Automated Plasma Cutting Power Supply MERLIN ® 1000 A-02157 Operating Manual December 21, 2004 Manual No.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Automated Plasma Cutting Power Supply Merlin 1000 Operating Manual No. 0-2708 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................. 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ..................................................................... Important Safety Precautions ........................................................................ Publications ..................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................................................................................................................... 5-1 5.01 5.02 5.03 5.04 5.05 5.06 5.07 Introduction ................................................................................................... General Maintenance .................................................................................... Common Operating Faults ..........................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédure en question. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 AVERTISSEMENT 8.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau. • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz. • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés.
ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement. • Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire. • Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
1.08 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
SECTION 2: INTRODUCTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and basic maintenance procedures for the Merlin 1000 Automated Plasma Cutting Power Supply. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly.
5. Input Power (see NOTES) B. Requirements to Complete System 208/230/240 VAC (±10%), 50/60 Hz, Three-Phase To complete the system, the user needs to provide the following: 380-415 VAC (±10%), 50/60 Hz, Three-Phase • Primary Input Power Cable 460 VAC (±10%), 50/60 Hz, Three-Phase • Gas Supplies 575 VAC (±10%), 50/60Hz, Three-Phase NOTES 2.03 Specifications & Design Features Refer to Appendix 1 for suggested input wiring size, current ratings and circuit protection requirements.
12. Coolant Flow Rate 0.5 gpm (1.9 lpm) with 150 feet of total torch and torch leads at 70°F (21°C) NOTE The flow rate varies with lead length, torch configuration, ambient temperature, amperage level, etc. 2.04 Power Supply Options and Accessories The following accessories are available for this Power Supply. Refer to Section 6, Parts Lists, for part numbers and ordering information. A. High Pressure Regulators High pressure regulators are available for air, oxygen, argon-hydrogen and nitrogen.
F. Interlocks 2.05 Theory Of Operation A. Plasma Arc Cutting and Gouging Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away by the flow of gas. The system has several built-in interlocks to provide safe and efficient operation.
SECTION 3: INSTALLATION 3.02 Site Selection Select a clean, dry location with good ventilation and adequate working space around all components. NOTE 3.01 Introduction Review Important Safety Precautions in Section 1 to be sure that the selected location meets all safety requirements. NOTE Depending on how the system was ordered, some Power Supply options may already be installed. If option(s) have been factory installed some of the instructions may not apply.
3.04 Lifting Options WARNINGS Do not touch live electrical parts. C. Opening Power Supply Enclosure The left side panel of the Power Supply must be removed to gain access to the input power connections and the input voltage selection. Use caution when removing the panel as there is a ground wire connected to the inside of each panel. Disconnect input power conductors from de-energized supply line before moving unit.
3.06 Input Voltage Selection 2. Pull the single wire voltage selection plug from the auxiliary transformer input connector. NOTE For power supplies to use 575 VAC input power, the unit must be setup for 460V three-phase operation and the Optional 575V Transformer Assembly must be installed. Voltage Selection Block Auxilliary Transformer Input Connector The Power Supply has two voltage settings; HIGH VOLTAGE (380-415/460 VAC) or 208/230 VAC.
7. Reinstall the star washers and nuts. 3.07 Input Power Cable Connections 8. Tighten all the nuts. NOTE If changing from low voltage to HIGH VOLTAGE all nuts must be tightened even if not used on the terminal block. WARNING Disconnect primary power at the source before connecting the primary power cable to the power supply. 9. Insert the single wire voltage selection plug into the auxiliary transformer input connector.
2. Connect the input cable inside the power supply as follows: 3.08 Gas Connections NOTE The Power Supply provides the liquid cooling and gases to support operation of the Liquid Cooled Maximizer 300 Torch. Three-phase operation requires a 3-conductor cable with ground. NOTE Refer to the Liquid Cooled Maximizer 300 Torch Instruction Manual (Cat. No. 0-2710) for information on plasma and secondary gas selection and requirements. a. Locate the ground stud and remove the top nut and washer. b.
A. Using Shop Air B. Using High-Pressure Gas Cylinders NOTE NOTES The Two Stage Air Line Filter Assembly is to be used when using shop air as the Plasma Gas. Refer to the regulator manufacturer’s specifications for installation and maintenance procedures. Refer to Section 6.05, System Options and Accessories, or a listing of available high-pressure regulators. An inline pneumatic dryer/evaporator type air filter, capable of filtering particulates to at least 5 microns with a dew point of 35°F (1.
3. Connect the gas supply to the Power Supply as follows: a. Remove the plasma and secondary gas hoses and adapters from the PLASMAand SECONDARY fittings at the rear panel. Adapter Fitting Plasma Gas Hose Plasma Gas Hose PLASMA GAS Fitting SECONDARY GAS Fitting PLASMA GAS Fitting Secondary Gas Hose SECONDARY GAS Fitting Adapter Fitting A-02162 Secondary Gas Hose Figure 3-8 Gas Connections Using Gas Cylinders c.
C. Using Plasma Shop Air And Secondary High-Pressure Gas Cylinder Plasma Gas Hose NOTES Refer to the regulator manufacturer’s specifications for installation and maintenance procedures. Refer to Section 6.05, System Options and Accessories, for a listing of available high-pressure regulators. PLASMA GAS Fitting Do not use an air line filter with high pressure gas cylinders. SECONDARY GAS Fitting 1. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material.
c. Connect the air supply hose (see note) to the Air Line Filter input port (IN) barb fitting and secure with a customer supplied hose clamp. NOTE 3.09 Connecting Torch Leads To System Without Optional Remote Arc Starter NOTE The supply hose must be 1/4 inch (6.3 mm) minimum inside diameter to provide adequate air flow. For Systems using the Optional Remote Arc Starter refer to Section 3.13 for connecting the Torch. D.
4. Feed the connector on the end of the CNC Control Cable through the rubber boot on the front panel of the Power Supply (see NOTE). NOTE Feed the Control Cable through the rubber boot first as there will not be enough space inside the rubber boot for the connector if the Coolant and Gas Leads have been fed through the rubber boot first. 5. Connect the CNC Control Cable connector to the Control Cable connector on the Torch Bulkhead Panel.
3.10 Ground Connections For Mechanized Applications A. Electromagnetic Interference (EMI) Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems: B. Grounding 5. Make sure work cable and ground cables are properly connected.
To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be as follows: 3. The following illustration shows proper connection of a customer-supplied ground cable to a grounding stud provided on the rear panel of the power supply. • For 115VAC: 3.0 VAC • For 230VAC: 1.5 VAC 115VAC: 3.0 VAC 230VAC: 1.5 VAC V~ V~ Meter set to VAC setting WARNING Use extreme caution. This test uses live voltage.
5. After the complete system has been installed do the following procedure to make sure the coolant has been pumped through the system (see NOTE): 3.11 Filling Power Supply Coolant The ambient temperature of the environment where the Power Supply will be located determines the coolant to be used. The Extra-CoolTM Torch Coolant supplied with the system can be used in ambient temperatures down to 10° F (-12° C).
3.12 External Control Connections CNC Knockout External control signal connections can be made to the Rear Panel of the power supply. Connections can be made to interface with CNC Controls, Standoff Control SC11 or Remote Hand Pendant. 1/2" (12.7 mm) Strain Relief (Customer Supplied) Depending on the option installed determines how the option is connected to the Power Supply. A. Computer Control Interface (CNC) A-02859 NOTE Used when Standoff Control SC11 are not used.
NOTES B. Optional Standoff Control SC11 Cable ARC V+ Power supply positive output voltage (work lead) connection to TB position 1 through a 100k resistor. ARC V- Power supply negative output voltage (torch electrode) connection to TB position 2 through a 100k resistor. START + signal at TB position 3, 15 vdc at 10 ma, must be brought low by connecting it to START at TB position 4, using a switch or relay contact, to start the plasma torch.
3. Mount the base assembly of the Arc Starter Box to the cutting table gantry using the four holes provided in the base. 3.13 Optional Remote Arc Starter A. Mounting Arc Starter Box NOTE Mount the Arc Starter Box to the cutting table gantry as follows: The last page of this Manual has a full size hole template for use in locating the mounting holes. 1. Remove the four screws securing the cover to the base assembly of the Arc Starter Box.
5. Connect the inner shield leads with red wires and ring terminals to the mounting stud on the bulkhead panel. B. Connecting Torch 6. Remove the nut and bolt mounted to the Remote Arc Starter front panel. Connect the outer shield leads with green/yellow wires and ring terminals to the mounting stud on the inside of the front panel. Secure the stud to the front panel with a hex nut. Connect a customersupplied external ground wire to the stud, outside the front panel, and secure with a hex nut.
5. Connect the control cable connector to the mating connector on the end of the Arc Starter Box. C. Connecting Torch Supply Leads 6. The Power Supply requires internal changes when the Optional Remote Arc Starter is to be used as follows: WARNING a. Open the Front Control/Access Panel. Disconnect primary power at the source before disassembling the torch or torch leads. b. Remove the panel by lifting the panel up and off the studs being careful not to damage the wiring.
SECTION 4: OPERATION A. Lower Front Panel 4.01 Introduction 1 This section provides a description of the Power Supply operating controls and procedures. Identification of the Front and Rear Panel components is followed by operating procedures. 2 4.02 Functional Overview The Power Supply provides a degree of operating flexibility and the use of simple controls. A-02170 4.
7. DC Indicator Green light indicates voltage is present at the power supply output and cutting current is available. C. Gas Control Front Panel 4 5 8 3 2 6 6 5 100 6 20 bar psi P L A S M A Plasma Gas A-02172 H2O Mist 4 3 5 2 20 5 1 80 S E C O N D A R Y 4 3 2 80 7 3 60 40 6 1 bar psi 100 60 40 Sec Lo-Flow Pressure Gas H2O Mist Lo-Flow Gas 1 7 4 2 Figure 4-4 Gas Control Front Panel 1. Plasma Gas Pressure Control 1 Adjusts plasma gas pressure.
7. Control Cable Connector D. Torch Bulkhead Connector is no longer used. Use connector located on Rear Panel. The torch bulkhead is located under the Control/Gauge Panel. E. Rear Panel 6 2 1 1. PLASMA Gas Input Fitting 5 1/4 NPT female gas fitting used to supply the plasma gas to the system. 3 7 2. SECONDARY Gas Input Fitting 1/4" NPT female gas fitting used to supply the secondary gas to the system. 3.
4.04 Sequence of Operation 8 The following is a typical sequence of operation for the cutting system. Refer to Appendix 2 for a block diagram. 9 1. Close main power source disconnect. 1 a. AC power is available at the Power Supply. 7 2 2. Place RUN/SET switch to RUN mode. 3. Place the ON/OFF power switch on the front panel of the Power Supply to ON. 3 6 a. Fan turns on. 4 b. Coolant Pump turns on. c. AC Power indicator blinks ON and OFF for eight seconds then stays ON.
10. Complete cutting operation. NOTE 4.05 Preparations for Operating Follow this set-up procedure each time the system is operated: If the torch is lifted from the workpiece, while still having the torch activated, the main arc will stop and the pilot arc will automatically restart. WARNING 11. Release or deactivate the torch switch. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and leads assemblies or adding coolant. a. Main arc stops. b.
Select the desired secondary gas as follows: c. Turn the knob clockwise to increase or counterclockwise to decrease gas pressure. 1. If gas secondary is desired, set secondary mode selector switch to gas cylinder symbol position. d. Push the knob back in to lock the pressure setting. e. Slowly close the valve on the top of the Plasma Gas flowmeter until the desired flow rate is achieved. NOTES Tap water should only be used for secondary gas on machine torches. 3.
Dross Build-up and Top Spatter 4.06 Cut Quality Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece.
4.07 System Operation Kerf Width NOTE Cut Surface Bevel Angle Frequently review the safety precautions in Section 1. Top Spatter This section contains operating information which is specific to the power supply. Detailed operating information for torches can be found in the appropriate Torch Instruction Manual.
B. Fold Back Feature Should the torch tip contact the workpiece or molten slag, the output current will immediately drop to 35 amps to minimize potential tip damage. Logic PC Board NOTE A-02258 The torch is not designed for drag cutting. 4.08 Optional Power Supply Settings The following functions can be used to tailor a system for special application requirements or unique user preferences. These functions are controlled by DIP switches located on the Logic Control PC board in the power supply.
B. Gas Pre-Flow Delay (SW3) The pre-flow delay allows time for gases to flow to the torch when the torch is activated. Pre-flow is immediately followed by pilot arc initiation. Gas Pre-Flow Delay is set depending on the total torch lead length used in the system. All power supplies are factory set at 2 seconds and must be reset either to 3.4 or 4 seconds as required if total torch lead length in the system is over 60 ft (18.3 m).
SECTION 5: SERVICE While the unit is open, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected. C. Coolant Filter Assembly 5.01 Introduction This section describes maintenance procedures, basic troubleshooting and service performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.
Coolant Hose Connection Coolant Hose Filter Filter Holder A-02153 Figure 5-2 In-Line Filter Assembly E. Coolant Level and Conductivity A-02178 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 (50 mm) from the top of the reservoir then add Torch Coolant. Figure 5-3 Draining Coolant From Reservoir 3. Reconnect the hose to the Coolant Filter Assembly. 2.
2. Main Arc Extinguishes 5.04 Common Operating Problems a. Cutting speed too slow b. Torch standoff too high from workpiece WARNINGS c. Cutting current too high Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. d. Work cable disconnected e. Worn torch parts f. Frequently review the Important Safety Precautions in Section 1. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection.
Basic Troubleshooting Left Side Cut Angle This manual covers a basic level of troubleshooting that requires limited disassembly and measurements. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair. Right Side Cut Angle Follow all instructions as listed and complete each section in the order presented. For major troubleshooting and parts replacement procedures refer to Merlin 1000 Power Supply Service Manual 0-2709.
2. Poor input or output connections B. AC Power Indicator ON; TEMP Indicator ON 1. Airflow obstructed a. Check all input and output connections. a. Check for obstructed air flow and correct condition. 3. Low plasma gas flow 2. Fan(s) blocked a. Check for leaks or restriction in gas supply line a. Check and correct condition b. Replace all Torch Consumables 3. Unit is overheated a. Allow unit to cool down for about 5 minutes. Make sure the unit has not been operated beyond duty cycle limit. 4.
3. Excessive oil or moisture in torch M. Leaking torch connection a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch) 4. Worn torch parts 1. Loose torch connection a. Check connection making sure connector is fully seated. N. Weak or sputtering pilot; HF stays on during pilot a. Replace torch consumables. 1. Plasma gas pressure too high 5. Using wrong gas for material being cut a. Adjust pressure a. Use correct gas for operation.
Troubleshooting With Optional Remote Arc Starter 5.06 Test Procedures For Optional Remote Arc Starter NOTE The following troubleshooting is to be used only if the system has the Optional Remote Arc Starter installed. WARNING High voltage may be present in the Arc Starter Box. Q. Start signal given to the Power Supply. Gas flows for selected pre-flow time. DC Indicator is OFF, does not even come ON momentarily. 1. Problem not in the Remote Arc Starter. The Power Supply is has no DC voltage output.
9. Measure for 36 VAC between J1-1 and J1-3 on the connector. 17. Measure between E1(+) and E2 (-) on the Arc Starter PC Board. • If 36 VAC is at the connector, Arc Starter PC Board is defective. WARNING • If 36 VAC is not present at J1 proceed to Step 10. DO NOT accidently measure P1 and P2, studs and brass nuts, where the CD Transformer (T1) connects to the Arc Starter PC Board. 10. Place the RUN/SET switch on the Power Supply to the RUN position. 11.
B. Fuse Replacement 5.07 Power Supply Parts Replacement 1. Remove the left side panel per paragraph "A" above. 2. Locate the internal fuse below the voltage selection block on the left side of the unit. WARNING 3. Replace the fuse (5 amp, 600V). 4. Reinstall the left side panel per paragraph "A" above. Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torch and leads assemblies. Voltage Selection Block A.
C. Coolant Filter Assembly Replacement D. In-Line Filter Assembly Replacement The Coolant Filter Assembly is located on the rear panel of power supply. The In-Line Filter Assembly is located inside behind the right side panel (viewed from the front of the unit). 1. Remove the two Coolant Hose connections to the Coolant Filter Assembly. 1. Remove the right side panel from the Power Supply per paragraph 'A' above. 2. Locate the In-Line Coolant Filter near the center of the unit. 3.
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Complete System Replacement Section 6.04 Power Supply Replacement Only Section 6.05 Basic Replacement Parts Section 6.06 Options and Accessories NOTE Parts listed without item numbers are not shown, but may be ordered by the catalog number shown. B.
6.03 Complete System Replacement Includes the following components: Power Supply with work cable and clamp, torch and leads (as ordered), coolant, torch spare parts kit, CNC interface cable and operating manual. Qty Description Catalog # 1 Merlin 1000 with 180° torch with 25 ft (7.6 m) Leads 1-9000 1 Merlin 1000 with 180° torch with 50 ft (15.2 m) Leads 1-9001 6.
APPENDIX 1: INPUT WIRING REQUIREMENTS Power Input Current Voltage Input Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) 208 220 230 240 380 415 460 (Hz) 50/60 50/60 50/60 50/60 50/60 50/60 50/60 (kVA) 23.4 24 24.7 24.9 24.4 24.4 24.
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION Close external disconnect switch ACTION Enable ON ON/OFF switch to ON ACTION RUN/SET switch to SET ACTION RUN/SET switch to RUN RESULT • Power to system RESULT • AC indicator ON • TEMP Indicator ON • GAS indicator ON • Fan and pump ON • 20 second auto-purge RESULT • Gas solenoids open, gases flow to set pressures • GAS indicator ON RESULT • Gas flow stops • Power circuit ready • GAS indicator OFF ACTION Protect eyes and activate torch ACTION
APPENDIX 3: TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM Connection for Systems Without Standoff Control Standoff Control CNC Control CNC Control Earth Ground Plasma Power Supply 3-Phase Input Work Cable Workpiece Earth Ground Earth Ground A-02176 NOTE Work Cable must connect direct to workpiece. DO NOT connect Work Cable to earth ground and then to workpiece.
APPENDIX 4: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM NOTE Refer to Appendix 5 for complete data on the Cables and Hoses.
APPENDIX 5: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES Identifier Description Catalog # A Remote Standoff Control Cable 50 ft (15.2 m) 9-9021 75 ft (22.9 m) 9-9022 100 ft (30.5 m) 9-9023 B* Remote Arc Starter Control Cable 35 ft (10.7 m) 9-9016 50 ft (15.2 m) 9-9017 75 ft (22.9 m) 9-9018 100 ft (30.5 m) 9-9019 C Work Cable, 22 ft (6.7 m) 9-7792 D Lifter Motor Cable 10 ft (3.0 m) 9-4535 15 ft (4.6 m) 9-4536 20 ft (6.1 m) 9-4537 25 ft (7.6 m) 9-4538 40 ft (12.2 m) 9-7795 50 ft (15.
APPENDIX 6: POWER SUPPLY CNC INTERFACE DIAGRAM WITHOUT STANDOFF CONTROL NOTE Cable connections from Cutting Machine Controller (CNC) to Plasma Power Supply without any Standoff Control Accessory.
A-02131 APPENDIX 7: OPTIONAL REMOTE ARC STARTER INTERCONNECTING DIAGRAM Manual 0-2708 A-7 APPENDIX
APPENDIX 8: 36 VAC CIRCUIT DIAGRAM CD PC Board 2 3 1 J11 J5 2 3 Pilot/Output PC Board 14 15 16 J13 1 17 18 19 Logic PC Board J4 J9 5 7 3 2 1 4 5 7 3 2 1 4 J1 3 Auxiliary Transformer Outputs 36 VAC 5 1 115 VAC 2 6 Gate Drive PC Board Input Voltage Sense A-02325 J3 3 1 2 4 ON/OFF Switch J9 1 2 3 J4-5 J4-7 4 5 Gate Drive PC Board 7 APPENDIX A-8 Manual 0-2708
APPENDIX 9: ROUTINE MAINTENANCE SCHEDULE 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. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Arc Hours: 1. Check torch parts, replace if damaged. 2. Check plasma and secondary supply and pressure/flow. 3.
APPENDIX 10: SYSTEM SCHEMATIC Art # A-04329 APPENDIX A-10 Manual 0-2708
Art # A-04329 Manual 0-2708 A-11 APPENDIX
