ESAB MERLIN® 1000 Automated Plasma Cutting Power Supply User manual

Brand: ESAB

Model: MERLIN® 1000 Automated Plasma Cutting Power Supply

Category: Welding System

Type: User manual

This manual is also suitable for

MERLIN® 1000 Automated Plasma Cutting Power Supply (CE)

Manual No. 0-2731

September 30, 1999

MERLIN

1000

Automated Plasma Cutting

Power Supply (CE)

Operating Manual

A-02157

WARNING

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 our

best judgement, Thermal Dynamics Corporation assumes no

liability for its use.

Merlin

1000 Automated Plasma Cutting Power Supply (CE)

Operating Manual Number 0-2731

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written

permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liabil-

ity to any party for any loss or damage caused by any error or

omission in the Merlin

1000 Automated Plasma Cutting Power

Supply (CE) Operating Manual, whether such error results from

negligence, accident, or any other cause.

Printed in the United States of America

September 30, 1999

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION .................................................................................................. 1

1.01 Notes, Cautions and Warnings ...................................................................... 1

1.02 Important Safety Precautions ........................................................................ 1

1.03 Publications ................................................................................................... 2

1.04 Note, Attention et Avertissement ................................................................... 3

1.05 Precautions De Securite Importantes ............................................................ 3

1.06 Documents De Reference ............................................................................. 5

1.07 Declaration of Conformity .............................................................................. 7

1.08 Statement of Warranty ................................................................................... 8

SECTION 2:

INTRODUCTION ................................................................................................................. 9

2.01 Scope of Manual............................................................................................ 9

2.02 Power Supply General Description ................................................................ 9

2.03 Specifications & Design Features ................................................................ 10

2.04 Power Supply Options and Accessories ...................................................... 11

2.05 Theory Of Operation.................................................................................... 11

SECTION 3:

INSTALLATION PROCEDURES ........................................................................................ 13

3.01 Introduction.................................................................................................. 13

3.02 Site Selection............................................................................................... 13

3.03 Unpacking ................................................................................................... 13

3.04 Input Power Cable Connections................................................................... 13

3.05 Gas Connections......................................................................................... 14

3.06 Connecting Torch Leads To System Without Optional Remote Arc Starter .. 17

3.07 Work Cable And Ground Connections ......................................................... 18

3.08 Filling Power Supply Coolant ....................................................................... 19

3.09 External Cable Connections ........................................................................ 20

3.10 Lifting Options.............................................................................................. 20

3.11 Optional Remote Arc Starter ....................................................................... 21

SECTION 4:

OPERATION ...................................................................................................................... 25

4.01 Introduction.................................................................................................. 25

4.02 Functional Overview .................................................................................... 25

4.03 Front and Rear Panel Descriptions .............................................................. 25

4.04 Sequence of Operation................................................................................ 28

4.05 Preparations for Operating........................................................................... 29

4.06 Cut Quality................................................................................................... 30

4.07 System Operation........................................................................................ 32

4.08 Optional Power Supply Settings................................................................... 32

TABLE OF CONTENTS (continued)

SECTION 5:

MAINTENANCE & CUSTOMER/OPERATOR SERVICE................................................... 35

5.01 Introduction.................................................................................................. 35

5.02 Recommended Routine Maintenance Schedule .......................................... 35

5.03 General Maintenance .................................................................................. 35

5.03 Common Operating Faults........................................................................... 37

5.04 Common Operating Problems ..................................................................... 37

5.05 Troubleshooting Guide ................................................................................. 38

5.07 Test Procedures For Optional Remote Arc Starter....................................... 41

5.08 Power Supply Parts Replacement ............................................................... 43

SECTION 6:

PARTS LISTS.....................................................................................................................45

6.01 Introduction.................................................................................................. 45

6.02 Ordering Information.................................................................................... 45

6.03 Complete System Replacements ................................................................ 46

6.04 Power Supply Replacement Only ................................................................ 46

6.05 Basic Replacement Parts ............................................................................ 46

6.06 Options and Accessories............................................................................. 46

APPENDIX I: INPUT WIRING REQUIREMENTS ...................................................................... 47

APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 48

APPENDIX III: TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM ........................... 49

APPENDIX IV: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM .. 50

APPENDIX V: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES ........... 51

APPENDIX VI: POWER SUPPLY CNC INTERFACE DIAGRAM................................................ 52

APPENDIX VII: OPTIONAL REMOTE ARC STARTER INTERCONNECTING DIAGRAM......... 53

APPENDIX VIII: 36 VAC CIRCUIT DIAGRAM ............................................................................ 54

APPENDIX IX: SYSTEM SCHEMATIC ...................................................................................... 56

Date: 6/22/99 1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

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.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS)

that should be supplied with the material you are

using. These MSDSs will give you the information

regarding the kind and amount of fumes and gases

that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection

1.03, Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live” or

“hot.”

• Wear dry gloves and clothing. Insulate yourself from

the work piece or other parts of the welding cir-

cuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

GENERAL INFORMATION 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 before performing any ser-

vice or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have held

combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

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. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS,

29CFR 1910, obtainable from the Superintendent of

Documents, U.S. Government Printing Office, Wash-

ington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELD-

ING AND GAS WELDING AND CUTTING, obtain-

able from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-

CUPATION AND EDUCATIONAL EYE AND FACE

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the

American National Standards Institute, 1430 Broad-

way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES,

obtainable from American National Standards Insti-

tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

Date: 6/22/99 3 GENERAL INFORMATION

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from

the Compressed Gas Association, 1235 Jefferson

Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING, obtainable from the Ca-

nadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W

1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-

PHY obtainable from the National Welding Supply

Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, REC-

OMMENDED SAFE PRACTICES FOR THE PREPA-

RATION FOR WELDING AND CUTTING OF CON-

TAINERS AND PIPING THAT HAVE HELD

HAZARDOUS SUBSTANCES, obtainable from the

American Welding Society, 550 N.W. LeJeune Rd,

Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-

TORY PROTECTION, obtainable from American

National Standards Institute, 1430 Broadway, New

York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

• Eloignez toute fumée et gaz de votre zone de respi-

ration. 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.

GENERAL INFORMATION 4 Date 6/22/99

• 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. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un

ou plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des

gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans

une zone où se trouvent des matières ou des gaz

combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou

“vive”; portez des gants et des vêtements secs.

Isolez-vous de la pièce de travail ou des autres par-

ties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la

page 5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel

de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail.

Protégez toute telle matière qu’il est impossible de

retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail

dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler

sous les pièces de travail en aluminium lorsqu’elles

sont coupées sous l’eau ou sur une table d’eau. NE

PAS couper les alliages en aluminium sous l’eau ou

sur une table d’eau à moins que le gas hydrogène

peut s’échapper ou se dissiper. Le gas hydrogène

accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de plasma

produit une lumière infra-rouge et des rayons ultra-vio-

lets 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 lu-

nettes de protection ou une autre sorte de protec-

tion oculaire.

• Portez des gants de soudeur et un vêtement

protecteur approprié pour protéger votre peau

contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protec-

tion en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant

des cabines ou des écrans de protection.

Date: 6/22/99 5 GENERAL INFORMATION

• 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. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres

personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer

que les décibels (le bruit) ne dépassent pas les

niveaux sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus

récentes ayant été faites à celles-ci pour de plus amples

renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET

DE PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Docu-

ments, U.S. Government Printing Office, Washing-

ton, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine de

Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES

OPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA

PROTECTION DES YEUX ET DU VISAGE AU

TRAVAIL ET DANS LES ECOLES, disponible de

l’Institut Américain des Normes Nationales (Ameri-

can National Standards Institute), 1430 Broadway,

New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES

INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS

DE COUPE ET DE SOUDAGE, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du

Soudage (AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES

PRODUITS COMBUSTIBLES, disponible auprès de

la American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection 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. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ

DU SOUDAGE, disponible auprès de l’Association

Nationale de Fournitures de Soudage (National

Welding Supply Association), 1900 Arch Street,

Philadelphia, PA 19103

GENERAL INFORMATION 6 Date 6/22/99

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRA-

TIQUES SURES POUR LA PRÉPARATION À LA

COUPE ET AU SOUDAGE DE CONTENEURS

ET TUYAUX AYANT RENFERMÉ DES

PRODUITS DANGEREUX , disponible auprès de

la American Welding Society, 550 N.W. LeJeune

Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-

TION RESPIRATOIRE, disponible auprès de

l’American National Standards Institute, 1430

Broadway, New York, NY 10018

Date: 6/22/99 7 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: Industrial Park #2

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc-

tive’ (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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"

(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture

a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and

related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing

process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our

area of manufacture.

Manufacturers responsible representative: Steve Ward

Director of Operations

Thermadyne UK

Chorley England

GENERAL INFORMATION 8 Date 6/22/99

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. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus Series & Parts Parts

PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation

charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall

be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective May 6, 1999

Manual 0-2731 9 INTRODUCTION

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 (CE). Service

of this equipment is restricted to Thermal Dynamics

trained personnel; unqualified personnel are strictly cau-

tioned against attempting repairs or adjustments not cov-

ered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understand-

ing of the characteristics and capabilities of this equip-

ment will assure the dependable operation for which it

was designed.

2.02 Power Supply General

Description

This Power Supply is designed to cut most metals up to

1-1/4 inches (31.8 mm) using air, oxygen, nitrogen, or ar-

gon/hydrogen as the plasma gas. This system is also ca-

pable of satisfying many mechanized gouging applica-

tions.

The Merlin 1000 is designed to use the Maximizer 300

torch in automated applications. Torch will provide pierc-

ing and production cutting up to 1/2 inch (12.7 mm) and

maximum cut capacity of 1-1/4 inches (31.8 mm). The

torch is available in the following configurations:

• 180° Torch Head using 1-3/8 inch diameter Rack

and Pinion Mounting Assembly

• 70° or 90° Torch Head with Machine Mounting Point

NOTE

For more information about the Maximizer Torch,

refer to Instruction Manual 0-2710.

This unit provides 100 amp maximum output and in-

cludes all control circuitry, electrical and gas inputs and

outputs, pilot circuitry, torch leads receptacle and a 20

foot (6.1 m) work cable with ring terminal. All Merlin

1000 systems also include a CNC Interface Cable or Re-

mote Pendant Control.

NOTE

The power supply can be ordered in various op-

tions factory installed.

Refer to Section 2.04 for list of Power Supply Op-

tions and Accessories.

A-02157

Figure 2-1 Merlin 1000 Power Supply

The Standard Coolant supplied with the Power Supply

can be used in ambient temperatures down to 10° F

(-12° C). If the ambient temperature will be below 10° F

(-12° C) then Super Coolant should be used. This coolant

can be used in areas where the ambient temperature drops

to -34° F (-36° C).

A. Typical System

A typical system configuration will contain the follow-

ing:

• Power Supply

• 20 ft (6.1 m) Work Cable and Ring Terminal

• Maximizer 300 180° Torch with 25 ft (7.6 m) or 50 ft

(15.2 m) Lead length as ordered

• Maximizer 300 Spare Parts Kit

• CNC Interface Cable 25 ft (7.6 m) or 50 ft (15.2 m)

length as ordered or Remote Pendant Control

• Standard Thermal Arc Coolant - 3 gallons

NOTE

Refer to Section 2.04 for complete list of Power Sup-

ply Options and Accessories.

INTRODUCTION 10 Manual 0-2731

B. Requirements to Complete System

To complete the system, the user needs to provide the

following:

• Primary input power

• Gas supplies

2.03 Specifications & Design

Features

The following specifications apply to the Power Supply

only:

1. Front Panel Controls

• ON/OFF and RUN/SET Switches

• Output Current Control

• Work Cable Connection

• Torch Leads Connection

2. Front Panel LED Indicators

• AC

• TEMP

• GAS Pressure/Coolant Flow

• DC Output

3. Gas Control Panel

• Plasma and Secondary Gas Pressure Controls and

Gauges

• Plasma Gas Flowmeter

• Secondary Lo-Flow Gas Flowmeter

• Secondary Mode Selector Switch

• Secondary Water Mist Flowmeter

4. Rear Panel

• Primary Input Power Cable Strain Relief

• Plasma Gas Supply Connection

• Secondary Gas Supply Connection

• Secondary Water Supply Connection

• Dual Stage Air Filter

5. Input Power (see NOTES)

380-415 VAC (±10%), 50/60 Hz, Three-Phase

NOTES

Refer to Appendix I for suggested input wiring size,

current ratings and circuit protection requirements.

6. Output Power

Continuously variable from 30 to 100 amps (±5%)

7. Duty Cycle

100% Duty Cycle @ 130V output at 100 amps

8. Cut Capacity

Pierce and Production Rating: 1/2 inch (12.7 mm)

9 Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC (See Note)

NOTE

Optional Remote Arc Starter available.

10. CNC Interface Signals

Start/Stop and OK-To-Move

11. Coolant Pressure

Internal Service-adjustable

130 psi (8.8 bar) at zero flow

120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)

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 con-

figuration, ambient temperature, amperage level,

etc.

13. Cooling Capacity

4,000 to 10,000 BTU

NOTE

Maximum value based on “free flow” condition.

14. Coolant Reservoir Capacity

2 gallons (Use Thermal Arc

coolant only)

Capable of handling a total of 150 feet of torch lead

length

15. Secondary Water

Clean drinking quality tap water can be used as a sec-

ondary and must be capable of delivering the follow-

ing minimums:

• Water pressure of 50 - 100 psi (3.5 - 6.9 bar)

• Flow of 9 gph (34 lph)

Manual 0-2731 11 INTRODUCTION

16. Overall Dimensions

Height: 40-1/2 inches (1.03 m)

Width: 20-1/2 in (0.52 m)

Depth: 30-1/4 inches (0.77 m)

17. Weight

Power Supply with Torch: 275 lbs (125 kg)

2.04 Power Supply Options and

Accessories

NOTE

Refer to Section 6, Parts Lists, for part numbers

and ordering information.

The following are accessories that are available for this

Power Supply:

A. High Pressure Regulators

High pressure regulators are available for air, oxygen,

argon-hydrogen and nitrogen. The regulators are used

to set the proper pressure for the type of gas being

used.

B. Standoff Control (SC11)

Optional Standoff Control automatically finds height

and maintains torch standoff with a high speed torch

lifter motor. Refer to Standoff Control (SC11) Manual,

0-2556, for more information.

C. Remote Arc Starter

Option available to remote the arc starting circuits

closer to the Torch Head Assembly. The option in-

cludes a Remote Arc Starter and Torch Supply Leads.

The Torch Supply Leads are available in 25 ft (7.6 m)

to 100 ft (30.5 m) lengths.

D. Remote Pendant Control

Control used to manually start and stop cutting op-

erations from a location up to 25 ft (7.6 m) from the

Plasma Power Supply.

2.05 Theory Of Operation

A. Plasma Arc Cutting and Gouging

Plasma is a gas which is heated to an extremely high tem-

perature and ionized so that it becomes electrically con-

ductive. 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.

With a simple change of torch parts, the system can also

be used for plasma arc gouging. Plasma arc gouging uses

the same process to remove material to a controlled depth

and width.

B. Input and Output Power

The unit converts AC input power to DC power for the

main cutting arc. The negative output is connected to

the torch electrode through the negative torch lead, and

the positive output connects to the workpiece through

the work cable.

C. Pilot Arc

When the torch is activated there is a 2 second (service

adjustable) gas pre-flow, followed by an uninterrupted

pulsed DC pilot arc established between the electrode and

tip. The pilot arc is initiated by a momentary high fre-

quency pulse from the Power Supply or the Optional

Remote Arc Starter. The pilot creates a path for the main

arc to transfer to the work. When the main arc is estab-

lished, the pilot arc shuts off. The pilot automatically re-

starts when the main arc stops, as long as the torch re-

mains activated.

D. Main Cutting Arc

The power supply converts the AC input power to DC

power for the main cutting arc. The negative output is

connected to the torch electrode through the negative

torch lead. The positive output is connected to the work-

piece via the work cable and ring lug connection.

E. RF Shielding

All machine torch systems are shielded to minimize ra-

dio frequency (RF) interference which results from the

high frequency arc initiation. These shielded systems are

designed with features such as a wire for establishing an

earth ground and shielded torch and control leads.

F. Interlocks

The system has several built-in interlocks to provide safe

and efficient operation. When an interlock shuts down

the system, the fault condition must be remedied and the

system recycled using the applicable control device.

1. Parts-In-Place (PIP) Interlock

The Power Supply has a built-in parts-in-place in-

terlock that prevents accidental torch starting

when torch parts are not properly installed. A flow

switch on the coolant return lead detects reduced

coolant flow caused by improper torch assembly.

If not satisfied, the switch interrupts power to the

tip and electrode.

INTRODUCTION 12 Manual 0-2731

2. Gas Pressure Interlock

A pressure switch acts as an interlock for the

plasma gas supply. If the plasma gas supply pres-

sure falls below minimum requirements the pres-

sure switch will open, shutting off the power to

the contactors, and the GAS indicator will go out.

When adequate plasma supply pressure is avail-

able the pressure switch will close, allowing power

to be resumed for cutting.

NOTE

There is no gas pressure interlock for secondary

gas.

Manual 0-2731 13 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

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. It is recommended

that all sub-sections be read for general informa-

tion.

This section describes installation of the Power Supply

and connecting the Torch.

These instructions apply to the Power Supply only; in-

stallation procedures for the Torch, Options, and Acces-

sories are given in Manuals specifically provided for those

units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input power

b. Work cable

c. Gas connections

d. Torch Installation

e. Connecting auxiliary devices

4. Grounding

5. Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and ad-

equate working space around all components.

NOTE

Review Important Safety Precautions (page 1) to

be sure that the selected location meets all safety

requirements.

The power supply is fan cooled by air flow through the

front panel to the rear panel. Air flow must not be ob-

structed. Provide at least 2 feet (0.61 m) in the rear and at

least 6 inches (0.15 m) on each side for clearance . Pro-

vide sufficient clearance in front of the unit to allow ac-

cess to the front panel controls (minimum 6 inches or 0.15

m).

CAUTION

Operation without proper air flow will inhibit

proper cooling and reduce duty cycle.

Review the safety precautions in the front of this manual

to be sure that the location meets all safety requirements.

3.03 Unpacking

NOTE

Equipment that was ordered as a system is pack-

aged in one shipping carton. All options and the

torch are factory installed.

Each component of the system is packaged and protected

with a carton and packing material to prevent damage

during shipping.

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify

and account for each item.

3. Inspect each item for possible shipping damage. If

damage is evident, contact your distributor and/or

shipping company before proceeding with system

installation.

3.04 Input Power Cable Connections

The Power Supply is factory wired to accept input volt-

ages of 380-415 VAC, 50 or 60 Hz, three-phase power.

A. Power Source

The power source must conform to local and national elec-

tric codes. For suggested circuit protection and wiring

requirements refer to Appendix I.

WARNING

Disconnect primary power at the source before as-

sembling or disassembling the Power Supply, torch

parts, or torch and leads assemblies.

B. Input Power Cable Connections

The shielded input power cable must be connected to a

380-415 VAC, three-phase power source. Refer to the fol-

lowing procedure:

INSTALLATION PROCEDURES 14 Manual 0-2731

CAUTION

The input power cable must not be modified in any

way as shielding is installed on the cable.

1. At the free end of the input power cable, cut back

the insulation on the individual wires approxi-

mately 1/8 - 3/16 inch (3-5 mm).

2. Connect the ends of the individual wires and shield

to a customer supplied plug or disconnect box per

the following (see NOTES):

• Brown wire to Line 1 (Live)

• Blue wire to Line 2 (Live)

• Black wire to Line 3 (Live)

• Yellow/Green wire to Ground (power ground)

• Cable shield to earth ground

NOTES

The shield braid on the free end of the input cable

must be connected to a solid earth ground with as

short a connection as possible at the plug or dis-

connect box. Refer to Subsection 3.07 for proce-

dures on installing an earth ground.

Make sure that the yellow/green wire is connected

to power line safety ground.

3.05 Gas Connections

The Power Supply provides the liquid cooling and gases

to support operation of the Liquid Cooled Maximizer 300

Torch.

NOTE

Refer to the Liquid Cooled Maximizer 300 Torch

Instruction Manual (Cat. No. 0-2710) for infor-

mation on plasma and secondary gas selection and

requirements.

The following are available gases that can be used with

the Liquid Cooled Maximizer 300 Torch:

Plasma Gases: Compressed Air, Oxygen (O2), Nitro-

gen (N2), or Argon/Hydrogen (Ar/H2)

Secondary Gases: Compressed Air, Oxygen (O2),

Nitrogen (N2), Carbon Dioxide (CO2), or Tap Water

Gas requirements vary depending on the application. The

gases are connected to the rear panel connections of the

power supply. Depending on the options installed and

the source of the gases will determine the installation of

filters and regulators.

This sub-section includes information for connecting the

gas supplies to the Power Supply. The information is

grouped in paragraphs for different types of gases and

options per the following:

A. Using Shop Air

B. Using High-Pressure Gas Cylinders

C. Using Plasma Shop Air and Secondary High-

Pressure Gas Cylinder

D. Using Water Secondary

Refer to the appropriate paragraph(s) for the desired ap-

plication to be used.

A. Using Shop Air

NOTE

The Two Stage Air Line Filter Assembly is to be

used when using shop air as the Plasma Gas.

An inline pneumatic dryer/evaporator type air filter, ca-

pable of filtering particulates to at least 5 microns with a

dew point of 35°F (1.7°C), is required when using air from

a compressor. This type filter will insure that moisture,

oil, dirt, chips, rust particles, and other contminants from

the supply hose do not enter the torch. For highly auto-

mated applications, a refrigerated drier plus a particu-

late filter may be used to chill the air to remove all mois-

ture.

CAUTION

Excessive oil or moisture in compressed air will

reduce torch parts life and cutting performance and

may cause torch failure.

All Merlin 1000 Systems are supplied with a Two Stage

Air Line Filter attached to the rear of the Power Supply.

The following procedure is the recommended shop air

connection method:

Connect the air supply hose (see note) to the Air Line

Filter input port (IN) barb fitting and secure with a cus-

tomer supplied hose clamp.

Manual 0-2731 15 INSTALLATION PROCEDURES

A-02348

Air Supply Hose

(Customer Supplied)

Two-Stage

Air Filter

PLASMA GAS

SECONDARY

GAS

Barb Fitting

Figure 3-1 Supply Hose Connections

NOTE

The supply hose must be 1/4 inch (6.3 mm) mini-

mum inside diameter to provide adequate air flow.

B. Using High-Pressure Gas Cylinders

NOTES

Refer to the regulator manufacturer’s specifications

for installation and maintenance procedures. Re-

fer to Section 6.05, System Options and Accesso-

ries, or a listing of available high-pressure regula-

tors.

Do not use an air line filter with high pressure gas

cylinders.

1. Examine the cylinder valves to be sure they are clean

and free of oil, grease or any foreign material. Mo-

mentarily open each cylinder valve to blow out any

dust which may be present.

WARNING

Do not stand in front of the valve outlet when open-

ing.

2. Each cylinder must be equipped with an adjustable

high-pressure regulator capable of pressures up to 125

psi (8.6 BAR) maximum and flows of up to 700 scfh

(328 lpm) for cutting or gouging.

CAUTION

Maximum input pressure to the internal regula-

tor on the Power Supply must not exceed 125 psi

(8.6 BAR).

NOTE

A typical 50 lb. CO2 cylinder can deliver a con-

tinuous flow rate of 35 scfh (16.5 lpm). To obtain

the required flow rate for the torch, it may be nec-

essary to manifold several CO2 cylinders. Con-

tinuous flow requirements will depend on the spe-

cific application and duty cycle.

3. Connect the gas supply to the Power Supply per

the following:

a. Remove the plasma and secondary gas hoses

and adapters from the PLASMA and SECOND-

ARY fittings at the rear panel.

PLASMA GAS

Fitting

SECONDARY

GAS Fitting

Plasma Gas

Hose

Secondary Gas

Hose

Adapter

Fitting

A-02355

Adapter Fitting

Figure 3-2 Removal Of Factory Installed Hardware

b. Connect the gas hose from the plasma gas

source directly to the input fitting on the rear

panel of the Power Supply marked PLASMA.

INSTALLATION PROCEDURES 16 Manual 0-2731

PLASMA GAS

Fitting

SECONDARY

GAS Fitting

Plasma Gas

Hose

Secondary Gas

Hose

A-02349

Figure 3-3 Gas Connections Using Gas Cylinders

c. Connect the gas supply hose from the second-

ary gas supply directly to the input fitting on

the rear panel of the Power Supply marked

SECONDARY.

C. Using Plasma Shop Air And Secondary

High-Pressure Gas Cylinder

NOTES

Refer to the regulator manufacturer’s specifications

for installation and maintenance procedures. Re-

fer to Section 6.05, System Options and Accesso-

ries, for a listing of available high-pressure regu-

lators.

Do not use an air line filter with high pressure gas

cylinders.

1. Examine the cylinder valves to be sure they are clean

and free of oil, grease or any foreign material. Mo-

mentarily open each cylinder valve to blow out any

dust which may be present.

WARNING

Do not stand in front of the valve outlet when open-

ing.

2. Each cylinder must be equipped with an adjustable

high-pressure regulator capable of pressures up to 125

psi (8.6 BAR) maximum and flows of up to 700 scfh

(328 lpm) for cutting or gouging.

CAUTION

Maximum input pressure to the internal regula-

tor on the Power Supply must not exceed 125 psi

(8.6 BAR).

NOTE

A typical 50 lb. CO2 cylinder can deliver a con-

tinuous flow rate of 35 scfh (16.5 lpm). To obtain

the required flow rate for the torch, it may be nec-

essary to manifold several CO2 cylinders. Con-

tinuous flow requirements will depend on the spe-

cific application and duty cycle.

3. Connect the gas supply to the Power Supply per

the following:

a. Remove the secondary gas hose and adapter

from the SECONDARY fitting at the rear panel.

PLASMA GAS

Fitting

SECONDARY

GAS Fitting

Plasma Gas

Hose

Secondary Gas

Hose

A-02356

Adapter Fitting

Figure 3-4 Removal Of Factory Installed Hardwre

b. Connect the gas supply hose from the second-

ary gas supply directly to the input fitting on

the rear panel of the Power Supply marked

SECONDARY.

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