Tweco 6000GST Merlin Plasma Cutting CE Slave Power Suppl Manuel d'utilisateur

August 19, 2005 Manual No. 0-2653MERLIN ® 6000GSTPlasma CuttingCE Master Power SupplyOperating ManualA-01759

GENERAL INFORMATION 1-4 Date: January 27, 2004• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fum

Date: January 27, 2004 1-5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous p

GENERAL INFORMATION 1-6 Date: January 27, 20049. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection As

Date: January 27, 2004 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest

GENERAL INFORMATION 1-8 Date: January 27, 20041.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warr

Manual 0-2653 2-1 INTRODUCTION & DESCRIPTIONSECTION 2:INTRODUCTION &DESCRIPTION2.01 Scope of ManualThis manual contains descriptions, operatin

INTRODUCTION & DESCRIPTION 2-2 Manual 0-26532.03 Specifications & DesignFeaturesThe following apply to the Master Power Supply only:1. Control

Manual 0-2653 2-3 INTRODUCTION & DESCRIPTIONTap water can be used as a secondary gas and mustbe capable of delivering the following minimums:• Wat

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2653the contactors, and the GAS indicator will go out.When adequate plasma supply pressure is availablethe

Manual 0-2653 3-1 INSTALLATION PROCEDURESSECTION 3:INSTALLATIONPROCEDURES3.01IntroductionNOTEDepending on how the system was ordered, somePower Supply

INSTALLATION PROCEDURES 3-2 Manual 0-2653C. Options and AccessoriesOptions and Accessories are packaged separately from thePower Supply.D. Unpacking P

Manual 0-2653 3-3 INSTALLATION PROCEDURES3. Pull the top of the Left Side Panel out and then lift up toremove the panel from the Power Supply.3.06 Che

INSTALLATION PROCEDURES 3-4 Manual 0-2653Input PowerFilter PC Boardand BracketPrimary PowerCableStrain ReliefFittingInput GroundConnectionA-00896L1L2L

Manual 0-2653 3-5 INSTALLATION PROCEDURES2. Grounding for components mounted on the cutting table(CNC controllers, height controllers, plasma remote c

INSTALLATION PROCEDURES 3-6 Manual 0-26532. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1m) does not generally increase the effectiven

Manual 0-2653 3-7 INSTALLATION PROCEDURESA-01761Shop AirGas InputAir FilterAssemblySECONDARY AIRGas FittingY-HoseAssemblyFrom SupplyFigure 3-7 Supply

INSTALLATION PROCEDURES 3-8 Manual 0-2653Connect the gas supply to the Power Supply as follows:1. Connect the black supply hose(s) from the plasma gas

Manual 0-2653 3-9 INSTALLATION PROCEDURES2. Connect the tap water supply hose to the input of a WaterPressure Regulator.3. Connect the output of the w

INSTALLATION PROCEDURES 3-10 Manual 0-2653Small StrainReliefBlack Wireof Pilot LeadGround TerminalNutStar WasherPilot TerminalRed Wireof Pilot LeadA-0

Manual 0-2653 3-11 INSTALLATION PROCEDURESCoolant ReservoirFiller CapDeionizerBagBasketCoolant Level IndicatorA-00872Figure 3-14 Coolant Reservoir4.

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

INSTALLATION PROCEDURES 3-12 Manual 0-2653B. Computer Control Interface (CNC)NOTEUsed when Remote Control RC6010 or StandoffControl SC11 are not used.

Manual 0-2653 3-13 INSTALLATION PROCEDURESC. Optional SC-10 or SC11 Standoff ControlCableFor mechanized systems, the Standoff Control automati-cally f

INSTALLATION PROCEDURES 3-14 Manual 0-2653E. Gas Control Module ConnectionThe Gas Control Module (GCM6000) allows setting pressuresand flows of variou

Manual 0-2653 3-15 INSTALLATION PROCEDURESApproach From Front Or RearDo Not Lift From SidesA-01499Figure 3-20 Lifting the Power Supply3.15 Pilot Resi

INSTALLATION PROCEDURES 3-16 Manual 0-2653Wire#96APilot ResistorR16ClampClampA-01853Wire#150Pilot ResistorR21Pilot ResistorR22Wire#74Wire #99Wire#96Te

Manual 0-2653 3-17 INSTALLATION PROCEDURESPulser99150Wire #99Tap9.0 ohmsAt EndR16 (4.5 ohms)R22 (2.2 ohms)R21 (2.2 ohms)Temp SwitchWire#96AWire #150Ta

INSTALLATION PROCEDURES 3-18 Manual 0-2653

Manual 0-2653 4-1 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis Section provides a description of the CE MasterPower Supply operating controls and

OPERATION 4-2 Manual 0-26535. Power Lead Strain ReliefStrain relief to secure the power lead to the PowerSupply after it is installed.B. Control Front

Manual 0-2653 4-3 OPERATION7. Coolant Level IndicatorA slot provided in the rear panel allows the operatora visual check of the coolant level. The co

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.0

OPERATION 4-4 Manual 0-265316. SECONDARY (N2) & PRE FLOW N2 Gas Input Fit-ting1/4 NPT female gas fitting used to supply the nitro-gen (N2) seconda

Manual 0-2653 4-5 OPERATIONG. Plasma Gas PurgeEnable the system by doing one of the following:• Turn the Enable switch to ON at the front panelof the

OPERATION 4-6 Manual 0-2653B. Using Corner Slowdown for MechanizedCuttingNOTECorner Slowdown (CSD) is available only if theRemote Control RC6010 is us

Manual 0-2653 4-7 OPERATIONAuto Piot Restart provides an immediate pilot arc re-start during post-flow if the torch is brought withinrange of the work

OPERATION 4-8 Manual 0-2653C. Gas Pre-Flow Delay (SW3)ONOFF1 2SW3A-00993Logic PC BoardFigure 4-10 Gas Pre-Flow Delay Switch SW3LocationThe pre-flow

Manual 0-2653 4-9 OPERATIONE. OK-To-Move Selection (SW5)SW5A-00995LogicPC BoardFigure 4-12 OK-To-Move Selection Switch SW5LocationThe OK-To-Move Sele

OPERATION 4-10 Manual 0-2653F. Current Ramping Selection (SW1)The Current Ramping Selection Switch (SW1), locatedon the Switching PC Board, turns curr

Manual 0-2653 5-1 CUSTOMER/OPERATOR SERVICESECTION 5:CUSTOMER/OPERATORSERVICE5.01 IntroductionThis Section describes basic maintenance procedures per-

CUSTOMER/OPERATOR SERVICE 5-2 Manual 0-2653ant. Check the condition of the deionizer bag inthe reservoir basket, if the bag is yellowish brown(straw

Manual 0-2653 5-3 CUSTOMER/OPERATOR SERVICE5. Poor Pilot Startinga. Non-Genuine Thermal Dynamics Partsb. High coolant conductivity5.04 Troubleshooting

TABLE OF CONTENTS (continued)SECTION 5:CUSTOMER/OPERATOR SERVICE ... 5-

CUSTOMER/OPERATOR SERVICE 5-4 Manual 0-2653D. TEMP indicator ON (red)1. Unit overheateda. Clean radiator and check for obstructionb. Check for adequat

Manual 0-2653 5-5 CUSTOMER/OPERATOR SERVICE4. Faulty power supplya. Isolate and replace component(s) per ServiceManual.N. No pilot; PILOT indicator O

CUSTOMER/OPERATOR SERVICE 5-6 Manual 0-26534. Pull the top of the side panels out and then lift upto remove the panels from the Power Supply.5. Reinst

Manual 0-2653 6-1 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all basic replace-abl

PARTS LISTS 6-2 Manual 0-26536.03 Complete Power Supply Replacement Parts ListQty. Description Catalog #1 CE Merlin 6000GST Master Power Supply (with

Manual 0-2653 6-3 PARTS LISTS6.04 Basic Component Replacement Parts ListQty. Description Catalog #1 Coolant Filter 8-42761 Hose Assembly - Tank to Coo

PARTS LISTS 6-4 Manual 0-26536.05 Power Supply Options And AccessoriesItem # Qty. Description Catalog #1 1 Remote Control (RC6010) 3-61062 1 Standoff

Manual 0-2653 6-5 PARTS LISTSA-02049OUTPUT AMPSPLASMAPLASMAENABLEENABLEONSTARTREMOTE POWER SUPPLY CONTROLSD(%)257510050TRAVELTRAVELSPEEDSPEED125+ IPM

PARTS LISTS 6-6 Manual 0-2653

Manual 0-2653 A-1 APPENDIXAPPENDIX 1: INPUT WIRING REQUIREMENTSNOTESRefer to Local and National Codes or local authority having jurisdiction for prop

APPENDIX A-2 Manual 0-2653APPENDIX 2: SEQUENCE OF OPERATIONBLOCK DIAGRAMA-03298ACTIONClose externaldisconnect switchRESULT• Power to systemACTIONEna

Manual 0-2653 A-3 APPENDIXAPPENDIX 3: TYPICAL MECHANIZED SYSTEM WORKAND GROUND CABLE CONNECTIONSRemote ControlorStandoff ControlEarthGroundMasterPowe

APPENDIX A-4 Manual 0-2653APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLEINTERCONNECTION DIAGRAMNOTERefer to Appendix 5 for completedata on the Cables an

Manual 0-2653 A-5 APPENDIXArc Starter Control CableDIIWorkpieceJ1Arc Starter PCBShieldJ58+_Arc Starter BoxSOL1SOL4T1J59J60SOL2SOL3Gas Control ModuleGC

APPENDIX A-6 Manual 0-2653APPENDIX 5: QUICK REFERENCE TO INTERCONNECTINGCABLES AND HOSESCable/Hose Diameter Cable/Hose DiameterCable Description Cata

Manual 0-2653 A-7 APPENDIXAPPENDIX 6: INTERFACE CABLE FOR REMOTECONTROL (RC6010)A-01513Remote ControlRC6010RC6010 Remote Cable Merlin 6000

APPENDIX A-8 Manual 0-2653APPENDIX 7: INTERFACE CABLE FOR STANDOFFCONTROL (SC11)A-01433J41Standoff ControlSC11Merlin 3000 orMerlin 6000Remote CableJ1

Manual 0-2653 A-9 APPENDIXAPPENDIX 8: CNC INTERFACE CABLESA-01514Cable Connections Used With Remote Control RC6010Cutting MachineCNC CableRemote Cont

APPENDIX A-10 Manual 0-2653APPENDIX 9: LADDER DIAGRAM - 120 VAC5A, 250 VACACT1MC1MC2W1W2PCRK1-AK5K3K4K2HFWS110110932424LOGIC BOARD2350575SOL 1 Plasma

Manual 0-2653 A-11 APPENDIX3LOGIC CONTROL BOARD172119597241112184862212K4K3K2K5K1PLASMASECONDARYGASCONTROLCIRCUITPRE-FLOW &POST-FLOWCIRCUITSWITCHR

Date: January 27, 2004 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions,

APPENDIX A-12 Manual 0-2653APPENDIX 10-B: LADDER DIAGRAM - 15 vdc(Rev AF or Later Logic Control PC Board)3LOGIC CONTROL BOARD172119597241112184862212

Manual 0-2653 A-13 APPENDIXAPPENDIX 11: PARALLEL CABLEMaster PowerSupply J54Slave PowerSupply J15Cable12711341412891051312323324251715343130193536262

APPENDIX A-14 Manual 0-2653APPENDIX 12: ROUTINE MAINTENANCE SCHEDULEThis recommended schedule applies to all types of liquid cooled plasma cutting sy

Manual 0-2653 A-15 APPENDIXAPPENDIX 13: GAS SOLENOID CIRCUIT DIAGRAMGas ControlConnectorMerlin 6000GST Power SupplyJ55-15Arc Starter BoxPanel Connect

APPENDIX A-16 Manual 0-2653APPENDIX 14-A: SYSTEM SCHEMATIC (Sheet 1)Art # A-06025

Manual 0-2653 A-17 APPENDIXArt # A-06025

APPENDIX A-18 Manual 0-2653APPENDIX 14-B: SYSTEM SCHEMATIC (Sheet 2)Art # A-06026

Manual 0-2653 A-19 APPENDIXArt # A-06026

APPENDIX A-20 Manual 0-2653

GENERAL INFORMATION 1-2 Date: January 27, 2004• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcirc

Date: January 27, 2004 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from Am