Instruction/ maintenance manual of the product 3000 Thermal Comfort
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Manual No. 0-2533 October 6, 1999 MERLIN 3000 Plasma Cutting Power Supply Service Manual A-00907.
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.
T ABLE OF CONTENTS SECTION 1: GENERAL INFORMA TION .................................................................................................. 1 1.01 Notes, Cautions and W arnings ................................................................
T ABLE OF CONTENTS (continued) SECTION 6: P AR TS LISTS .................................................................................................................... .5 1 6.01 Introduction .......................................................
Date: 6/22/99 1 GENERAL INFORMA TION SECTION 1: GENERAL INFORMA TION 1.01 Notes, Cautions and W arnings Throughout this manual, notes, cautions, and warnings are used to highlight important information.
GENERAL INFORMA TION 2 Date 6/22/99 • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publica- tions. • Disconnect power source befor e performing any ser - vice or repairs. • Read and follow all the instructions in the Operat- ing Manual.
Date: 6/22/99 3 GENERAL INFORMA TION 8. NFP A Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- CESSES, obtainable from the National Fir e Protection Association, Batterymarch Park, Quincy , MA 02269 9.
GENERAL INFORMA TION 4 Date 6/22/99 • Les sortes de gaz et de fumée provenant de l’ar c de plasma dépendent du genre de métal utilisé, des revêtements se tr ouvant sur le métal et des différents procédés.
Date: 6/22/99 5 GENERAL INFORMA TION • Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1: Nuance Minimum Nuance Suggerée Courant 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 observé clairement.
GENERAL INFORMA TION 6 Date 6/22/99 14. Norme A WSF4.1 de l’Association Américaine de Soudage, RECOMMANDA TIONS DE PRA- TIQUES SURES POUR LA PRÉP ARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUY AUX A Y ANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American W elding Society , 550 N.
Date: 6/22/99 7 GENERAL INFORMA TION 1.07 Dec laration of Conf ormity Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 W est Lebanon, New Hampshir e 03784 USA The equipment descr.
GENERAL INFORMA TION 8 Date 6/22/99 1.08 Statement of W arranty LIMITED W ARRANTY : Thermal Dynamics ® Corporation (hereinafter “Thermal”) warrants that its products will be fr ee of defects in workmanship or material.
Manual 0-2533 9 INTRODUCTION SECTION 2: INTR ODUCTION 2.01 Scope Of Manual This Manual provides Service Instructions for Thermal Dynamics Merlin 3000 Power Supply .
INTRODUCTION 10 Manual 0-2533.
Manual 0-2533 11 INTRODUCTION & DESCRIPTION SECTION 3: INTR ODUCTION & DESCRIPTION 3.01 Scope of Manual The information in this Section is the same information contained in Section 2 of the Operating Manual. It is sup- plied here to familiarize the Service T echnician with the capabilities and limitations of the equipment.
INTRODUCTION & DESCRIPTION 12 Manual 0-2533 5. Duty Cycle 100% 6. Pilot Modes Auto-Restart, Pre-Flow Delay , Recycle 7. CNC Signals Enable Start/Stop, OK-to-Move, Pilot Sensing Relay (PSR), Full CNC A vailable with Remote 8. Coolant Pressure Internal Service-adjustable 130 psi (8.
Manual 0-2533 13 INTRODUCTION & DESCRIPTION E. RF Shielding All machine torch systems ar e shielded to minimize ra- dio frequency (RF) interfer ence which results from the high frequency ar c initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded tor ch and contr ol leads.
INTRODUCTION & DESCRIPTION 14 Manual 0-2533 G. Hour/Counter Meters Meter assembly containing two meters. One meter indicates the total number of hours that the main cut- ting arc has been on. The second meter counts the number of times that the cutting arc has been started.
Manual 0-2533 15 SER VICE TROUBLESHOO TING SECTION 4: SER VICE TR OUBLESHOO TING DIA GNOSTICS 4.01 Intr oduction This Section provides service diagnostics for the Merlin 3000 Power Supply , allowing the T echnician to islolate any faulty Subassemblies.
SER VICE TROUBLESHOO TING 16 Manual 0-2533 hot soapy water . Remove soap residue by rinsing with clean hot water . Be sur e that all the soap has been removed and the scr een is dry of water before re-in- stalling in the Internal Filter Assembly . E. Coolant Level and Conductivity 1.
Manual 0-2533 17 SER VICE TROUBLESHOO TING C. Switch-Mode P ower Suppl y Operation Primary three-phase power is r ectified by the three- phase bridge diodes D1-D6. The resulting negative DC voltage (approximately -320 VDC) is applied to the switching transistor (Q1).
SER VICE TROUBLESHOO TING 18 Manual 0-2533 nector and an internal terminal strip are pr ovided for CNC connections. The remote includes internal con- nections to interface to the SC10 standoff contr ol so the single remote cable works for both.
Manual 0-2533 19 SER VICE TROUBLESHOO TING The advanced tr oubleshooting covered in this Service Manual requir es Power Supply disassembly and live mea- surements. It is helpful for solving many of the common problems that can arise with the Merlin 3000 Plasma Cut- ting System.
SER VICE TROUBLESHOO TING 20 Manual 0-2533 E. Fuse blown at disconnect when primary power is connected 1. V oltage selection busbars connected incorr ectly a. Check and correct if necessary . 2. One leg of three-phase primary connected to chassis ground a.
Manual 0-2533 21 SER VICE TROUBLESHOO TING 3. Gas Control (GC3000) on wr ong setting a. Select input that has gas connected. 4. Gas supply turned off (or tank empty) a. Check gas supply 5. Faulty solenoid valve: SOL1 - plasma gas, SOL2 - secondary gas, SOL3 - secondary water , SOL4 through SOL9 - Optional Gas Select a.
SER VICE TROUBLESHOO TING 22 Manual 0-2533 M. DC indicator off (after pre-flow); Main contactor comes on momentarily; No pilot arc; No main arc transfer 1. Switching transistor (Q1) not turning on a. Refer to Section 4.05-M, Switching Contr ol Check (Q1).
Manual 0-2533 23 SER VICE TROUBLESHOO TING U. Main arc transfers and pierces through the plate, but cutting machine doesn’t move 1. Incorrect or missing OK-T o-Move signal. a. Many cutting machines require an AC voltage to activate the motion input.
SER VICE TROUBLESHOO TING 24 Manual 0-2533 work check continuity from TB2, wir es 102 & 103, to J50-10 & 1 1. If correct, r eplace the Switching Contr ol PC Board.
Manual 0-2533 25 SER VICE TROUBLESHOO TING 2. High frequency pr otection for the input rectifier diodes (D1-6) is provided by capacitors C1 - C6 and MOV 1-3, which ar e located between each side of the diode heatsink on the input filter PC board. Except for the shorts, these components can not be checked with a volt/ohm meter .
SER VICE TROUBLESHOO TING 26 Manual 0-2533 2. If the coolant conductivity indicator is not lit with the probe disconnected, measur e between the Logic PC Board common (TP1) and J3-1. If the voltage measur es below +12 VDC, replace the LED PC board. If the voltage measur es above +12 VDC, replace the Logic PC Boar d.
Manual 0-2533 27 SER VICE TROUBLESHOO TING lem is in the Standoff Contr ol (SC10) or the ribbon cable. Refer to Section 5, Customer/Operator Service, in the Standoff Contr ol Instr uction Manual.
SER VICE TROUBLESHOO TING 28 Manual 0-2533 The PWM compares shunt amp output on J9-5 with the current contr ol signal (3.3 - 10 VDC) fr om the re- mote (J7-18) or the panel control (J10-15). A faulty shunt amp could cause the output, normally 0 VDC with no cutting arc, to go higher , shutting of f the PWM and thus producing no DC.
Manual 0-2533 29 SER VICE TROUBLESHOO TING If 24 V AC is not present, r emove J14 contr ol connec- tor at the torch bulkhead and measur e for 24 V AC be- tween pins 5 and 8 of the receptacle. The 24 V AC comes fr om T3, is fused by F3, 1A 250v , and passes through the filter FL1 to J14.
SER VICE TROUBLESHOO TING 30 Manual 0-2533 The display signal at J7-2 should be equal to the control pot wiper voltage at J7-18 measur ed in Step 3 above.
Manual 0-2533 31 SER VICE TROUBLESHOO TING Q. OK-T o-Move T ests 1. The Shunt Amp sends a voltage level to the Switch- ing Contr ol PC Board that corr esponds to the work lead or cutting current.
SER VICE TROUBLESHOO TING 32 Manual 0-2533 CAUTION Move the clamps only what is necessary for a steady pilot. T oo much adjustment can cause increased parts wear . DO NOT move each clamp mor e than a total of 2 inches (50.8 mm). If a steady pilot cannot be achieved with the adjust- ment, then something else is wrong.
Manual 0-2533 33 REPLACEMENT PR OCEDURES SECTION 5: REP AIRS & REPLA CEMENT PR OCEDURES 5.01 Intr oduction This Section describes parts replacement pr ocedur es and all repairs which may be performed on the Merlin 3000 Power Supply .
REPLACEMENT PR OCEDURES 34 Manual 0-2533 W ARNING Disconnect primary power from the source befor e opening or disassembling the power supply . Make sure AC indicator on the Power Supply fr ont panel is OFF .
Manual 0-2533 35 REPLACEMENT PR OCEDURES 2. Loosen the two screws of the W ork Cable strain relief securing the W ork Cable at the Front Panel. 3. Remove the nut (under the Horizontal Chassis Panel) securing the W ork Cable connection to the Shunt Assembly .
REPLACEMENT PR OCEDURES 36 Manual 0-2533 3. Remove the Coolant Hose from the Internal Cool- ant Filter Assembly . 4. Remove the Internal Coolant Filter from the fitting on the Radiator .
Manual 0-2533 37 REPLACEMENT PR OCEDURES 7. Locate and remove the four bolts and lock nuts securing the Fan Assembly to the Rear Panel As- sembly . 8. Car efully pull the Fan Assembly from the Rear Panel Assembly feeding the wiring through the hole. 9.
REPLACEMENT PR OCEDURES 38 Manual 0-2533 G. Coolant T ank Replacement 1. Remove the Left, Right, and T op Side Panels per Section 5.04-B. 2. Drain the coolant from the Coolant T ank per Sec- tion 4.02-F . CAUTION Handle and dispose of the used coolant per recom- mended procedur es.
Manual 0-2533 39 REPLACEMENT PR OCEDURES CAUTION Handle and dispose of the used coolant per recom- mended pr ocedur es. 3. Remove the two wires fr om the Conductivity Sen- sor Assembly . 4. Remove the Conductivity Sensor Assembly from the Coolant T ank.
REPLACEMENT PR OCEDURES 40 Manual 0-2533 6. Install the replacement T ransformer Assembly by reversing the above pr ocedur e. C. Main Contactor (W1 or W2) Replacement NOTE The Main Contactors, W1 and W2, are r eplaced in the same manner .
Manual 0-2533 41 REPLACEMENT PR OCEDURES Driver PC Board Rear of F ront 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 om the Driver PC Board. 7. Press in the securing tab knob on the PC Boar d Guide to release the PC Boar d fr om the PC Boar d Guides.
REPLACEMENT PR OCEDURES 42 Manual 0-2533 PTC Resistor Assembly Q1 Main Heatsink A-01089 17. Remove the four screws securing the Switching T ransistor module to the Main Heatsink. 18. Pry between the Main Heatsink and the faulty Switching T ransistor Assembly until it slides eas- ily .
Manual 0-2533 43 REPLACEMENT PR OCEDURES C. Pressure Gaug e Replacement NOTE Both the Plasma and Secondary gauges are r eplaced in the same manner 1. Remove the T op Panel per Section 5.04-B. 2. Disconnect the wiring tho the desired Pr essure Switch. 3.
REPLACEMENT PR OCEDURES 44 Manual 0-2533 3. Disconnect the gas Hose Assembly from the fitting at the end of the Gas Input Fitting. 4. Remove the fitting screwed into the end of the Gas Input Fitting. 5. Remove the first nut from the Gas Input Fitting.
Manual 0-2533 45 REPLACEMENT PR OCEDURES Symbol Direction Of Flow Check Valve A-00370 5. Install the replacement Check V alve by reversing the above procedur e and noting the following: • Coat the threads of the Fittings with a teflon sealer before installing on the r eplacement Check V alve.
REPLACEMENT PR OCEDURES 46 Manual 0-2533 d. Re-solder the wire lead to the r eplacement di- ode. e. Apply a layer of R TV over the top of the Diode Assembly to encapsulate the lead and top of the diode. RT V 70 Amp Diode Wire Lead A-01166 f. Close up the Power Supply .
Manual 0-2533 47 REPLACEMENT PR OCEDURES 7. Make sure the r eplacement diode is a direct re- placement for the old one. 8. Install the replacement diode by r eversing the above procedur e and noting the following: a. W ipe the surface clean where the replacement diode is to be installed.
REPLACEMENT PR OCEDURES 48 Manual 0-2533 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 Pr essure Gauge connec- tor .
Manual 0-2533 49 REPLACEMENT PR OCEDURES 3. Remove the Hose Assembly from the unit. 4. Install the replacement Hose Assembly by revers- ing the above procedur e.
REPLACEMENT PR OCEDURES 50 Manual 0-2533.
Manual 0-2533 51 P ARTS LISTS SECTION 6: P AR TS LISTS 6.01 Intr oduction A. Parts List Breakdown The parts list provides a br eakdown of all basic replace- able parts. The parts lists are arranged as follows: Section 6.03: External Power Supply Replacement Parts List Section 6.
P AR TS LISTS 52 Manual 0-2533 A-01220 1 2 3 4 5 6 6.03 External P o wer Supply Replacement P arts List Item # Qty . Description Catalog # Complete Merlin 3000 Power Supply W ith Running Gear and W ork Cable 1 W ithout Gas Control GC3000 3-5100 1 W ith Gas Control GC3000 3-5101 1 1 W ork Cable with Clamp - 25 ft (7.
Manual 0-2533 53 P ARTS LISTS 6.04 Access P anel Replacement P arts Item # Qty . Description Catalog # 1 Access Panel Assembly Includes: 8-3257 1 1 Access Panel W ith Overlay 8-6302 2 1 Access Panel O.
P AR TS LISTS 54 Manual 0-2533 6.05 Front P anel/Chassis Replacement P arts Item # Qty . Description Catalog # 1 1 Front Panel W ith Overlay 8-6304 2 1 Front Panel Overlay ------ 3 1 Cord Grip 8-6307 .
Manual 0-2533 55 P ARTS 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.
P AR TS LISTS 56 Manual 0-2533 6.06 Rear P anel Replacement P ar ts Item # Qty . Description Catalog # 1 1 Rear Panel 8-4505 2 1 Fan, 16" Axial 8-6312 3 2 Contactor , 25 amp, 2-pole, 120V Coil 8-.
Manual 0-2533 57 P ARTS 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.
P AR TS LISTS 58 Manual 0-2533 6.07 Base Assembly Replacement P ar ts Item # Qty . Description Catalog # 1 1 Base 8-5145 2 2 Caster , 5" Diameter 8-5578 3 2 Wheel, 8" Diameter 8-5579 4 1 Axl.
Manual 0-2533 59 P ARTS 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.
P AR TS LISTS 60 Manual 0-2533 6.08 Upper Chassis Replacement P ar ts Item # Qty . Description Catalog # 1 1 Panel, Upper Chassis/Gauge 9-1302 2 1 Power Driver PC Board Assembly Includes: 7-3360 1 Thermstrate, T ransistor (Refer to Section 6.09 Item # 7) 9-1406 1 T ransistor , 300A, 550V Darlington (Refer to Section 6.
Manual 0-2533 61 P ARTS LISTS Item # Qty . Description Catalog # 43 1 Check V alve, Male, 1/4 NPT , 5 PSI 8-4512 44 1 Hose Assembly , Secondary W ater , Gauge T o T -Fitting 8-4513 45 1 Hose Assembly .
P AR TS LISTS 62 Manual 0-2533 6.09 Main Heatsink Assembl y Replacement P ar ts Item # Qty . Description Catalog # 1 1 Main Heatsink 9-1404 2 4 Capacitor , 550 mfd, 400VDC 9-1303 3 1 Bracket, Capacito.
Manual 0-2533 63 P ARTS 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.
P AR TS LISTS 64 Manual 0-2533 6.10 P o wer Supply Options And Accessories Item # Qty . Description Catalog # 1 1 Remote Control (RC6010) 3-6106 2 1 Standoff Contr ol (SC10) 3-61 10 3 1 Gas Contr ol (.
Manual 0-2533 65 P ARTS LISTS A-01218 OUTPUT AMPS PLASMA ENABLE ON START REMOTE POWER SUPPLY CONTROL SD (%) 25 75 100 50 TRAVEL SPEED 125+ IPM 0-125 IPM RUN PURGE SET PLASMA ON ARC VOLTS REMOTE STANDOFF CONTROL T.H.C. ACTIVE PIERCE HT (inches) 0.1 0.3 0.
P AR TS LISTS 66 Manual 0-2533.
Manual 0-2533 67 APPENDIX APPENDIX I: INPUT WIRING REQUIREMENTS I nput P ow e r I npu t Curre nt S ugge st e d S i ze s ( S e e Not es ) V o ltag e F r eq .
APPENDIX 68 Manual 0-2533 APPENDIX II: SEQUENCE OF OPERA TION BLOCK DIA GRAM A-01016 ACTION Close external disconnect switch RESULT • Power to system ACTION Enable ON at Remote or TB2 ON/OFF switch .
Manual 0-2533 69 APPENDIX APPENDIX III: TYPICAL MECHANIZED SYSTEM CABLE CONNECTIONS Ca bl e De s cr i pt i o n Let t er Des i g na t i on Po w e r S u pp l y to R e m o te C o ntrol A St andof f Contr.
APPENDIX 70 Manual 0-2533 APPENDIX IV : INTERF A CE CABLES FOR REMO TE CONTROL (RC6010) AND ST ANDOFF CONTROL (SC11) A-00983 MERLIN 3000 REMOTE CABLES FOR RC 6010 & SC11.
Manual 0-2533 71 APPENDIX APPENDIX V : CNC INTERF A CE A-00982.
APPENDIX 72 Manual 0-2533 APPENDIX VI: 120 V A C CIRCUIT DIA GRAM K1 J28 TO OPTIONAL ST ANDOFF CONTR OL PCR (881) (89) SW3-A (5) K5 LOGIC PCB (75) K3 (110) SOL3 SOL2 SOL1 (50) K4 K2 T2 -1 -3 (24) V OL.
Manual 0-2533 73 APPENDIX APPENDIX VII: LADDER DIA GRAM - 15 VDC 3 LOGIC CONTROL BO ARD 13 11 19 15 5 9 7 24 11 12 18 14 4 8 6 22 12 K4 K3 K2 K5 K1 PLASMA SECOND AR Y GAS CONTROL CIRCUIT PRE-FLO W &am.
APPENDIX 74 Manual 0-2533 APPENDIX VIII: SIGNAL FLO W BLOCK DIA GRAM A-01139.
Manual 0-2533 75 APPENDIX APPENDIX IX: ST ART CIRCUIT 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 ST AR T OPT O- Isola.
APPENDIX 76 Manual 0-2533 APPENDIX X: CURRENT CONTR OL / DISPLA Y CIRCUIT DIA GRAM A-01138.
Manual 0-2533 77 APPENDIX APPENDIX XI: CSD (CORNER SLO WDO WN) CIRCUIT DIA GRAM A-01140.
APPENDIX 78 Manual 0-2533 APPENDIX XII: OK-T O-MO VE CIRCUIT DIA GRAM A-01081 PIERCE DELA Y 0 - 3 seconds OFF = OK-T o-Move 24 V A C Source Merlin 3000 or Merlin 6000 or Mer lin 6000GST with Remote Co.
Manual 0-2533 79 APPENDIX APPENDIX XIII: HOSE BLOCK DIA GRAM Coolant Filter Assembly (Rear Panel) Internal Filter Assembly Gas Connections (Rear Panel) Plasma Gas (+) Secondary Gas Secondary Water Rad.
APPENDIX 80 Manual 0-2533 APPENDIX XIV : SYSTEM SCHEMA TIC A-00981.
Manual 0-2533 81 APPENDIX A-00981.
APPENDIX 82 Manual 0-2533 APPENDIX XV : RECOMMENDED R OUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.
An important point after buying a device Thermal Comfort 3000 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Thermal Comfort 3000 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Thermal Comfort 3000 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Thermal Comfort 3000 you will learn all the available features of the product, as well as information on its operation. The information that you get Thermal Comfort 3000 will certainly help you make a decision on the purchase.
If you already are a holder of Thermal Comfort 3000, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Thermal Comfort 3000.
However, one of the most important roles played by the user manual is to help in solving problems with Thermal Comfort 3000. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Thermal Comfort 3000 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
