Thermal Dynamics MERLIN 6000 - Service Manual

Thermal Dynamics MERLIN 6000

112 pages

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Manual No. 0-2569

October 6, 1999

MERLIN

®

6000

Plasma Cutting

Master Power Supply

Service Manual

A-01497

Table of Contents

Service Manual1
Table of Contents3
General Information7
- Notes, Cautions and Warnings7
- Important Safety Precautions7
- Publications8
- Note, Attention Et Avertissement9
- Precautions de Securite Importantes9
- Documents de Reference11
- Declaration of Conformity13
- Statement of Warranty14
Introduction15
- Scope of Manual15
- General Service Philosophy15
- Service Responsibilities15
- Section 2 Introduction15
Introduction & Description17
- Scope of Manual17
- General Description17
- Section 3 Introduction & Description17
- Specifications & Design Features18
- Theory of Operation19
- Options and Accessories20
Service Troubleshooting Diagnostics21
- Introduction21
- Periodic Inspection & Procedures21
- System Theory22
- Troubleshooting Guide25
- Test Procedures30
Repairs & Replacement Procedures49
- Introduction49
- Anti-Static Handling Procedures49
- Parts Replacement - General Information49
- External Parts Replacement50
- Access Panel Parts Replacement50
- Front Panel/Chassis Parts Replacement51
- Rear Panel Parts Replacement52
- Base Assembly Parts Replacement55
- Upper Chassis Parts Replacement56
- Main Heatsink Assembly Parts Replacement61
- Hose Assembly Replacements63
- Parts Lists67
Appendix I: Input Wiring Requirements83
Appendix II: Sequence of Operation Block Diagram84
Appendix III: Typical Mechanized System Work and Ground Cable Connections85
Appendix IV: Typical Mechanized System Cable Interconnection Diagram86
Appendix V: Quick Reference to Interconnecting Cables and Hoses88
Appendix VI: Recommended Routine Maintenance Schedule for Liquid Cooled Plasma Cutting Systems89
Appendix VII: Merlin 6000 Master Power Supply - 120 Vac Circuit Diagram90
Appendix VIII: Merlin 6000 Slave Power Supply - 120 Vac Circuit Diagram91
Appendix IX: Ladder Diagram - 15 VDC92
Appendix X: Signal Flow Block Diagram93
Appendix XI: Start Circuit Diagram with Standoff Control Sc1094
Appendix XII: Current Control and Display Diagram95
Appendix XIII: Corner Slowdown (Csd) Circuit Diagram96
Appendix XIV: Ok-To-Move Circuit Diagram97
Appendix XV: Arc Starter Box - 24 Vac Circuit Diagram98
Appendix XVI: Power Supply Hose Block Diagram99
Appendix XVII: Interface Cable for Remote Control (Rc6010)100
Appendix XVIII: Cnc Interface Cable101
Appendix XIX: Parallel Cable102
Appendix XX: Arc Starter Box Option System Schematic103
Appendix XXI: Parallel Interface Diagram104
Appendix XXII: Gas Control (Gc3000) Wiring Diagram106
APPENDIX XXIII: SYSTEM SCHEMATIC - Rev 'B' or Earlier108
APPENDIX XXIV: SYSTEM SCHEMATIC - Rev 'C' or Later110

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