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WARNING

WARNING

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

While the information contained in this Service Manual repre-
sents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.

MERLIN 3000 Plasma Cutting Power Supply
Service Manual Number 0-2533

Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA  03784
(603) 298-5711

Copyright 1996 by
Thermal Dynamics Corporation

All rights reserved.

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

The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in the MERLIN 3000 Plasma Cutting Power Supply
Service Manual, whether such error results from negligence,
accident, or any other cause.

Printed in the United States of America

October 6, 1999

Summary of Contents for MERLIN 3000

Page 1: ...Manual No 0 2533 October 6 1999 MERLIN 3000 Plasma Cutting Power Supply Service Manual A 00907...

Page 2: ...rmal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1996 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole o...

Page 3: ...s Design Features 11 3 04 Theory Of Operation 12 3 05 Options And Accessories 13 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 15 4 01 Introduction 15 4 02 Periodic Inspection Procedures 15 4 03 Syste...

Page 4: ...PPENDIX II SEQUENCE OF OPERATION BLOCK DIAGRAM 68 APPENDIX III TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS 69 APPENDIX IV INTERFACE CABLES FOR REMOTE CONTROL RC6010 AND STANDOFF CONTROL SC11 70 APPEND...

Page 5: ...ep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the ki...

Page 6: ...yes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from...

Page 7: ...uit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sul...

Page 8: ...9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE ET EXPLOSION Les incendies et les explos...

Page 9: ...ashington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l InstitutAm ricain des Normes Nationales Ameri can National...

Page 10: ...LAPR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2...

Page 11: ...andardsAssociation standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 9...

Page 12: ...roducts shall be as follows with the exception of XL Plus Series CutMaster 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 yea...

Page 13: ...cessories or Factory approved updates are to be made to this equipment C Customer Operator Responsibilities It is the customer operators responsibility to maintain the equipment and peripheral Accesso...

Page 14: ...INTRODUCTION 10 Manual 0 2533...

Page 15: ...re the ambient temperature drops to 34 F 36 C A typical system configuration will contain the follow ing Power Supply with Running Gear and Handles Arc Starter Box Maximizer 300 Machine Torch with Mou...

Page 16: ...simple change of torch parts the system can also be used for plasma arc gouging Plasma arc gouging is used to remove material to a controlled depth and width B Input and Output Power The Power Supply...

Page 17: ...si 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 positively charged tip Once the pilo...

Page 18: ...main cut ting arc has been on The second meter counts the number of times that the cutting arc has been started Both meters display a maximum of 999999 hours or starts and cannot be reset H Plasma Sec...

Page 19: ...Routine Maintenance The only other routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment To cl...

Page 20: ...and consists of the Merlin 3000 plasma power supply the Maximizer 300 Torch Torch Leads Extension and Arc Starter Box An Optional Remote Control RC6010 Standoff Control SC10 or SC11 see notes and Gas...

Page 21: ...ons The Logic PC Board controls the timing and sequenc ing of the system It monitors the pressure tempera ture and flow interlocks and controls the gas flow in run set and purge modes by turning on th...

Page 22: ...onal connectors on the rear panel J40 for CNC J41 for EXT PWR and J42 for plasma labeled PL A remote cable connects from the Power Supply J15 to both J41 and J42 carrying power and sig nals to the Sta...

Page 23: ...problems Do not forget about these cables when troubleshooting A No front panel LED indicators ON Fan and pump not operating 1 No primary power Refer to symptoms C and D also a Check for proper three...

Page 24: ...ssary 4 Faulty LED Current Control PC Board a Refer to Section 4 05 F Thermal Sensing Circuit Check Replace LED Current Control PC Board if necessary H No GAS indicator Motor and Pump operating Other...

Page 25: ...will be normal but the Pressure LED indicates flow will be OFF 3 Clogged torch or leads a Check torch and leads and replace if necessary Flush the old coolant from the system see note above 4 Faulty f...

Page 26: ...Starter Box 1 Electrode shorted against tip a Thread electrode securely into torch head or replace tip and electrode 2 Shorted torch head a Check and replace if necessary 3 Broken conductor in torch l...

Page 27: ...2 for 12 18 VAC 2 Check the AC voltage from J6 24 to both J6 17 and J6 18 for 16 22 VAC 3 If input voltages are correct check output from J6 24 to both J6 19 and J6 21 for 14 18 VAC 4 If output is not...

Page 28: ...Check the voltage across the coil on the contactor for approximately 120 VAC If voltage is present replace the contactor If it is not perform the 120 VAC test refer to test paragraph A above to check...

Page 29: ...n se ries to J1 7 on the Logic PC Board PS2 is jumpered out by SW3 B when the unit is set to the O2 no sec ondary gas or water secondary mode or by SW2 B in the GC3000 Gas Control if that option is in...

Page 30: ...ts that voltage to either W1 or W2 depending on the level of incoming line voltage If high LED D38 on the Voltage Selection PC Board will be ON and the 120 VAC should go to W2 otherewise it goes to W1...

Page 31: ...and off rapidly Power Supply output is controlled by the on time At the same time the Main Contactor W1 or W2 closes the Logic PC Board grounds pins 9 and 23 of the 34 pin ribbon cable J3 9 on the Lo...

Page 32: ...to the PCR contactor but there are no sparks at the spark gap in the arc starter box first confirm that there is open circuit voltage OCV of 280 350 vdc between torch NEG and the work lead then measur...

Page 33: ...Refer to Appendix X for Current Control Display Circuit Diagram The Remote Control RC 6010 has front panel controls for OUTPUT AMPS and CSD The up per and lower limits of the current control range are...

Page 34: ...te Control RC6010 will reverse the logic so a closure is required at the CSD input for normal operation and an open for CSD For the Standoff Control SC11 used without the Remote Control RC6010 the CNC...

Page 35: ...o OFF the Remote Control PC Board is defective If the Standoff Control SC10 is used set the torch to proper cutting height manually and disconnect the Standoff Control SC10 by removing the ribbon cabl...

Page 36: ...the clamps only what is necessary for a steady pilot Too much adjustment can cause increased parts wear DO NOT move each clamp more than a total of 2 inches 50 8 mm If a steady pilot cannot be achiev...

Page 37: ...e copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5...

Page 38: ...nels are replaced in the same manner The Left Side Panel of the Supply is the panel on the left side of the unit as viewed from the front of the unit Left Side Panel Screws 10 Places A 00954 1 Remove...

Page 39: ...GE Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement RUN SET PURGE Switch by reversing the above procedure D LED Current Control PC B...

Page 40: ...the Left Side Panel per Section 5 04 B 2 Disconnect all the wiring connections to the Trans former Assembly 3 Remove the four screws which secure the Trans formerAssembly to the Horizontal Chassis Pan...

Page 41: ...ly 7 Install the replacement Solenoid Valve Assembly by reversing the above procedure and noting the following Remove the fittings from the old assembly and install on the replacement assembly E Secon...

Page 42: ...zer Bas ket from the faulty Coolant Tank 11 Fill the replacement Coolant Tank with the cool ant removed or fresh Thermal Arc Torch Coolant 12 Place the Deionizer Basket and Bag into the Cool ant Tank...

Page 43: ...Elbow Fitting with a teflon sealer before installing the replacement Check Valve 5 08 Base Assembly Parts Replacement NOTE Refer to Section 6 07 Base Assembly Replacement Parts for parts list and ove...

Page 44: ...tion 5 04 B 2 Disconnect the two Hose Assemblies at the fittings on the Pump Assembly 3 Loosen the allen set screw securing the Coupling to the Pump Assembly shaft 4 Note the orientation of the Pump A...

Page 45: ...f the unit Switching Transistor Q1 Large Blue Capacitors A 01085 Transistor Coil Bracket 11 There are two different styles of the Switching Transistor Q1 The style can be identified by look ing at the...

Page 46: ...Transistor Thermstrate onto the Main Heatsink at the Switching Tran sistor mounting location Depending on the style of the replacement Switching Transistor connect the wires per one of the following...

Page 47: ...ntation is cor rect when installed The 80 PSI mark should be at the twelve o clock position E Pressure Switch Replacement NOTE Both the Plasma and Secondary Pressure Switches are replaced in the same...

Page 48: ...ccess cover open with string or rubber band 3 Note where each connector is located on the old Control Logic PC Board 4 Disconnect the three connectors from the old Con trol Logic PC Board 5 Note the o...

Page 49: ...1168 is a direct parts replacement for the failed Diode Assembly in the Power Supply The following parts are supplied with each replace ment assembly 70 Amp 600V Str Diode Assembly 1 each 0 75 inch di...

Page 50: ...the diode wire lead to the PC Board 7 Make sure the replacement diode is a direct re placement for the old one 8 Install the replacement diode by reversing the above procedure and noting the followin...

Page 51: ...T Fitting on the Check Valve from the Secondary Gas Pressure Gauge at the front panel 4 Remove the Hose Assembly from the unit 5 Install the replacement Hose Assembly by revers ing the above procedure...

Page 52: ...t Parts for part numbers and detail drawing 1 Remove the Right Side Panel per Section 5 04 B 2 Disconnect the HoseAssembly from the front panel PLASMA GAS connector 3 Disconnect the Other end of the H...

Page 53: ...Secondary Gas Check Valve to the T Fitting on the Secondary Gas Pressure Gauge As sembly Replace the HoseAssembly using the follow ing procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace me...

Page 54: ...REPLACEMENT PROCEDURES 50 Manual 0 2533...

Page 55: ...nt Parts Section 6 10 Power Supply Options And Accessories NOTE Parts listed without item numbers are not illus trated but may be ordered by the catalog numbers shown B Returns If a Thermal Dynamics p...

Page 56: ...e Merlin 3000 Power Supply With Running Gear and Work Cable 1 Without Gas Control GC3000 3 5100 1 With Gas Control GC3000 3 5101 1 1 Work Cable with Clamp 25 ft 7 6 m 9 4380 2 1 Panel Top 8 3300 3 1 P...

Page 57: ...ccess Panel With Overlay 8 6302 2 1 Access Panel Overlay 8 3306 3 1 ON OFF Rocker Switch DPST 8 3258 4 1 Switch Rocker SPDT Center Off 8 3259 5 1 LED Current Control PC Board Assembly 9 5759 6 1 Knob...

Page 58: ...t Lower Coolant Filter 8 5577 10 1 8 JIC to 3 8 NPT Straight Adapter 8 1251 11 1 Panel Access Divider 8 6310 12 1 Horizontal Chassis Panel 8 4500 13 1 Assembly Torch Leads Shield 2 1 4 8 3314 14 1 Res...

Page 59: ...Manual 0 2533 55 PARTS LISTS 1 2 4 3 5 6 7 8 9 10 11 12 13 14 15 16 19 18 17 20 21 A 01217 22 23...

Page 60: ...ket Coolant Tank 8 4273 14 1 Deionizer Bag 8 3312 15 1 Coolant Tank 8 4275 16 2 Bracket Tank Support 8 4506 17 1 Cap Coolant Tank 8 5142 18 3 4 JIC 1 8 NPT x 90 Adapter 8 0262 19 1 Check Valve 1 8 NPT...

Page 61: ...Manual 0 2533 57 PARTS LISTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 21 22 23 24 25 26 27 28 29 30 31 18 18 20 32 20 20 3 A 01216 11...

Page 62: ...2391 12 1 Westinghouse 1 2 HP Motor 1PH 50HZ 110 220V 9 3496 13 1 5 8 Coupling Body 9 4018 14 1 Coupling Spider 9 4019 15 1 Body Coupling 7 16 Diameter Bore 8 6146 16 2 8 JIC x 3 8 NPT Straight Adapte...

Page 63: ...Manual 0 2533 59 PARTS LISTS 9 10 1 2 11 12 3 4 13 14 5 6 15 16 7 8 17 18 19 20 21 22 23 24 21 20 A 00894 26 25 9...

Page 64: ...ody Bulkhead 1 8 NPT LH 8 4510 15 1 Receptacle Square Flanged 14 Circuit CPC Rev Sex 9 3293 16 1 Fuse Holder For 1 4 x 1 Fuse 9 2936 17 1 5 Amp Fuse MTH5 250V 8 1025 18 1 Fuse Holder Buss HPS 9 2937 1...

Page 65: ...d to Coolant Pressure Gauge 8 4516 48 1 Hose Assembly Secondary Water Inlet to Gauge 8 4517 49 1 Hose Assembly Plasma Gas Inlet to Regulator 8 4515 50 1 Hose Assembly Plasma Gas Regulator To Bulkhead...

Page 66: ...6316 15 1 Assembly Heatsink Suppression PC Board 9 1410 16 1 Support Capacitor Bracket PC Board 8 6315 17 3 Resistor 100 Ohm 100W Style J 9 1405 18 1 Internal Wire Assembly Package 8 4522 19 2 Resist...

Page 67: ...Manual 0 2533 63 PARTS LISTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 11 19 9 2 2 2 17 17 11 11 28 A 00971 32 32 32 32 32 32...

Page 68: ...endant Plug 8 4524 16 1 Cable Clamp for Remote Pendant 9 3295 17 1 Remote Pendant Adapter 9 4393 The following are not shown 1 Plasma Gas Supply Line 10 ft 3 0 m 9 2146 1 Secondary Gas Supply Line 10...

Page 69: ...AR C VO LT S RE MO TE ST AN DO FF CO NT RO L T H C AC TIV E PIE RC E HT inc hes 0 1 0 3 0 4 0 5 0 2 EN D OF CU T RE TRA CT 0 25 75 100 UP DN TO RC H TO RC H MO DE MO DE LIF TE R SP EE D SP EE D PIE R...

Page 70: ...PARTS LISTS 66 Manual 0 2533...

Page 71: ...rotec tion and W ire S izes B ased on National E lectric Code and Canadian E lec trical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requireme...

Page 72: ...indicator ON Pilot contactor closes PILOT indicator ON Pilot arc established PILOT ARC ACTION Torch de activated by torch switch released or remote device RESULT Main arc stops Main contactor opens D...

Page 73: ...u p p ly W o rk C a b le to W o rkp ie ce E GC3000 Gas Control Option Torch Lifter Assembly CNC CONTROL B A 01261 RC6010 Remote Control SC 10 Standoff Control GC3000 Gas Control Option C Earth Ground...

Page 74: ...APPENDIX 70 Manual 0 2533 APPENDIX IV INTERFACE CABLES FOR REMOTE CONTROL RC6010 AND STANDOFF CONTROL SC11 A 00983 MERLIN 3000 REMOTE CABLES FOR RC 6010 SC11...

Page 75: ...Manual 0 2533 71 APPENDIX APPENDIX V CNC INTERFACE A 00982...

Page 76: ...DIAGRAM K1 J28 TO OPTIONAL STANDOFF CONTROL PCR 881 89 SW3 A 5 K5 LOGIC PCB 75 K3 110 SOL3 SOL2 SOL1 50 K4 K2 T2 1 3 24 VOLTAGE SELECTION PCB 24 23 K5 K5 22 21 W2 W1 MC2 MC1 4 3 K4 K3 K3 K4 15 14 T1...

Page 77: ...Only after main con tactor initially closes SENSE BRIDGE VOLTAGE 60VDC SENSE BRIDGE VOLTAGE 60VDC TP1 TP4 To disable this circuit for troubleshooting short test points together PILOT CONTROL HF AND P...

Page 78: ...APPENDIX 74 Manual 0 2533 APPENDIX VIII SIGNAL FLOW BLOCK DIAGRAM A 01139...

Page 79: ...DIARGRAM A 01080 Standoff Control SC11 Merlin 3000 or Merlin 6000 or Merlin 6000GST J15 24 J15 25 J42 3 J42 4 J8 11 J8 10 K10 START OPTO Isolator K10 START FIND HT PLASMA ON START D79 FIND HT OFF J8...

Page 80: ...APPENDIX 76 Manual 0 2533 APPENDIX X CURRENT CONTROL DISPLAY CIRCUIT DIAGRAM A 01138...

Page 81: ...Manual 0 2533 77 APPENDIX APPENDIX XI CSD CORNER SLOWDOWN CIRCUIT DIAGRAM A 01140...

Page 82: ...00GST with Remote Control RC6010 Standoff Control SC10 OK To Move Circuit OK Logic PCB J2 14 J2 16 J15 11 J15 10 J42 12 J42 14 OK PS D82 OK OUT D37 Pierce Delay 0 3 Seconds OK Standoff Control SC11 K1...

Page 83: ...embly Tank To Coolant Filter Coolant Supply Hose Assembly Coolant Filter To Pump Coolant Return Hose Assembly Internal Filter To Flow Switch Coolant Return Hose Assembly Bulkhead To Radiator Coolant S...

Page 84: ...APPENDIX 80 Manual 0 2533 APPENDIX XIV SYSTEM SCHEMATIC A 00981...

Page 85: ...Manual 0 2533 81 APPENDIX A 00981...

Page 86: ...Weekly or Every 30 Arc Hours 1 Blow or vacuum dust and dirt out of the entire machine Six Months or Every 720 Arc Hours 1 Remove and clean in line filter screens 2 Check cables and hoses for leaks or...

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