.

9. Once there is a good steady pilot, test for the de-sired transfer height. If the transfer height is nothigh enough, between 3/8 inch (9.5 mm) to 1/2inch (12.7 mm), move the wire #150 tap to the lefton R22, 1 inch (25.4 mm) at a time, until the de-sired height is obtained.

Manual 0-2568 4-1 OPERATION

SECTION 4:OPERATION

4.01 Introduction

This Section provides a description of the Master PowerSupply operating controls and procedures. Identificationof 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 plasmacutting system which can cut most metals from gaugethickness up to two inches. With a quick change of torchparts, power supply can also be used for plasma arc goug-ing. In its simplest form, a system consists of one MasterPower Supply, one Arc Starter Box and one Maximizer300 Liquid Cooled Torch and leads connected.

With the addition of a Slave Power Supply or a secondMaster Power Supply the system becomes a 100 to 300amp plasma cutting system which can cut most metalsfrom gauge thickness up to three inches.

4.03 Front and Rear PanelDescriptions

This sub-section provides specific functional descriptionsof the Power Supply front and rear panel operating con-trols, indicators and connections. The Power Supply hasthree main front panels and one rear panel. Each panel isdescribed in this sub-section as to the functions of theconnections, switches, and indicators.

A-01500

Control Front Panel

Gauge Front Panel

Lower Front Panel

Figure 4-1 Main Front Panels

A. Lower Front Panel

A-01501

1

2

3

5

4

6

Figure 4-2 Lower Front Panel

1. Work Cable Strain Relief

Strain relief to secure the factory installed work cablewith ring lug to the Power Supply.

2. Torch Supply Leads Boot

NOTE

The Torch cannot be connected directly to theTORCH connector as the High Frequency (HF) isgenerated in the Arc Starter Box.

Connection inside at the bulkhead for the Torch Sup-ply Leads Assembly. The connections supply all therequired signals, gases, and coolant to the torch ArcControl Box.

3. Optional Meters

a. Upper Meter - Hour and Minutes

The upper meter indicates the total number ofhours and minutes that the main cutting arc hasbeen on. The meter will display a maximum of99999-59 (hours-minutes). The meter can be resetby the use of the meter pushbutton.

b. Lower Meter - Counter

The lower meter counts the number of times thatthe cutting arc has been started. The meter willdisplay a maximum of 99999999 starts. The metercan be reset by the use of the meter pushbutton.

4. Pilot Lead Strain Relief

Strain relief to secure the pilot lead to the Power Sup-ply after it is installed.

OPERATION 4-2 Manual 0-2568

5. Power Lead Strain Relief

Strain relief to secure the power lead to the PowerSupply after it is installed.

6. Secondary Water Flowmeter/Regulator

Used to adjust and monitor the flow of the second-ary water from 0 - 10 gph (0 - 44 lph).

B. Control Front Panel

NOTE

This panel is the access cover to the Logic ControlPC Board.

1. ON/OFF Switch

ON position activates all system control circuits whenremote or CNC enable is ON.

OFF position deactivates control circuits.

2. RUN/SET/PURGE Switch

RUN position is used for torch operation.

SET position is used for setting gas pressures.

PURGE position is for purging the plasma gas line.

3. Current Control (Dual Scale)

Selects output current for the application on variousmaterials and thicknesses. Current control is disabledwhen Remote Control is used.

Current is adjustable for the application as follows:

• 50 to 150 amps for single power supply

• 100 to 300 amps for dual power supplies

OFF

ON RUN

PURGE

SET

A-01502

AC TEMP GAS PRES.

COOLANT

COND. DC PILOT

1 2 3 4 5 6 7 89

10

150300300100100

75

200200

125

50

100

DUALDUALSINGLE

AMPS

150150 250250

Figure 4-3 Front Control Panel

4. AC Power Indicator

Green light indicates AC power is being supplied tothe system when the ON/OFF switch is in ON posi-tion.

5. TEMP Indicator

Green light indicates proper operating temperature.Red light indicates overheating. Unit must be allowedto cool.

6. GAS Indicator

In RUN or SET position, yellow light indicates gaspressure switches are satisfied when gas is flowingto the torch. Light goes out in PURGE mode. RUN/SET/PURGE switch must be in the RUN position forproper cutting operation.

7. COOLANT PRES. (Coolant Pressure) Indicator

Yellow light indicates adequate coolant flow.

8. COOLANT COND. (Coolant Conductivity) Indica-tor)

Yellow light indicates proper coolant conductivity.Light out indicates excessive coolant conductivity (re-sistivity less than 0.1 megaohms per centimeter). Re-place coolant and de-ionizer cartridge.

9. DC Indicator

Yellow light indicates voltage is present at the powersupply output and cutting current is available.

10. PILOT Indicator

Yellow light indicates pilot arc contactor closure. Lightgoes out when cutting arc is established and comesback on if cutting arc is interrupted. Refer to Section4.07-A and -B, Auto Restart Function.

C. Gauge Front Panel

Figure 4-4 Upper Gauge Panel

1. Secondary Pressure Control

Adjusts secondary gas pressure. Pull knob out andturn clockwise to increase secondary pressure to de-sired level.

2. Secondary Pressure Gauge

Displays secondary pressure from 0 - 100 psi (0 - 6.9bar).

3. Secondary Mode Selector

Selects secondary mode to gas, oxygen (no second-ary), or water. This mode selector is disabled whenusing the Remote Gas Control Option (GC 3000).


NOTE

This switch must be in the gas (cylinder symbol)mode for all secondary gases when the Gas Con-trol Option is installed.

4. Coolant Pressure Gauge

Displays coolant pressure from 0 - 160 psi (0 - 11.0bar). Normal operation is 100 - 120 psi (6.9 - 8.3 bar)

5. Plasma Pressure Gauge

Displays plasma gas pressure from 0 - 100 psi (0 - 6.9bar).

6. Plasma Pressure Control

Adjusts plasma gas pressure. Pull knob out and turnclockwise to increase plasma pressure to desired level.

D. Rear Panel

1. Fan Assembly

Fan used to move the air across the internal compo-nents for cooling purposes.

2. SECONDARY Gas Input Fitting

1/4 NPT female gas fitting used to supply the sec-ondary gas to the system.

3. PLASMA Gas Input Fitting

1/4 NPT female gas fitting used to supply the plasmagas to the system.

4. SECONDARY WATER Fitting

1/4 NPT female fitting used for connection of tap wa-ter to the Power Supply. The water can be used as asecondary gas for the torch when the front panel SEC-ONDARY switch is in the WATER position or the GasControl Option is installed.

5. Coolant Reservoir and Filler Cap

The coolant reservoir is located under the top panelcover. The coolant reservoir supplies the system withcoolant to cool the torch parts during operation. Themaximum capacity of the reservoir is two gallons ofcoolant.

Inside the reservoir, in the filler neck, is a basket anda deionizer bag. The bag removes charged particlesfrom the coolant after it is returned to the reservoir.If the coolant in the reservoir breaks down becauseof these charged particles then a sensor on the reser-voir will cause the COOLANT COND indicator togo OFF.

6. Coolant Level Indicator

A slot provided in the rear panel allows the operatora visual check of the coolant level. The coolant shouldbe above the indicator mark on the slot.

A-01509

1

23

4

5

6

7

8

9

10

11

12

13

14

15

16

Figure 4-5 Power Supply Rear Panel

7. Coolant Filter Assembly

The Coolant Filter Assembly on the rear panel is usedto filter the coolant as it returns to the reservoir. Thefilter is a screen type which is easily cleaned or re-placed.

8. Primary Input Power Cable Strain Relief

A strain relief supplied to secure the customer sup-plied primary input power cable to the power sup-ply. The input AC power cable is routed through thestrain relief and is connected to the power input ter-minals inside the unit.


9. Remote Control and CNC Interface Connector

NOTE

For use with Remote Control RC6010 or StandoffControl SC11. Refer to the Remote Control(RC6010) Instruction Manual 0-2478 or theStandoff Control (SC11) Instruction Manual 0-2556 for more information.

REMOTE CONTROL connector (J15) used to inter-face remote controls with mechanized systems. Theconnector can be used to interface the Power Supplywith one of the following:

• Optional Remote Control (RC 6010) which al-lows the operator to control all system func-tions from a remote location.

• Optional SC-11 Standoff Control or other stan-dard control (CNC) which allows the opera-tor to control various functions of the mecha-nized system from a remote location.

10. High Flow Water Shield

Output connector to allow the use of the OptionalHigh Flow Water Shield on the system.

11. CNC Cable Strain Relief

Used to secure a CNC cable to the Power Supplywhen the CNC cable does not have a connector in-stalled. The CNC cable is fed through the strain re-lief and connected to an internal terminal strip (TB2).

12. Optional Gas Selection Interface Connector

Connector used to interface the Power Supply to theOptional Gas Control (GC3000) Accessory. The GasControl Accessory connects to the connector markedGAS CONTROL (J63).

13. Optional PLASMA GAS Selection

Optional panel with multiple ports (manifolds) forconnection to four plasma gases. The gas manifoldsare controlled by the Gas Control Accessory. Eachfitting is a 1/4 NPT type.

OUTPUTOUTPUT

AIRAIRPLASMAINPUT

N2

PLASMAINPUT

O2

PLASMAINPUT

PLASMA GAS

Ar/HAr/H2

PLASMAINPUT

A-01011

Plasma GasManifold

Figure 4-6 Optional PLASMA Gas Selection

14. Optional Gas Secondary (N2) Input Fitting

Optional 1/4 NPT female gas fitting used to supplythe secondary gas (N2) to the system.

15. Optional Gas Secondary (OTHER) Input Fitting

Optional 1/4 NPT female gas fitting used to supplythe secondary gas (OTHER) to the system.

16. Parallel Cable Connector

Connector J54 is used to interface the Master PowerSupply to the Slave Power Supply.

4.04 Operating Unit Without GasControl Option

NOTE

This Subsection describes the normal operation ofthe system without the Gas Control Option in-stalled. Refer to Section 4.05 for systems with theGas Control Option installed.

This procedure should be followed at the beginning ofeach shift:

WARNING

Disconnect primary power at the source before as-sembling or disassembling power supply, torchparts, torch and leads assemblies or adding cool-ant.


A. Coolant Level

Check the coolant level at the coolant reservoir at therear of the Power Supply. If the coolant is down fromthe top of the reservoir more than 2 inches (50mm)add coolant.

B. Deionizer Bag

Check the condition of the deionizer bag in the reser-voir basket. If the bag is a yellowish brown (strawcolor) then replace the bag.

C. Torch Parts

Check the torch for proper assembly. Install propertorch parts for the application (refer to Maximizer300 Torch Instruction Manual, Catalog No. 0-2573).

D. Input Power

Check the power source for proper input voltage.Make sure that Power Supply is set for the propervoltage. Close main disconnect switch or plug unitin to supply primary power to the system.

E. Plasma Gas Supply

Connect desired plasma gas. Make sure gas sourcesmeet requirements (refer to appropriate Torch Instruc-tion manual). Check connections and turn plasmagas supply on.

F. Secondary Gas Supply

Connect desired secondary gas. Make sure gassources meet requirements (refer to Torch InstructionManual). Check connections and turn secondary sup-plies on.

Select the desired secondary gas per the following:

1. If gas secondary is desired, set secondary modeselector switch to gas cylinder symbol position.

NOTES

Tap water should only be used for secondary gason machine torches.

To use tap water there must be a Water Regulator(Catalog No. 8-6118) installed between the watersource and the Power Supply.

2. If tap water secondary is desired, set secondarymode selector switch to water tap symbol posi-tion and connect tap water to the Power Supplyrear panel at the secondary water connection. Itmay take two or three minutes for the water tostart flowing out the front of the torch.

3. If no secondary gas is desired, set secondary se-lector switch to O2 position.

NOTE

Refer to the Torch Instruction Manual for propersecondary gas selection.

G. Plasma Gas Purge

Enable the system by doing one of the following:

• Turn the Enable switch to ON at the front panelof the RC6010 Remote Control

• Signal supplied through the CNC control cable

• Signal supplied from a customer supplied switchconnected to the CNC terminal block (TB2) in-side the Power Supply

Move the Power Supply ON/OFF switch to the ONposition (see note). The Enable Signal must be turnedON either by a switch or contact closure.

NOTE

In systems using more than one Power Supply bothfront panel ON/OFF switches must be ON.

An automatic gas purge will remove any condensa-tion that may have accumulated in the torch and leadswhile the system was shut down. The gas purge du-ration is 40 seconds. After the purge is complete, ifthe RUN/SET/PURGE switch is in SET position,gases will flow. If the switch is in PURGE positiononly plasma gas will flow. If the switch is in RUNposition there will be no gas flow.

NOTE

RUN/SET/PURGE may be selected at the RC6010Remote Control. Both switches must be in theRUN position for normal operation.

H. Current Output Level

Single Power Supply System:

Select the desired current output level from 50 to150 amps.

Dual Power Supply System:


I. Pressure Settings

Move the RUN/SET/PURGE switch to SET position.Set plasma and secondary pressures (refer to Maxi-mizer 300 Torch Instruction Manual 0-2573).


J. Additional Gas Purging

If additional purging of the plasma gas line is neces-sary, move the RUN/SET/PURGE switch to PURGEposition. In PURGE mode, the GAS indicator will beOFF because only plasma gas flows and the secon-dary gas flow switch is not satisfied.

K. Ready for Operation

Return the RUN/SET/PURGE switch to RUN posi-tion.

The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram ofthe Sequence Of Operation.

4.05 Operating Unit With GasControl Option

NOTE

This Subsection describes the normal operation ofthe system with the Gas Control Option installed.Refer to Section 4.04 for systems without the GasControl Option installed.

This procedure should be followed at the beginning ofeach shift:

WARNING

Disconnect primary power at the source before as-sembling or disassembling power supply, torchparts, or torch and leads assemblies, or adding cool-ant.

A. Coolant Level

Check the coolant level at the coolant reservoir at therear of the Power Supply. If the coolant is down fromthe top of the reservoir more than 2 inches (50mm)add coolant.

B. Deionizer Bag

Check the condition of the deionizer bag in the reser-voir basket. If the bag is a yellowish brown (strawcolor) then replace the bag.

C. Torch Parts

Check the torch for proper assembly. Install propertorch parts for the application (refer to Maximizer300 Torch Instruction Manual, Catalog No. 0-2573).

D. Input Power

Check the power source for proper input voltage.Make sure that Power Supply is set for the propervoltage. Close main disconnect switch or plug unitin to supply primary power to the system.

E. Plasma Gas Supply

NOTE

Refer to the Gas Control Option InstructionManual 0-2477 for more information.

Connect the desired plasma gases to the gas mani-fold at the rear panel of the Power Supply. Makesure plasma gas sources meet requirements (refer toTorch Instruction Manual). Check connections andturn plasma gas supplies on.

Select the desired plasma gas at the Gas Control Op-tion front panel PLASMA gas switch.

F. Secondary Gas Supply

NOTE

Refer to the Gas Control Option InstructionManual 0-2477 for more information.

Connect the desired secondary gases to the gas con-nections at the rear of the Power Supply. Make suregas sources meet requirements (refer to Torch Instruc-tion Manual). Check connections and turn secondarysupplies on.

NOTE

For all secondary gases set the Power Supply frontpanel gas selector mode switch to the gas cylindersymbol position.

Select the desired secondary gas at the Gas ControlOption front panel SECONDARY gas switch.

NOTE

To use tap water there must be a Water Regulator(Catalog No. 8-6118) installed between the watersource and the Gas Control Option

When using water as the secondary it may take twoor three minutes for the water to start flowing outthe front of the torch.

NOTE

Refer to the Torch Instruction Manual for propersecondary gas selection.

G. Plasma Gas Purge

Enable the system by doing one of the following:


• Turn the Enable switch to ON at the front panelof the RC6010 Remote Control

• Signal supplied through the CNC control cable

• Signal supplied from a customer supplied switchconnected to the CNC terminal block (TB2) in-side the Power Supply

Move the Power Supply ON/OFF switch to the ONposition (see note). The Enable Signal must be turnedON either by a switch or contact closure.

NOTE

In systems using more than one Power Supply bothfront panel ON/OFF switches must be ON.

An automatic gas purge will remove any condensa-tion that may have accumulated in the torch and leadswhile the system was shut down. The gas purge du-ration is 40 seconds. After the purge is complete, ifthe RUN/SET/PURGE switch is in SET position,gases will flow. If the switch is in PURGE positiononly plasma gas will flow. If the switch is in RUNposition there will be no gas flow.

NOTE

RUN/SET/PURGE may be selected at the RC6010Remote Control. Both switches must be in theRUN position for normal operation.

H. Current Output Level

Single Power Supply System:


Dual Power Supply System:


I. Pressure Settings

Move the RUN/SET/PURGE switch to SET position.Set plasma and secondary pressures (refer to Maxi-mizer 300 Torch Instruction Manual 0-2573).

J. Additional Gas Purging

NOTE

Additional gas purging should be done whenswitching to a new plasma gas. This will makesure that the old gas in the lines has been purged.

If additional purging of the plasma gas line is neces-sary, move the RUN/SET/PURGE switch to PURGEposition. In PURGE mode, the GAS indicator will beOFF because only plasma gas flows and the secon-dary gas flow switch is not satisfied.

K. Ready for Operation

Return the RUN/SET/PURGE switch to RUN posi-tion.

The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram ofthe Sequence Of Operation.

4.06 System Operation

NOTE

Frequently review the safety precautions at the frontof this manual.

This section contains operating information which is spe-cific to the power supply. Detailed operating informa-tion for torches can be found in the appropriate TorchInstruction Manual.

WARNINGS

Disconnect primary power at the source before as-sembling or disassembling power supply, torchparts, or torch and leads assemblies, or adding cool-ant.

It is not enough to simply move the ON/OFFswitch on the unit to OFF position when cuttingoperations have been completed. Always open thepower supply disconnect switch five minutes afterthe last cut is made.

A. Operational Suggestions

The suggestions below should be followed in all cuttingand gouging operations:

1. Wait five minutes before setting the ON/OFF switchto OFF after operation. This allows the cooling fan torun to dissipate operating heat from the power sup-ply.

2. For maximum parts life, do not operate the pilot arcany longer than necessary.

3. Use care in handling torch leads and protect them fromdamage.

4. In continuous cutting applications using CO2, it is of-ten necessary to manifold four to six cylinders togetherto maintain adequate flow at operating pressures.


B. Using Corner Slowdown for MechanizedCutting

NOTE

Corner Slowdown (CSD) is available only if theRemote Control RC6010 is used.

The corner slowdown (CSD) function provides a re-duction in output current which corresponds withthe reduced travel speed of a mechanized torch as itchanges direction at a sharp corner. When activated(by CNC or other control device) corner slowdowneliminates excessive metal removal and bottom drossin corners.

Normally open (NO) contacts (supplied by the con-trol device) close when the torch travel speed de-creases through a corner. When the contacts close,power supply output drops to a preset current level.

C. Setting CSD Output

NOTE

Corner Slowdown (CSD) is set at the RC6010Remote Control.

OUTPUT AMPSPLASMAPLASMAENABLEENABLE

ON

START

REMOTE POWER SUPPLY CONTROL

CSD(%)

0

25 75

100

50

TRAVELTRAVELSPEEDSPEED

125+ IPM

0-125 IPM

RUN

PURGE

SET

Front Panel ofRC6010 Remote Control

CSD (%)Adjustment

A-00997

Figure 4-7 Corner Slowdown (CSD) Adjustment

The corner slowdown adjustment is located on the frontpanel of the RC6010 Remote Control. The control setscorner slowdown output to any current level from theminimum (50 amps) to the maximum (150 amps) level ofthe system. The corner slowdown output level is a per-centage of the main output level. Typically the CSD out-put level should not be set lower than 70% of the maincurrent level to insure full arc penetration during cornerslowdown.

If the cutting machine controller activates CSD (threedecimals on the display) during pierce starts it may notbe desirable to set CSD below 100% as starting currentwill be reduced requiring longer pierce times.

NOTE

For electrical connections, refer to Appendix 7,CNC Interface Schematic

D. Fold Back Feature

Should the torch tip contact the workpiece the out-put current will immediately drop to 50 amps (100amps with Slave Power Supply connected) to mini-mize potential tip damage.

NOTE

The torch is not designed for drag cutting.

4.07 Optional Power SupplySettings

NOTE

The adjustments in this sub-section should be setin the Master Power Supply ONLY.

The following functions can be used to tailor a system forspecial application requirements or unique user prefer-ences. These functions are controlled by DIP switches lo-cated on the Logic Control PC board in the power sup-ply. Locate the Logic Control PC Board under the frontpanel access cover and set the functions as required.

A. Auto-Restart Function (SW1)

ON

OFF1 2

SW1

A-00991 Logic PC Board

Figure 4-8 Auto-Restart Enable Switch SW1Location

Auto-restart provides an immediate pilot arc restartduring post-flow if the torch is brought within rangeof the workpiece. Auto-restart can be switched offso that the torch must be reactivated (via torch switchor control device) to restart the pilot arc each timethe main arc is interrupted. This setting may be use-


ful if the system is used to replace other units whichdo not have auto-restart, or for use with motion con-trol devices. In many applications, torch parts life maybe improved by disabling auto-restart to reduce ex-cessive pilot arc time.

NOTE

Either pole set to 1 (on) disables auto-restart func-tion.

Auto -RestartF u n ctio n

SW 1-1Po sitio n

SW 1-2Po sitio n

Enabled 0 (O ff ) 0 (O ff )

D isabled 0 (O ff ) 1 (O n)

D isabled 1 (O n) 0 (O ff )

D isabled * 1 (O n) 1 (O n)

* = Factory Set t ing

B. Auto-Restart Mode (SW2)

ON

OFF1 2 SW2


Figure 4-9 Auto-Restart Mode Switch SW2 Location

Normal mode provides an immediate pilot restartwhenever the main arc is interrupted and the Auto-Restart switch SW1 is set to ENABLE. Delayed modeprovides a gas pre-flow each time before the pilot arc

restarts. In some shape-cutting applications, it maynot be desirable to immediately restart the main arcafter the torch passes beyond the desired cutting line(or between cuts).

NOTE

Either pole set to 1 (on) sets delayed auto-restartfunction.

Auto -RestartMode

SW 2-1Position

SW 2-2Position

Normal * 0 (O ff) 0 (O ff)

Delayed 0 (O ff) 1 (O n)

Delayed 1 (O n) 0 (O ff)

Delayed 1 (O n) 1 (O n)

* = Factory Sett ing

C. Gas Pre-Flow Delay (SW3)

ON

OFF1 2

SW3


Figure 4-10 Gas Pre-Flow Delay Switch SW3Location

The pre-flow delay allows time for gases to flow tothe torch when the torch is activated. Pre-flow is im-mediately followed by pilot arc initiation Pre-flowdurations are factory set but extended torch leads mayrequire longer pre-flow durations.


NOTE

Pre-flow timing depends on the Logic PC Boardinstalled in the Power Supply.

Refer to one of the following descriptions for the LogicPC Board installed in the Power Supply:

• Power Supply Unit Rev AF or Earlier UsingLogic PC Board 19x1247

Pre-flow is factory-set at 2 seconds, but can be re-set to 4, 7, or 10 seconds as desired.

Pre-Flow Time(Seconds)

SW3-1Position

SW3-2Position

2 * 0 (Off) 0 (Off)

4 0 (Off) 1 (On)

7 1 (On) 0 (Off)

10 1 (On) 1 (On)

* = Factory Setting

Logic PC Board 19x1247

• Power Supply Unit Rev AG or Later Using LogicPC Board 19x1360

Pre-flow is factory-set at 2 seconds, but can be re-set to 0.5, 3, or 4 seconds as desired.

Pre-Flow Time(Seconds)

SW3-1Position

SW3-2Position

0.5 0 (Off) 0 (Off)

2 * 0 (Off) 1 (On)

3 1 (On) 0 (Off)

4 1 (On) 1 (On)

* = Factory Setting

Logic PC Board 19x1360

D. Gas Post-Flow Delay (SW4)

ON

OFF 1 2SW4

A-00994

Logic PC Board

Figure 4-11 Gas Post-Flow Delay Switch SW4Location

Post-flow delay allows gases to flow after the maincutting arc is interrupted. Post-flow is factory-set at10 seconds, but can be reset to 5, 20, or 40 seconds.

Po st-F lo w T im e(Seco n d s)

SW 4-1Po sitio n

SW 4-2Po sitio n

5 0 (O f f ) 1 (O n)

10 * 0 (O f f ) 0 (O f f )

20 1 (O n) 0 (O f f )

40 1 (O n) 1 (O n)

* = F actory Set t ing


E. OK-To-Move Selection (SW5)

SW5

A-00995LogicPC Board

Figure 4-12 OK-To-Move Selection Switch SW5Location

The OK-To-Move Selection Switch (SW5) selects ei-ther contact closure or 24 VAC for the OK-To-Movesignal (motion start).

OK-To-Move Selection SW5

Contact Closure * UP

24 VAC DOWN

* = Factory Setting

NOTE

Switch SW5 must be in the UP position when us-ing Remote Control RC6010 or Standoff ControlSC11.

To use the contact closure for the OK-To-Move signalthe switch should be in the up position (factory set-ting). To use 24 VAC for the OK-To-Move signal theswitch should be in the down position.

To get a motion start signal when starting off the edgeof the workpiece, not a pierce start, jumper TB2-8 toTB2-9 and TB2-7 to TB2-10 to give an OK-To-Movecontact closure when the pilot starts via pilot sensing

relay (PSR). The switch, SW5, must be in the contactclosure (up) position or the 24 VAC will be shortedout and blow the internal fuse (F3).

24VAC

J2-19

J2-18

J15-11

J15-10

SW5

OK-To-MoveJ2-16

J2-14

Logic PCB

OK-To-MoveAt PilotInitiation

PSR

TB2-10

TB2-9

TB2-8

TB2-7

A-01009

Figure 4-13 OK-To-Move Using PSR

An external voltage source up to 120V may be con-nected in series with the Pilot Sensing Relay (PSR) orOK-To-Move. This also works with the RC6010, re-fer to RC6010 Manual for 24 VAC or external volt-age. RC6010 must have only contact closure fromthe Power Supply.

J15-11

J15-10

External VoltageSource Alternate

Positions

OK

PSR

TB2-10

TB2-9

TB2-8

TB2-7

A-01010

Figure 4-14 OK-To-Move Using External Supply


Manual 0-2568 5-1 SERVICE

SECTION 5:SERVICE

5.01 Introduction

This Section describes basic maintenance procedures per-formable by operating personnel. No other adjustmentsor repairs are to be attempted by other than properlytrained personnel.

For major troubleshooting and parts replacement proce-dures refer to the Master Power Supply Service Manual0-2569.

5.02 General Maintenance

A. Routine Maintenance

NOTE

Refer to Appendix 12 for a recommended mainte-nance schedule for water cooled plasma cuttingsystems.

Routine maintenance for the Power Supply should in-clude an occasional thorough cleaning and inspection. Thefrequency depends on the usage and the operating envi-ronment.

WARNING


Remove both Side Panels of the Power Supply and blowout any accumulated dirt and dust with compressed air.The unit should also be wiped clean. If necessary, sol-vents that are recommended for cleaning electrical appa-ratus may be used.

While the side panels are off, inspect the wiring in theunit. Look for any frayed wires or loose connections thatshould be corrected.

B. Coolant Filter Assembly (Rear Panel)

The rear panel filter screen should be cleaned periodi-cally. Remove the filter screen by unscrewing the filterholder from the Coolant Filter Assembly. Clean the filterscreen by rinsing with hot soapy water. Remove soapresidue by rinsing with clean hot water. Be sure that allthe soap has been removed and the screen is dry of waterbefore re-installing in the Coolant Filter Assembly.

Coolant Filter Assembly

Filter Screen

Filter HolderA-01510

Figure 5-1 Coolant Filter Assembly (Rear Panel)

C. In-Line Filter Assembly

The in-line filter screen should be cleaned periodically. Togain access to the In-Line Filter Assembly remove the LeftSide Panel (viewed from the front of unit) of the PowerSupply. Remove the filter screen by unscrewing the filterholder from the In-Line Filter Assembly. Clean the filterscreen by rinsing with hot soapy water. Remove soapresidue by rinsing with clean hot water. Be sure that allthe soap has been removed and the screen is dry of waterbefore re-installing in the In-Line Filter Assembly.

D. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day atthe rear panel coolant gauge. If the coolant in thereservoir is more than 2 inches (50mm) from thetop of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity LED on the front panelmust be ON for normal operation. If the LED isOFF then drain the old coolant from the PowerSupply and torch leads and replace with new cool-ant. Check the condition of the deionizer bag inthe reservoir basket, if the bag is yellowish brown(straw color) replace the bag.

SERVICE 5-2 Manual 0-2568

E. Draining Coolant

Remove the old coolant from the Power Supply reservoirper the following procedure:

1. Remove the right side and top panels from thePower Supply.

2. Disconnect the coolant hose input to the rear panelfilter assembly.

3. Carefully lower the hose out the right side of thePower Supply and drain the coolant into an ac-ceptable container.

CAUTION

Handle and dispose of the used coolant per recom-mended procedures.

Coolant Hose

Coolant HoseConnection

A-01511

Figure 5-2 Draining Coolant From Reservoir

4. Reconnect the hose to the filter assembly.

5. Install new coolant and deionizer bag.

6. Reinstall the top and right side panels.

5.03 Common Operating Faults

Listed below are common cutting problems followed byprobable causes of each. If the problems are caused by atorch problem, refer to the appropriate Torch Manual.

1. Insufficient Penetration

a. Cutting speed too high

b. Current too low

c. Metal too thick

d. Worn or damaged torch parts

2. Main Arc Extinguishes

a. Cutting speed too low

b. Standoff too high

3. Dross Formation

a. Improper gas pressure

b. Improper cutting speed

c. Worn or damaged torch parts.

4. Burned-Out Tips

a. Cutting current too high

b. Damaged or loose cutting tip

c. Tip in contact with work

d. Heavy spatter

e. Low plasma gas pressure

5. Poor Pilot Starting

a. High coolant conductivity

5.04 Troubleshooting

General

Troubleshooting and repairing the this unit is a processwhich should be undertaken only by those familiar withhigh voltage high power electronic equipment.

WARNING

There are extremely dangerous voltage and powerlevels present inside this unit. Do not attempt todiagnose or repair unless you have had training inpower electronics measurement and troubleshoot-ing techniques.

Basic Troubleshooting

This manual covers a basic level of troubleshooting thatrequires limited disassembly and measurements. It ishelpful for solving many of the common problems thatcan arise with a plasma cutting system.

NOTE

For major troubleshooting and parts replacementprocedures refer to Power Supply Service Manual0-2569.

If major complex subassemblies are faulty, the unit mustbe returned to an authorized service center for repair.

Follow all instructions as listed and complete each sec-tion of the troubleshooting guide in the order presented.


How to use this Guide

The following information is a guide to help the Customer/Operator determine the most likely causes for varioussymptoms.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your symptom, check the causes (easiest listed first)then remedies. Repair as needed being sure to verify thatunit is fully operational after any repairs.

Troubleshooting Specific Problems

A. Main disconnect fuse blows when primary poweris connected

1. Voltage selection busbars connected incorrectly

a. Check and correct if necessary.

2. One leg of three-phase primary connected to chassisground

a. Rewire input cable

3. Faulty power supply

a. Isolate and replace component(s) per ServiceManual.

B. AC Power Indicator on Front Panel not ON; Fanand pump OFF

1. Customer’s main power disconnect is turned OFF

a. Turn ON main power disconnect

2. Front Panel ON/OFF switch is turned OFF

a. Turn ON front panel power switch

3. No primary power

a. Check for proper three-phase power at inputterminal board

4. Blown fuse (F2)

a. Check and replace fuse if necessary



C. AC power indicator ON; Fan and pump OFF

1. Remote Control or TB2 Enable switch not ON

a. Turn ON switch or enable signal at TB2

2. Primary power - missing phase


3. Blown fuse (F1 or F2)


4. Power Supply Parallel Cable not installed and Fan inSlave Power Supply is not ON

a. Connect cable between Master and SlavePower Supplies


a. Isolate and replace component(s) per ServiceManual

D. TEMP indicator ON (red).

1. Unit overheated

a. Clean radiator and check for obstruction

b. Check for adequate air flow around unit


a. Isolate and replace component(s) per ServiceManual

E. GAS indicator OFF

1. RUN/SET/PURGE switch set to PURGE, secondarymode switch set to GAS secondary

a. Normal operation (purges plasma line only)

2. Gas pressure set too low

a. Adjust pressure




F. GAS indicator OFF, plasma and/or secondary gasdoes not flow

1. RUN/SET/PURGE switch set to PURGE, secondarymode switch set to GAS secondary

a. Normal operation (purges plasma line only,secondary does not flow)

2. Secondary mode set to O2

a. No secondary flow is normal operation in O2mode (but GAS indicator should be ON)

3. Low plasma pressure

a. Check plasma pressure

4. Secondary supply turned OFF (or tank empty)

a. Check secondary supply



H. No coolant pressure at gauge; COOLANT Indica-tor may be OFF or ON

1. Coolant level is too low

a. Check coolant level in Coolant Reservoir andadd if necessary.

2. Clogged Coolant Filter Assembly (Rear Panel)

a. Remove screen from filter and clean or replaceas necessary.

3. Clogged In-Line Coolant Filter Assembly (Behind SidePanels)

a. Remove screen from filter and clean or replaceas necessary.

4. Plugged or damaged coolant hoses

a. Inspect all coolant hoses and clean or replaceas necessary.

5. Plugged or damaged torch head

a. Inspect all torch head parts and replace as nec-essary.

6. Defective Coolant Flow Component(s)


I. COOLANT indicator flashing ON and OFF

1. Air in coolant lines

a. Run pump for ten minutes to purge air from thecoolant lines before using the system.

2. Coolant Level is low

a. Check for proper coolant level at rear panelgauge

J. Coolant CONDUCTIVITY Indicator OFF

1. Coolant conductivity is excessive.

a. Drain and replace coolant. Also check the con-dition of the deionizer bag in the reservoir bas-ket, if the bag is yellowish brown (straw color)replace the bag.



K. Leaking torch connection

1. Loose torch connection

a. Check connection making sure connector isfully seated.

L. DC indicator OFF (after pre-flow); No maincontactor closure

1. RUN/SET/PURGE switch not set to RUN

a. Normal operation, set switch to RUN position

2. Faulty torch switch, remote control, or remote pendant




M. Weak or sputtering pilot; HF stays on during pilot

1. Plasma gas pressure too high

a. Adjust pressure

2. Low OCV (normal 290-350 vdc) caused by improperconnection of voltage selection bus bars

a. Check input voltage connections

3. Pilot Resistor out of adjustment

a. Adjust Pilot Resistor per Section 3.15




N. No pilot; PILOT indicator ON; Strong spark visibleat spark gap points in Arc Starter Box

1. Faulty torch parts

a. Repair per Torch Manual



O. Pilot arc ON; No main arc transfer (torch broughtwithin range of work)

1. Work cable not connected

a. Connect work cable securely



P. System cuts at one-half expected current

1. Work cable not connected

a. Check work cable connection from MasterPower Supply. If using Slave Power Supply,work cable must also be connected.

2. Slave Power Supply not ON

a. Turn ON front panel ON/OFF power switch

3. Parallel Cable not connected

a. Install Parallel Cable between Master and SlavePower Supplies

Q. Slave Power Supply AC Power Indicator on FrontPanel not ON; Fan OFF

1. Customer’s main power disconnect is turned OFF

a. Turn ON main power disconnect

2. Front Panel ON/OFF switch is turned OFF

a. Turn ON front panel power switch

3. No primary power


4. Blown fuse (F2)




5.05 Basic Parts Replacement

NOTE

For more detailed Parts Replacement Proceduresand Replacement Parts refer to Power Supply Ser-vice Manual 0-2569.

The parts replacement procedures described in thismanual are for basic replacement of parts that requireslimited disassembly of the Power Supply.

WARNING

Disconnect primary power from the source beforedisassembling the power supply.

A. Side Panel Removal

The replacement of the fuse and filter assemblies can bemade through the left and right sides of the Power Sup-ply. Remove the Right and Left Side Panels as follows:

1. Locate the removable Left and Right Side Panelof the Supply as viewed from the front of the unit.

Left Side Panel

Screws(10 Places)

A-01535

Figure 5-3 Side Panel Screw Removal


2. Remove the ten screws that secure each side panelto the Power Supply.

3. Remove the side panels from the Power Supply.

4. Reinstall the panels by reversing the above steps.

B. Fuse Replacement

There are three fuses located on the Power Supply as fol-lows:

• Two fuses are located in the torch leads connectionarea under the hinged cover at the Front Panel.These fuses are in a typical fuse holder that requiresremoval of the fuse holder cap to replace the fuse.

• One fuse is located inside the Power Supply behindthe Right Side Panel. The fuse is located above theBias PC Board and to the right of the line filter.

Replace the fuse inside the Power Supply per the follow-ing:

1. Remove the Right Side Panel as described in para-graph “A” above.

2. Locate the internal fuse mounted above the BiasPC Board and to the right of the line filter nearthe center edge of the unit.

3. Remove the damaged Fuse for the snap type fuseholder.

4. Reinstall the replacement Fuse by reversing theabove steps.

C. Coolant Filter Assembly Replacement

The Coolant Filter Assembly is located on a bracket onthe Rear Panel Assembly of the unit.

1. Remove the two Coolant Hose connections to theCoolant Filter Assembly.

2. Remove the two elbow fitting on each side of theCoolant Filter Assembly and remove the damagedassembly from the bracket.

3. Clean the old thread sealer from the threads ofthe elbow fittings.

4. Apply a thin coating of liquid teflon thread sealerto the threads of the elbow fittings.

5. Place the replacement Coolant Filter Assembly inthe bracket with the arrow pointing to the left andreinstall the two elbow fittings.

6. Reconnect the two Coolant Hoses to the CoolantFilter Assembly making sure that the hose to thePump Assembly is on the output of the CoolantFilter Assembly (left side as viewed from the back).

D. In-Line Filter Assembly Replacement

The In-Line Filter Assembly is located inside behind theLeft Side Panel (viewed from the front of the unit). Thefilter is attached to the radiator inside of the Lower FrontPanel.

1. Remove the Left Side Panel from the Power Supplyper paragraph 'A' above.

2. Locate the In-Line Coolant Filter near the front ofthe unit.

3. Remove the two Coolant Hose connections to theIn-Line Filter Assembly.

4. Clean the old thread sealer from the threads of thehoses and the fittings.

5. Apply a thin coating of liquid teflon thread sealerto the threads of the fittings.

6. Reconnect the two Coolant Hoses to the In-LineFilter Assembly making sure that the top hosegoes to the Flow Switch Assembly. The bottomhose comes from the Radiator Assembly.

Manual 0-2568 6-1 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 Complete Power Supply ReplacementParts List

Section 6.04 Basic Component Replacement Parts List

Section 6.05 Power Supply Options And AccessoriesNOTE

Parts listed without item numbers are not illus-trated, but may be ordered by the catalog numbersshown.

B. Returns

If a product must be returned for service, contact yourauthorized distributor. Materials returned without properauthorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and completedescription of the part or assembly, as listed in the de-scription column of the Parts List. Also include the modeland serial number of the machine as shown on the plateattached to the front panel of the unit. Address all in-quiries to your authorized distributor.

PARTS LISTS 6-2 Manual 0-2568

6.03 Complete Power Supply Replacement Parts List

Qty. Description Catalog #

Merlin 6000 Master Power Supply (with Running Gear and Work Cable)

1 Without Gas Control 3-6800

1 With Gas Control 3-6802

1 Work Cable with Ring Lug - 25 ft (7.6 m) 9-6892

Manual 0-2568 6-3 PARTS LISTS

6.04 Basic Component Replacement Parts List


1 Coolant Filter 8-4276

1 Hose Assembly - Tank to Coolant Filter 8-4274

1 Coolant Reservoir Basket 8-4273

1 Deionizer Bag 8-3312

1 Coolant Filler Cap 8-5142

1 Coolant Filter 8-4276

2 Caster 8-5578

2 Wheel 8-5579

1 Axle 9-1243

1 Fuse (F2) - 5 amp, 250V (F2) 8-1025

1 Fuse (F1) - 8 amp, 500V, Time Delay 9-3641

1 Spill Tray 8-6149

1 gal Torch Coolant

'Extra-CoolTM' Coolant for Ambient Temperatures to +10°F (-12°C) 7-3580

'Ultra-CoolTM' Coolant for Ambient Temperatures to -27°F (-33°C) 7-3581

NOTE

For Cable and Hose Replacement Partsrefer to Appendix 4 and 5.

PARTS LISTS 6-4 Manual 0-2568

6.05 Power Supply Options And Accessories


1 Merlin 6000 Slave Power Supply 3-6801

1 Remote Arc Starter Box 3-6820

Gas Regulators

1 Nitrogen Regulator 9-2722

1 CO2 Regulator 9-2759

1 Argon/Hydrogen Regulator 9-3053

1 High Pressure Air Regulator 9-3022

1 Oxygen Regulator 9-4379

1 Water Regulator 8-6118

1 Two Stage Air Line Filter Assembly 7-3139

1 Replacement First Stage Filter Element 9-1021

1 Replacement Second Stage Filter Element 9-1022

1 Plasma Gas Supply Line - 10 ft (3.0 m) 9-2146

1 Secondary Gas Supply Line - 10 ft (3.0 m) 9-2147

1 Remote Control (RC6010) 3-6106

1 Standoff Control (SC10) 3-6110

1 High-Flow Water Shield

220V Version 7-3284-1

460V Version 7-3284-2

Standoff Control Lifter Motor Control Cable

1 10 ft (3.0 m) 9-4535

1 15 ft (4.5 m) 9-4536

1 20 ft (6.0 m) 9-4537

Manual 0-2568 A-1 APPENDIX

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input P ow er Input Cur rent S uggested S izes (S ee Note)

V oltage Freq . 3-P h 3-P h Fuse (Am ps) W ire (AW G ) W ire (Canada)

(V olts) (Hz) (kV A) (Am ps) 3-P h 3-P h 3-P h

200 50/60 34 98 110 2 2

208 50/60 34 95 110 2 2

220 50/60 34 89 100 2 2

230 50/60 34 85 100 4 4

380 50/60 34 51 60 6 6

415 50/60 34 47 60 8 6

460 50/60 34 42 50 8 6

506 50/60 34 40 45 8 6

575 50/60 34 34 40 8 6

Line V oltages w ith S ugges ted C ircui t P rotec tion and W ire S izesB ased on National E lec tric Code and Canadian E lec trical Code

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installationsrefer to local or national codes.

Cable conductor temperature used is 167° F (75° C).

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should beused to minimize damage to Plasma Cutting, Welding or power distribution equipment.

NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

APPENDIX A-2 Manual 0-2568

APPENDIX 2: SEQUENCE OF OPERATIONBLOCK DIAGRAM

A-03294

ACTIONEnable ON at Remote or TB2

ON/OFF switch to ON

RESULT• AC indicator ON• TEMP Indicator ON• GAS indicator ON• Fan and pump ON• 40 second auto-purge

ACTIONRUN/SET/PURGE

switch to SET

RESULT• Gas solenoids open, gases flow to set pressures• GAS indicator ON

ACTIONRUN/SET/PURGE

switch to RUN

RESULT• Gas flow stops• Power circuit ready• GAS indicator OFF

PILOT ARC

ACTIONTorch de-activated by torch switch

release or remote device

RESULT• Main arc stops• Main contactor opens (Logic PC Board Rev AE or Earlier Only• DC indicator OFF• Pilot and PILOT indicator OFF

NOTEIf torch is activated during post-flow the pilot arc will immediately restart. If within range

of work, main arc will transfer.

After post-flow:• Main contactor opens (Logic PC Board Rev AF or Later Only• Gas solenoids close, gas flow stops• GAS indicator OFF

ACTIONON/OFF switch to OFF

RESULT• AC indicator OFF• TEMP Indicator OFF• Fan and pump OFF

ACTIONOpen external disconnect

RESULT• No power to system

ACTIONTorch moved to within1/8 - 3/8 inch of work

RESULT• Main arc transfer• PILOT indicator OFF• Pilot arc OFF

ACTIONTorch removed from

work

RESULT• Main arc stops• Pilot arc auto-restart• PILOT indicator ON

ACTIONProtect eyes and activate torch

RESULT• Gas indicator ON• Gas pre-flow• Main contactor closes• DC indicator ON• Pilot contactor closes• PILOT indicator ON• Pilot arc established

Logic PC BoardRev AE or Earlier

RESULT• Main contactor closes• Gas indicator ON• Gas pre-flow• DC indicator ON• Pilot contactor closes• PILOT indicator ON• Pilot arc established

Logic PC BoardRev AF or Later

ACTIONClose external

disconnect switch

RESULT• Power to system


APPENDIX 3: TYPICAL MECHANIZED SYSTEM WORKAND GROUND CABLE CONNECTIONS

Remote Controlor

Standoff Control

EarthGround

MasterPowerSupply

Work Cable

Workpiece

EarthGround

3-PhaseInput

A-01512

CNC Control

SlavePowerSupply

Work Cable

3-PhaseInput

EarthGround

NOTEWork Cable(s) must connect direct to workpiece.DO NOT connect Work Cable(s) to earth ground and then to workpiece.


APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLEINTERCONNECTION DIAGRAM

NOTE

Refer to Appendix 5 for completedata on the Cables and Hoses.

SLAVE POWERSUPPLY

J15

(+)

(-)

J54

J63

J15

PCR

(-)

OR

ORMASTER POWERSUPPLY

RC 6010

SC10

RC 6010

(+)

J37

J37

J29

CNC

CNC

CNC

A-01517

BulkheadJ14

K

A

B

B

C

Parallel CableJ

InternalRibbon Cable

GAS CONTROLGC3000

3 ØACINPUT

3 ØACINPUT


PILOT CABLE

PILOT CABLE

WORK CABLE

TORCH (-) CABLE

WORK CABLE

SHIELD

ARC STARTERPCB

ARC STARTER BOX

TORCH (-) CABLE

COOLANT

COOLANT

PLASMA GAS

SECONDARY GAS

WORKPIECE

A-01517

J2

D

Arc Starter Control

E

F

G

H

I

I

H

E


APPENDIX 5: QUICK REFERENCE TO INTERCONNECTINGCABLES AND HOSES

Cable/Hose Diameter

Cable Description Catalog # Inches mm

A Power Supply CNC Cable25 ft (7.6 m) 8-3380 3/8 9.550 ft (15.2 m) 8-3381 3/8 9.575 ft (22.9 m) 8-3382 3/8 9.5100 ft (30.5 m) 8-3383 3/8 9.5

B Remote Control Cable25 ft (7.6 m) 9-5961 1/2 1350 ft (15.2 m) 9-5962 1/2 1375 ft (22.9 m) 9-5963 1/2 13100 ft (30.5 m) 9-5964 1/2 13

C Remote Gas Select Cable25 ft (7.6 m) 9-4579 1/2 1350 ft (15.2 m) 9-4580 1/2 1375 ft (22.9 m) 9-4581 1/2 13100 ft (30.5 m) 9-4582 1/2 13

D Arc Starter Control Cable35 ft (10.7 m) 9-6901 1/4 650 ft (15.2 m) 9-6902 1/4 675 ft (22.9 m) 9-6903 1/4 6100 ft (30.5 m) 9-6904 1/4 6125 ft (38.1 m) 9-6905 1/4 6

E Positive Pilot Supply Cable35 ft (10.7 m) 9-6906 1/4 650 ft (15.2 m) 9-6907 1/4 675 ft (22.9 m) 9-6908 1/4 6100 ft (30.5 m) 9-6886 1/4 6115 ft (35.1 m) 9-6857 1/4 6125 ft (38.1 m) 9-6909 1/4 6

F Plasma or Secondary Gas Hose #410 ft (3.0 m) 9-6910 1/2 1315 ft (4.6 m) 9-6911 1/2 1320 ft (6.1 m) 9-6912 1/2 1325 ft (7.6 m) 9-6913 1/2 1330 ft (9.1 m) 9-6914 1/2 1335 ft (10.7 m) 9-6915 1/2 1340 ft (12.2 m) 9-6916 1/2 1350 ft (15.2 m) 9-6917 1/2 1375 ft (22.9 m) 9-6918 1/2 13100 ft (30.5 m) 9-6919 1/2 13125 ft (38.1 m) 9-6920 1/2 13

G Coolant Hose #835 ft (10.7 m) 9-6921 7/8 2250 ft (15.2 m) 9-6922 7/8 2275 ft (22.9 m) 9-6923 7/8 22100 ft (30.5 m) 9-6924 7/8 22115 ft (35.1 m) 9-6858 7/8 22125 ft (38.1 m) 9-6925 7/8 22

H Torch (-) Cable25 ft (7.6 m) 9-6892 3/4 1935 ft (10.7 m) 9-6926 3/4 1950 ft (15.2 m) 9-6927 3/4 1975 ft (22.9 m) 9-6928 3/4 19100 ft (30.5 m) 9-6896 3/4 19115 ft (35.1 m) 9-6856 3/4 19125 ft (38.1 m) 9-6929 3/4 19

I Work Cable25 ft (7.6 m) 9-6892 3/4 1935 ft (10.7 m) 9-6926 3/4 1950 ft (15.2 m) 9-6927 3/4 1975 ft (22.9 m) 9-6928 3/4 19100 ft (30.5 m) 9-6896 3/4 19115 ft (35.1 m) 9-6856 3/4 19125 ft (38.1 m) 9-6929 3/4 19

J Parallel Cable 8ft (2.4 m) 9-6800 1/2 13

Parallel Cable 30 ft (9.1 m) 9-6997 1/2 13

K CNC Cable5 ft (1.5 m) 9-4483 5/8 1610 ft (3.0 m) 9-4484 5/8 1615 ft (4.6 m) 9-4485 5/8 1620 ft (6.1 m) 9-4486 5/8 1625 ft (7.6 m) 9-4486-25 5/8 1630 ft (9.1 m) 9-4486-30 5/8 1650 ft (15.2 m) 9-4486-50 5/8 16


APPENDIX 6: INTERFACE CABLE FOR REMOTECONTROL (RC6010)

A-01513

Remote ControlRC6010 RC6010 Remote Cable Merlin 6000


APPENDIX 7: INTERFACE CABLE FOR STANDOFFCONTROL (SC11)

A-01433

J41Standoff Control

SC11Merlin 3000 or

Merlin 6000

Remote Cable

J15

6

8

7

9

+48 VDC1A

48 VDCCommon

J15J42

J41

Black

Red

White

Green

10

11

24

25

28

29

19

3

4

1

2

12

14

3

4

5

6

13

OK-To-Move

Torch VoltsSignal

START/STOP

Orange

Blue

Yellow

Brown

Violet

Gray

Shield Drain

-

+

J42


APPENDIX 8: CNC INTERFACE CABLES

A-01514

Cable Connections Used With Remote Control RC6010

Cutting Machine CNC CableRemote Control

RC6010

Contact **24 VAC

Source **

* Refer to Remote Control RC6010Manual for Station Select and CSD options

** Selected inside theRemote Control RC6010

A-01515

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


APPENDIX 9: LADDER DIAGRAM - 120 VAC

5A, 250 VAC

AC

T1

MC1

MC2

W1

W2

PCR

K1-A

K5

K3

K4

K2

HFWS110

110

93

24

24

LOGIC BOARD

23

50

5

75

SW3-A 88

89SEC 02 N/C

SOL1 - PLASMA GAS

SOL3 - SECONDARY WATER

SOL2 - SECONDARY GAS

K5 (HV)

K5 (LV)21

22

4

3

K4 (HV)

K3 (LV)

K3 (LV)

K4 (HV)

VOLTAGE SELECTION BOARD

NEON IND1

1415

10 9 8

K1

SWITCHING CONTROL BOARD (Energized by Enable Switch)

SW1-AF2

SECONDARYSELECTION SWITCH

A-01012


APPENDIX 10-A: LADDER DIAGRAM - 15 vdc(Rev AE or Earlier Logic Control PC Board)

3

LOGIC CONTROL BOARD

13

11

19

15

5

9

7

24

11

12

18

14

4

8

6

22

12

K4

K3

K2

K5

K1

PLASMA

SECONDARY

GASCONTROLCIRCUIT

PRE-FLOW &POST-FLOW

CIRCUIT

SWITCHRECOGNITION

RUN

SET

PURGE

SW2

START/STOP (CNC)

START/STOP (Hand)

FS1

D8

STARTINDICATOR

CONTACTORCONTROL

WCONTACTOR

D9

J3-9PWM

ENABLE

CONTACTOR DISABLE (Only after main con-tactor initially closes)

SENSE BRIDGEVOLTAGE<60VDC

SENSE BRIDGE VOLTAGE>60VDC

TP1

TP4

To disable this circuit for troubleshooting short test points together.

PILOTCONTROL

HF AND PILOT

DISABLE

HF AND PILOTCONTACTOR

OK to MoveHFWS

CSR Indicator

D10

15 VDC SUPPLY

21

28 VAC CENTER TAP

TORCH VOLTAGE/23

CSR (from Current Control Board)

PS1

TS3 TS5 TS2

ALL PC BOARD INPUTSACTIVE LOW EXCEPT

J1-24 AND J1-21.

21 22

OVER-CURRENT SHUTDOWN(From Switching Control)

REFERENCES J1 CONNECTOR REFERENCES J3 CONNECTOR A-01557

D7 RUN

TS1 TS4

W-ON


APPENDIX 10-B: LADDER DIAGRAM - 15 vdc(Rev AF or Later Logic Control PC Board)

3

LOGIC CONTROL BOARD

13

11

19

15

5

9

7

24

11

12

18

14

4

8

6

22

12

K4

K3

K2

K5

K1

PLASMA

SECONDARY

GASCONTROLCIRCUIT

PRE-FLOW &POST-FLOW

CIRCUIT

SWITCHRECOGNITION

RUN

SET

PURGE

SW2

START/STOP (CNC)

START/STOP (Hand)

FS1

D8

STARTINDICATOR

PWMCONTROL

WCONTACTOR

D9

J3-9PWM

ENABLE

PWM DISABLE (Only after main con-tactor initially closes)

SENSE BRIDGEVOLTAGE<60VDC

SENSE BRIDGE VOLTAGE>60VDC

TP1

TP4

To disable this circuit for troubleshooting short test points together.

PILOTCONTROL

HF AND PILOT

DISABLE

HF AND PILOTCONTACTOR

OK to MoveHFWS

CSR Indicator

D10

15 VDC SUPPLY

21

28 VAC CENTER TAP

TORCH VOLTAGE/23

CSR (from Current Control Board)

PS1

TS3 TS5 TS2

ALL PC BOARD INPUTSACTIVE LOW EXCEPT

J1-24 AND J1-21.

21 22

OVER-CURRENT SHUTDOWN(From Switching Control)

REFERENCES J1 CONNECTOR REFERENCES J3 CONNECTOR A-03295

D7 RUN

TS1 TS4PWM-ON


APPENDIX 11: PARALLEL CABLE

Master PowerSupply J54

Slave PowerSupply J15Cable

1

2

7

11

3

4

14

12

8

9

10

5

13

1

2

32

33

24

25

17

15

3

4

31

30

19

35

36

26

27

DEMAND3.3 - 10 VDC

ENABLE

START/STOP

SLAVE IS ON

SLAVE OUTPUTSignal

This Is Slave

Remote Installed

Shield Drain

A-01516

Isolation PCBoard Power

Supply

0 - 10 VDC


APPENDIX 12: ROUTINE MAINTENANCE SCHEDULE

This recommended schedule applies to all types of liquid cooled plasma cutting systems. Some systems will nothave 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 Arc Hours:

1. Check torch parts, replace if damaged.

2. Check plasma and secondary supply and pressure/flow.

3. Purge plasma gas line to remove any moisture build-up.

4. Check deionizer bag/cartridge, replace if color is predominantly yellow.

5. Check coolant pressure (100 - 120 psi).

Weekly or Every 30 Arc Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles tointerfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Arc Hours:

1. Remove and clean in-line filter screens.

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

4. Check all pillow blocks and bearings, clean and lubricate if necessary.

5. Check fan, pump and pulley belts for wear or cracking, replace if necessary.

Twelve Months or Every 1500 Arc Hours:

1. Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30minutes.

WARNING

DO NOT energize the Torch.

Drain distilled water and replace with Thermal Arc Coolant. Use Standard Mix Coolant (Catalog # 7-3580) or Super MixCoolant (Catalog # 7-3581) for environments below +10° F (-12° C).

2. Check radiator fins, clean and comb out if necessary.

3. Repeat six month maintenance.



APPENDIX 13: SYSTEM SCHEMATIC - Rev 'B' or Earlier

A-01573


NOTE

System Schematic for units with the letter 'B' or earlier on the data tag.

A-01573


APPENDIX 14: SYSTEM SCHEMATIC - Rev 'AK' or Later

Art # A-06019


NOTE

System Schematic for units with the letter 'AK' or later on the data tag.

Art # A-06019
