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Thermal Dynamics
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MERLIN 6000
Thermal Dynamics MERLIN 6000 Service Manual
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Manual No.
0-2569
October 6, 1999
MERLIN
®
6000
Plasma Cutting
Master P
o
wer Supply
Ser
vice Manual
A-01497
2
Table of Contents
Service Manual
1
Table of Contents
3
General Information
7
Notes, Cautions and Warnings
7
Important Safety Precautions
7
Publications
8
Note, Attention Et Avertissement
9
Precautions de Securite Importantes
9
Documents de Reference
11
Declaration of Conformity
13
Statement of Warranty
14
Introduction
15
Scope of Manual
15
General Service Philosophy
15
Service Responsibilities
15
Section 2 Introduction
15
Introduction & Description
17
Scope of Manual
17
General Description
17
Section 3 Introduction & Description
17
Specifications & Design Features
18
Theory of Operation
19
Options and Accessories
20
Service Troubleshooting Diagnostics
21
Introduction
21
Periodic Inspection & Procedures
21
System Theory
22
Troubleshooting Guide
25
Test Procedures
30
Repairs & Replacement Procedures
49
Introduction
49
Anti-Static Handling Procedures
49
Parts Replacement - General Information
49
External Parts Replacement
50
Access Panel Parts Replacement
50
Front Panel/Chassis Parts Replacement
51
Rear Panel Parts Replacement
52
Base Assembly Parts Replacement
55
Upper Chassis Parts Replacement
56
Main Heatsink Assembly Parts Replacement
61
Hose Assembly Replacements
63
Parts Lists
67
Introduction
67
Ordering Information
67
External Power Supply Replacement Parts List
68
Access Panel Replacement Parts
69
Front Panel/Chassis Replacement Parts
70
Rear Panel Replacement Parts
72
Base Assembly Replacement Parts
74
Upper Chassis Replacement Parts
76
Main Heatsink Assembly Replacement Parts
78
Power Supply Options and Accessories
80
Appendix I: Input Wiring Requirements
83
Appendix II: Sequence of Operation Block Diagram
84
Appendix III: Typical Mechanized System Work and Ground Cable Connections
85
Appendix IV: Typical Mechanized System Cable Interconnection Diagram
86
Appendix V: Quick Reference to Interconnecting Cables and Hoses
88
Appendix VI: Recommended Routine Maintenance Schedule for Liquid Cooled Plasma Cutting Systems
89
Appendix VII: Merlin 6000 Master Power Supply - 120 Vac Circuit Diagram
90
Appendix VIII: Merlin 6000 Slave Power Supply - 120 Vac Circuit Diagram
91
Appendix IX: Ladder Diagram - 15 VDC
92
Appendix X: Signal Flow Block Diagram
93
Appendix XI: Start Circuit Diagram with Standoff Control Sc10
94
Appendix XII: Current Control and Display Diagram
95
Appendix XIII: Corner Slowdown (Csd) Circuit Diagram
96
Appendix XIV: Ok-To-Move Circuit Diagram
97
Appendix XV: Arc Starter Box - 24 Vac Circuit Diagram
98
Appendix XVI: Power Supply Hose Block Diagram
99
Appendix XVII: Interface Cable for Remote Control (Rc6010)
100
Appendix XVIII: Cnc Interface Cable
101
Appendix XIX: Parallel Cable
102
Appendix XX: Arc Starter Box Option System Schematic
103
Appendix XXI: Parallel Interface Diagram
104
Appendix XXII: Gas Control (Gc3000) Wiring Diagram
106
APPENDIX XXIII: SYSTEM SCHEMATIC - Rev 'B' or Earlier
108
APPENDIX XXIV: SYSTEM SCHEMATIC - Rev 'C' or Later
110
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Thermal Dynamics MERLIN 6000 Specifications
General
Brand
Thermal Dynamics
Model
MERLIN 6000
Category
Welding System
Language
English
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