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REPLACEMENT PROCEDURES

58

Manual 0-2569

3.  Disconnect the other end of the Hose Assembly

from the Pump Assembly.

4.  Remove the Hose Assembly from the unit.

5.  Install the replacement Hose Assembly by revers-

ing the above procedure.

D.  Coolant Supply Hose (Pump to Pressure

Gauge Connection) Assembly Replacement

The Coolant Supply Hose Assembly goes from the
Pressure Gauge T-Fitting to the front panel Coolant
Pressure Gauge connection.  Replace the Hose Assem-
bly using the following procedure:

NOTE

Refer to Subsection 6.08, Upper Chassis Replace-
ment Parts for part numbers and detail drawing.

1.  Remove the Right Side Panel per Section 5.04-B.

2.  Disconnect the Hose Assembly from the T-Fitting

at the front panel Coolant Pressure Gauge connec-
tor.

3.  Disconnect the other end of the Hose Assembly

from the Coolant Pressure Gauge.

4.  Remove the Hose Assembly from the unit.

5.  Install the replacement Hose Assembly by revers-

ing the above procedure.

E.  Secondary Gas Hose (T-Fitting to

SECONDARY GAS Connector) Assembly
Replacement

The Secondary Gas Hose Assembly goes from the T-
Fitting to front panel SECONDARY GAS connector.
Replace the Hose Assembly using the following pro-
cedure:

NOTE

Refer to Subsection 6.08, Upper Chassis Replace-
ment Parts for part numbers and detail drawing.

1.  Remove the Right Side Panel per Section 5.04-B.

2.  Disconnect the Hose Assembly from the T-Fitting

on the Check Valve from the Secondary Gas Regu-
lator Assembly.

3.  Disconnect the other end of the Hose Assembly

from the front panel SECONDARY GAS Connec-
tor.

4.  Remove the Hose Assembly from the unit.

5.  Install the replacement Hose Assembly by revers-

ing the above procedure.

F.  Plasma Gas Hose (PLASMA GAS to T-

Fitting) Assembly Replacement

The Plasma Gas Hose Assembly goes from the front
panel PLASMA GAS connector to the T-Fitting on the
Plasma Pressure Gauge Assembly.  Replace the Hose
Assembly using the following procedure:

NOTE

Refer to Subsection 6.08, Upper Chassis Replace-
ment Parts for part numbers and detail drawing.

1.  Remove the Right Side Panel per Section 5.04-B.

2.  Disconnect the Hose Assembly from the front panel

PLASMA GAS connector.

3.  Disconnect the Other end of the Hose Assembly

from the T-Fitting at the Plasma Pressure Gauge
Assembly.

4.  Remove the Hose Assembly from the unit.

5.  Install the replacement Hose Assembly by revers-

ing the above procedure.

G.  Coolant Supply Hose (Coolant Filter to

Pump) Assembly Replacement

The Coolant Supply Hose Assembly goes from the rear
panel Coolant Filter Assembly to the Pump Assem-
bly.  Replace the Hose Assembly using the following
procedure:

NOTE

Refer to Subsection 6.07, Base Assembly Replace-
ment Parts for part numbers and detail drawing.

1.  Remove the Right Side Panel per Section 5.04-B.

2.  Disconnect the Hose Assembly from the Coolant

Filter Assembly on the rear panel.

3.  Disconnect the other end of the Hose Assembly

from the Pump Assembly.

4.  Remove the Hose Assembly from the unit.

5.  Install the replacement Hose Assembly by revers-

ing the above procedure.

H.  Coolant Supply Hose (Tank to Coolant

Filter) Assembly Replacement

The Coolant Supply Hose Assembly goes from the
Coolant Tank to the Coolant Filter Assembly mounted
on the rear panel.  Replace the Hose Assembly using
the following procedure:

NOTE

Refer to Subsection 6.06, Rear Panel Replacement
Parts for part numbers and detail drawing.

Содержание MERLIN 6000

Страница 1: ...Manual No 0 2569 October 6 1999 MERLIN 6000 Plasma Cutting Master Power Supply Service Manual A 01497...

Страница 2: ...mal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1998 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or...

Страница 3: ...s Design Features 12 3 04 Theory Of Operation 13 3 05 Options And Accessories 14 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 15 4 01 Introduction 15 4 02 Periodic Inspection Procedures 15 4 03 Syste...

Страница 4: ...HANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM 80 APPENDIX V QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES 82 APPENDIX VI RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING...

Страница 5: ...96 APPENDIX XX ARC STARTER BOX OPTION SYSTEM SCHEMATIC 97 APPENDIX XXI PARALLEL INTERFACE DIAGRAM 98 APPENDIX XXII GAS CONTROL GC3000 WIRING DIAGRAM 100 APPENDIX XXIII SYSTEM SCHEMATIC Rev B or Earlie...

Страница 6: ...TABLE OF CONTENTS continued...

Страница 7: ...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...

Страница 8: ...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...

Страница 9: ...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...

Страница 10: ...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...

Страница 11: ...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...

Страница 12: ...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...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...ccessories 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 Access...

Страница 16: ...INTRODUCTION 10 Manual 0 2569...

Страница 17: ...e same power circuits as the Master Power Supply The Master Power Supply can also be connected to a second Master Power Supply and the equipment will automatically be configured when the parallel cabl...

Страница 18: ...ith Slave Power Supply Continuously adjustable by potentiometer from 100 to 300 amps 5 Duty Cycle 100 6 Pilot Modes Auto Restart Pre Flow Delay Recycle Required 7 CNC Signals Enable Start Stop OK To M...

Страница 19: ...h settings inside the Power Supply Refer to Operating Manual 0 2568 Section 4 07 D Main Cutting Arc The Power Supply accepts 50 or 60 Hz three phase line input An internal changeover switches input li...

Страница 20: ...trol For mechanized systems this low profile unit provides full CNC capability and allows the operator to con trol all system functions from a remote location B SC 10 or SC11 Standoff Controls For mac...

Страница 21: ...tion B 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 environmen...

Страница 22: ...panels 4 03 System Theory A System Description The Merlin 6000 is designed for mechanized cutting only and consists of the following Merlin 6000 Master Power Supply Maximizer 300 Torch Torch Supply L...

Страница 23: ...of pulses which are filtered back into pure DC volt age by the output network The output network consists primarily of the main inductor L2A and L2B resistor R13 and capacitor C23 D Switching Control...

Страница 24: ...SC11 is used The OK TO MOVE signal is sent to the remote control standoff control or direct to the cutting machine controller It also controls theArc Hour and Starts Counter Meters and the optional H...

Страница 25: ...ion of plasma and secondary gases The Gas Control GC 3000 can be mounted at the opera tors control station Plasma and secondary select switches activate the gas select solenoids in the Master Power Su...

Страница 26: ...e Selection PC Board a Refer to 4 05 A Voltage Selection PC Board Check Replace Voltage Selection PC Board if necessary 5 Faulty motor contactor MC1 MC2 or MC3 a Refer to Section 4 05 D Motor Control...

Страница 27: ...the Merlin 6000 connect a jumper wire across the Pressure Switch PS1 If the gas indicator comes ON the switch was faulty If gas indicator is OFF refer to Section 4 05 G Pressure Sensing Circuit 3 Fau...

Страница 28: ...ry 3 Faulty Logic PC Board a Refer to Section 4 05 J Coolant Conductivity Circuit Replace Logic PC Board if necessary 4 Faulty LED Current Control PC Board a Refer to Section 4 05 J Coolant Conductivi...

Страница 29: ...ircuit Check and replace if necessary 3 Broken conductor in torch lead a Check and replace if necessary 4 Shorted torch lead a Check and replace if necessary 5 Dirty or wet torch lead a Clean and dry...

Страница 30: ...s A Voltage Selection PC Board Check The Merlin transformer has three input voltage ranges 200 230 380 460 and 500 575 selected by buss bars Within each range there are transformer taps for the up per...

Страница 31: ...hen goes through the Parallel Cable to J15 on the Slave Power Supply Refer to Section 4 05 T Isolation PCB and Parallel Interface Check Enable Relay K1 circuit per the following NOTE This procedure ap...

Страница 32: ...is supplied to the Motor Control Con tactor MC1 and MC2 coils from the Voltage Selec tion PC Board which selects the proper tap on the Main Transformer T1 The return path travels from wire 110 through...

Страница 33: ...diode fails check the potential causes of diode failure to make sure the replacement diode will not also fail when it is installed 1 Isolate and check each diode separately to deter mine which indivi...

Страница 34: ...SOL4 Air Plasma 300 SOL5 Nitrogen Plasma 300 SOL6 Oxygen Plasma 300 SOL7 Argon Hydrogen Plasma 300 Normal operation is for one plasma gas solenoid to be ON when ever the power supply is ON 3 Optional...

Страница 35: ...ndary Water Problems With or Without Optional Gas Control GC3000 The Secondary Water Solenoid SOL3 is located at the rear panel of the power supply The secondary to be used is selected by the mode swi...

Страница 36: ...t also uses the origi nal Secondary H2 0 Control SOL3 to both select and control secondary water In addition two new solenoids SOL8 SOL9 are added to the Merlin 6000 Power Supply Rear Panel to select...

Страница 37: ...19 and J1 18 turning ON the Slave Power Supply START LED D18 If the Master Power Supply starts but the Slave Power Supply does not get a START signal START LED is OFF refer to Section 4 05 T Isolatio...

Страница 38: ...Standoff Control SC10 or the ribbon cable Refer to Section 5 Customer Operator Service in the Standoff Control Instruction Manual If the Standoff Control SC10 isn t used or the Power Supply didn t st...

Страница 39: ...read about 6 to 7 VAC from J8 2 to both J8 1 and J8 3 If 0 VAC is measured at both J8 1 and J8 3 with the enables J10 9 and J10 23 and shunt amp J9 5 input low replace the Switching Control PC Board...

Страница 40: ...oblem is no DC then the W contactor should now stay ON for 3 seconds then go OFF No DC may be caused by a faulty Q1 refer to Section 4 05 M If contactor still drops out in less than 1 2 second problem...

Страница 41: ...ng the CNC cable and connecting a start switch into the TB2 Start input and operate it manually That takes both the remote and con troller interface out of the system If problem persists go to step 2...

Страница 42: ...For the Arc Starter Box confirm that the OCV measured at the torch bulkhead is also present at E1 and E2 on the Arc Starter PC Board If not the torch leads extension may be open Check for 24 VAC from...

Страница 43: ...am The Remote Control RC 6010 has front panel con trols for OUTPUT AMPS and CSD The upper and lower limits of the current control range are set by the POT HI 10 vdc and POT LOW 3 3 vdc signals from J5...

Страница 44: ...tage is incorrect then the Switching Con trol PCB is faulty When cutting each Power Supply Master and Slave monitors the actual output amps with their own Shunt Amp PCB Each Power Supply Shunt Amp PCB...

Страница 45: ...able from the Remote Control RC6010 or the Standoff Control SC11 depending on remote used Temporally jumper TB2 1 to TB2 2 for enable For the Remote Control RC 6010 measure for 48 5 vdc from J37 16 35...

Страница 46: ...revi sion letter C or later at the end of the serial num ber on the data tag Slave Power Supplies with the revision letter E or later at the end of the serial number on the data tag Slave Power Suppl...

Страница 47: ...high or low tap on the transformer secondary This is based on the input AC line voltage at the time the Power Supply is turned ON If the line voltage is near one of these points the voltage might mea...

Страница 48: ...between the two units The Isolation PCB in the Master Power Supply accom plishes this using both digital and analog optoisolator intergated circuits IC NOTE For a simplified diagram refer to Appendix...

Страница 49: ...the 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 stra...

Страница 50: ...p and out on the Side Panel 4 Reinstall the replacement Side Panel by reversing the above procedure B Top Panel Replacement 1 Remove the Left and Right Side Panels per para graph B above 2 On the top...

Страница 51: ...ng components from the Ac cess Panel Current Knob per paragraph A above ON OFF Switch per paragraph B above RUN SET PURGE Switch per paragraph C above LED Current Control PC Board per paragraph D abov...

Страница 52: ...he above procedure F Fuse Holder Internal Replacement 1 Remove the Left Side Panel per Section 5 04 A 2 Remove the Fuse from the holder 3 Disconnect the two wires connected to the Fuse Holder 3 Remove...

Страница 53: ...ve Assembly 5 Remove the Panel Nut securing the assembly to the Rear Panel Assembly 6 Pull the old Secondary Water Solenoid Valve As sembly from the Rear Panel Assembly 7 Install the replacement Secon...

Страница 54: ...m the wiring harness at J25 4 Disconnect the hose connected to the bottom of the Flow Switch Assembly in the unit 5 Secure the end of the hose to prevent coolant from draining out of the Coolant Tank...

Страница 55: ...echanical lift 6 Install the replacement DC Inductor Assembly by reversing the above procedure B 29KVA Transformer T1 Assembly Replacement WARNING The removal of this Assembly requires the use of a me...

Страница 56: ...are all replaced in the same way To replace a Ther mostat Assembly use the following procedure 1 Remove the Left and Right Panels per Section 5 04 A 2 Locate the Thermostat Assembly to be replaced and...

Страница 57: ...viewed from the front of the unit Driver PC Board Rear of Front Panel A 01083 5 Note and label the two wiring connectors that con nect to the Driver PC Board 6 Disconnect the two wiring connectors fr...

Страница 58: ...atsink surface under the Transistor Assembly 19 Remove the faulty Switching Transistor Assem bly from the unit by sliding it towards the center of the Main Heatsink CAUTION DO NOT damage Heatsink 20 I...

Страница 59: ...ntation of the gauge dial 3 Unscrew the Pressure Gauge from the fitting 4 Reinstall the replacement Pressure Gauge Assem bly by reversing the above procedure NOTE Be sure that the Pressure Gauge orien...

Страница 60: ...e above procedure J Control Logic PC Board Assembly Replacement 1 Open the front panel access panel cover at the front of the Power Supply 2 Fasten the access cover open with string or rubber band 3 N...

Страница 61: ...lve 5 10 Main Heatsink Assembly Parts Replacement NOTE Refer to Section 6 09 Main Heatsink Assembly Re placement Parts for parts list and overall detail drawing A 70 Amp STR Diode Replacement The Diod...

Страница 62: ...ly ON OFF switch and at the main power disconnect 2 Wait at least two minutes to allow the input ca pacitors to discharge 3 Open the Power Supply to gain access to the faulty Diode Assembly 4 Locate t...

Страница 63: ...ndary Gas Pressure Gauge at the front panel Replace the Hose Assembly using the following procedure NOTE Refer to Subsection 6 08 Upper Chassis Replace ment Parts for part numbers and detail drawing 1...

Страница 64: ...the unit 5 Install the replacement Hose Assembly by revers ing the above procedure F Plasma Gas Hose PLASMA GAS to T Fitting Assembly Replacement The Plasma Gas Hose Assembly goes from the front pane...

Страница 65: ...rs ing the above procedure J Secondary Water Gas Hose T Fitting to T Fitting Assembly Replacement The Secondary Water Gas Hose Assembly goes from the T Fitting at the Secondary Gas Check Valve to the...

Страница 66: ...REPLACEMENT PROCEDURES 60 Manual 0 2569...

Страница 67: ...placement 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 Dyn...

Страница 68: ...Catalog 1 Complete Merlin 6000 Master Power Supply With Running Gear and Work Cable Without Gas Control 3 6800 With Gas Control 3 6802 1 1 Work Cable with Ring Lug 25 ft 7 6 m 9 6892 2 1 Panel Top 9...

Страница 69: ...ription Reference Catalog 1 Access Panel Assembly Includes 1 1 Access Panel With Overlay 9 7008 2 1 ON OFF Rocker Switch DPST SW1 8 3258 3 1 LED Current Control PC Board Assembly 9 5759 4 1 Knob Inner...

Страница 70: ...ght Adapter 8 1251 11 1 Horizontal Chassis Panel 9 6655 12 1 Arc Starts Counter Option 8 8020 13 1 Arc Hour Meter Option 8 8021 14 1 Resistor 8 ohm 9 3431 15 1 Resistor Mounting Bracket Kit 8 4234 16...

Страница 71: ...Manual 0 2569 65 PARTS LISTS 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 19 18 17 20 21 A 02341 22 23 3 3 25 24 26...

Страница 72: ...0262 19 1 Check Valve 1 8 NPT Female 8 1787 20 4 1 8 NPT Close Nipple 8 0354 21 2 Assembly Solenoid Valve Connection 8 1196 22 1 Fitting Adapter 3 8 NPT 9 16 18 O Ring 9 1412 23 1 Assembly Flow Switc...

Страница 73: ...Manual 0 2569 67 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 02342 11 37 35 38 39 40 35 33 36 34...

Страница 74: ...4 1 Coupling Spider 9 4019 15 1 Body Coupling 7 16 Diameter Bore 8 6146 16 2 8 JIC x 3 8 NPT Straight Adapter 8 1251 17 2 1 2 x 3 8 NPT Reducer 8 0353 18 1 Pump Procon Type 2507XH 8 1328 19 1 Plate Pu...

Страница 75: ...9 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 02048 26 25 9 27 28 29 29 29 NOTE Illustration is for Units with the letter C or later at the end of the serial num...

Страница 76: ...1 Adapter Bulkhead 3 8 NPT Inert B L H 8 6148 13 1 Body Bulkhead 1 8 NPT 8 4509 14 1 Body 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...

Страница 77: ...embly Bulkhead to Coolant Pressure Gauge 8 4516 45 1 Hose Assembly Secondary Water Inlet to Gauge 8 4517 46 1 Hose Assembly Plasma Gas Inlet to Regulator 8 4515 47 1 Hose Assembly Plasma Gas Regulator...

Страница 78: ...d 8 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 9 6661 19 2 Res...

Страница 79: ...Manual 0 2569 73 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...

Страница 80: ...en Regulator 9 3053 8 1 Oxygen Regulator 9 4379 9 1 Water Regulator Not required if item 4 is used 8 6118 The following are not shown 1 Merlin 6000 Slave Power Supply 3 6801 1 Master to Slave Parallel...

Страница 81: ...PL AS MA ON 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 LIF TE R...

Страница 82: ...PARTS LISTS 76 Manual 0 2569...

Страница 83: ...B ased on National E lectric Code and Canadian E lectrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated bas...

Страница 84: ...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...

Страница 85: ...e Control or Standoff Control Earth Ground Master Power Supply Work Cable Workpiece Earth Ground 3 Phase Input A 01512 CNC Control Slave Power Supply Work Cable 3 Phase Input Earth Ground NOTE Work Ca...

Страница 86: ...AM NOTE Refer to Appendix V for complete data on the Cables and Hoses SLAVE POWER SUPPLY J15 J54 J63 J15 PCR OR OR MASTER POWER SUPPLY RC 6010 SC10 RC 6010 J37 J37 J29 CNC CNC CNC A 01517 Bulkhead J14...

Страница 87: ...APPENDIX PILOT CABLE PILOT CABLE WORK CABLE TORCH CABLE WORK CABLE SHIELD ARC STARTER PCB ARC STARTER BOX TORCH CABLE COOLANT COOLANT PLASMA GAS SECONDARY GAS WORKPIECE A 01517 J2 D Arc Starter Contro...

Страница 88: ...10 ft 3 0 m 9 6910 1 2 13 15 ft 4 6 m 9 6911 1 2 13 20 ft 6 1 m 9 6912 1 2 13 25 ft 7 6 m 9 6913 1 2 13 30 ft 9 1 m 9 6914 1 2 13 35 ft 10 7 m 9 6915 1 2 13 40 ft 12 2 m 9 6916 1 2 13 50 ft 15 2 m 9 6...

Страница 89: ...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...

Страница 90: ...1 A K5 K3 K4 K2 HFWS 110 110 93 24 24 LOGIC BOARD 23 50 5 75 SW3 A 88 89 SEC 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 SELECT...

Страница 91: ...R SUPPLY 120 VAC CIRCUIT DIAGRAM 5A 250 VAC AC T1 MC1 MC2 W1 W2 K2 110 24 LOGIC PC BOARD 23 K5 HV K5 LV 21 22 4 3 K4 HV K3 LV K3 LV K4 HV VOLTAGE SELECTION PC BOARD NEON IND1 14 15 10 9 8 K1 SWITCHING...

Страница 92: ...ISABLE 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...

Страница 93: ...tandoff Control FIND HEIGHT DISABLE HEIGHT CONTROL OK TO MOVE DELAY VOLTS DISPLAY POWER SUPPLY POWER SUPPLY MAIN CSD AMP DISPLAY AMP Display Signal Demand 48 vdc Torch Volts Signal OK To Move START St...

Страница 94: ...3 TB2 4 J15 24 J15 25 J37 9 J37 10 Internal Ribbon Cable PLASMA ON J5 17 J7 15 START D79 Height Found or Find Ht OFF FIND HEIGHT START D103 With SC10 No Yes J5 13 J7 13 Internal Ribbon Cable ENABLE ON...

Страница 95: ...gh 10 VDC Pot Low 3 3 VDC J10 17 J10 15 J10 13 J5 17 J5 15 J5 13 LED and Current Control PCB J37 11 J37 12 J37 1 J37 2 DISPLAY 150 300A J15 26 J15 27 J15 3 J15 4 Shunt Amp PCB J11 5 J11 6 J9 5 J9 6 J7...

Страница 96: ...APPENDIX 90 Manual 0 2569 APPENDIX XIII CORNER SLOWDOWN CSD CIRCUIT DIAGRAM A 01140...

Страница 97: ...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...

Страница 98: ...T DIAGRAM Torch Control Connector Merlin 6000 Power Supply F3 1A 250V 24 VAC J14 5 J14 8 J1 1 J1 3 Arc Starter PC Board 24 VAC Present Red LED On J2 1 J2 2 Arc Starter Box Panel Connector Arc Starter...

Страница 99: ...se Assembly 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 Coo...

Страница 100: ...APPENDIX 94 Manual 0 2569 APPENDIX XVII INTERFACE CABLE FOR REMOTE CONTROL RC6010 A 01513 Remote Control RC6010 RC6010 Remote Cable Merlin 6000...

Страница 101: ...CE CABLE A 01514 Cable Connections Used With Remote Control RC6010 Cutting Machine CNC Cable Remote Control RC6010 Contact 24 VAC Source Refer to Remote Control RC6010 Manual for Station Select and CS...

Страница 102: ...J54 Slave Power Supply J15 Cable 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 DEMAND 3 3 10 VDC ENABLE START STOP SLAVE IS ON SLAVE OUTPUT Signal This Is Slave Remote...

Страница 103: ...Manual 0 2569 97 APPENDIX APPENDIX XX ARC STARTER BOX OPTION SYSTEM SCHEMATIC A 01575...

Страница 104: ...gnal CSR CSR To PWM 20 ma Current Source J7 8 J7 20 J7 19 Parallel Cable Installed J7 16 J7 2 J7 18 0 10 v Demand to Slave 0 10 v output sig To Master Switching Control PCB 120 119 J15 35 J15 36 124 1...

Страница 105: ...S J3 29 This is Slave 15 V J3 27 Slave is On J4 6 J3 9 J3 23 Start to Slave PWM Enable 2 PWM Enable Start Stop J1 19 J1 20 Slave is On Logic PCB 47 J15 25 J1 18 J15 J15 32 J15 33 Enable Relay 3 3 to...

Страница 106: ...APPENDIX 100 Manual 0 2569 APPENDIX XXII GAS CONTROL GC3000 WIRING DIAGRAM A 01129...

Страница 107: ...Manual 0 2569 101 APPENDIX...

Страница 108: ...APPENDIX 102 Manual 0 2569 APPENDIX XXIII SYSTEM SCHEMATIC Rev B or Earlier A 01573...

Страница 109: ...Manual 0 2569 103 APPENDIX NOTE System Schematic for units with the letter B or earlier at the end of the serial number on the data tag A 01573...

Страница 110: ...APPENDIX 104 Manual 0 2569 APPENDIX XXIV SYSTEM SCHEMATIC Rev C or Later A 01947...

Страница 111: ...Manual 0 2569 105 APPENDIX NOTE System Schematic for units with the letter C or later at the end of the serial number on the data tag A 01947...

Страница 112: ...APPENDIX 106 Manual 0 2569...

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