SERVICE TROUBLESHOOTING 16 Manual 0-2569
hot soapy water. Remove soap residue by rinsing with
clean hot water. Be sure that all the soap has been
removed and the screen is dry of water before re-in-
stalling in the Internal Filter Assembly.
E. Coolant Level and Conductivity
1. Coolant Level
The coolant level should be checked every day at
the rear panel coolant gauge. If the coolant in the
reservoir is more than 2 inches (50mm) from the
top of the reservoir then add Torch Coolant.
2. Coolant Conductivity
The coolant conductivity LED on the front panel
must be ON for normal operation. If the LED is
OFF then drain the old coolant from the Power
Supply and torch leads and replace with new cool-
ant. Check the condition of the deionizer bag in
the reservoir basket, if the bag is yellowish brown
(straw color) replace the bag.
F. Draining Coolant
Remove the old coolant from the Power Supply res-
ervoir per the following procedure:
1. Remove the right side and top panels from the
Power Supply.
2. Disconnect the coolant hose input to the rear panel
filter assembly.
3. Carefully lower the hose out the right side of the
Power Supply and drain the coolant into an ac-
ceptable container.
CAUTION
Handle and dispose of the used coolant per recom-
mended procedures.
Coolant Hose
Coolant Hose
Connection
A-01511
Figure 4-2 Draining Coolant From Reservoir
4. Reconnect the hose to the filter assembly.
5. Install new coolant and deionizer bag.
6. Reinstall the top and right side 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 Leads
• Arc Starter Box
• Optional Merlin 6000 Slave Power Supply
• Optional Gas Control (GC3000)
• Optional Remote Control (RC6010)
• Optional Standoff Control (SC10)
The output current of the basic system is 50-150 amperes
(A). Systems with the Optional Merlin 6000 Slave Power
Supply the output current of the system is 100 to 300
amperes (A). A second Master Power Supply may also
be used as the Slave Power Supply. Outputs between 50
to 100A are still available by shutting off the Slave Power
Supply.
All gas controls, including gas solenoids, gas pressure
regulators and gauges, are in the Merlin 6000 Master
Power Supply.
Optional Gas Control (GC3000), Remote Control (RC6010)
and Standoff Control (SC10), refer to note, may be used
in various combinations.
NOTE
The Standoff Control SC10 must be used with the
Remote Control RC6010.
The Optional Gas Control (GC3000) contains the gas se-
lect control switches and a switch for the set functions.
An Optional Remote Dual Meter with Hour Meter and
Arc Starts Counter is available with all Merlin 6000 Sys-
tems. The meters are mounted to the front panel of the
unit.
A Slave Power Supply has the same power circuits as the
Master Power Supply, but the gas controls, heat exchanger
(torch coolant) and pilot circuits have been removed.
When a Master Power Supply is used as a Slave, those
circuits are automatically disabled. The Merlin 6000 Sys-
tem uses the same Slave Power Supply as the Merlin
6000GST System. A switch on the Switching Control PC
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