Tweco 15XC Merlin Bedienungsanleitung

August 19, 2005 Manual No. 0-2251PLASMA CUTTINGSYSTEMMerlin® PAK® 15XC™Instruction Manual

GENERAL INFORMATION 1-4 Date: January 27, 2004• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fum

CUSTOMER/OPERATOR SERVICE 5-28 Manual 0-22515.12 SERVICE AND TEST PROCEDURES (continued)1. Check the voltage input from F2 (wire #10) to J6-9 for100

Manual 0-2251 5-29 CUSTOMER/OPERATOR SERVICE5.12 SERVICE AND TEST PROCEDURES (continued)120 VAC is supplied to the motor control contactors (MC1and M

CUSTOMER/OPERATOR SERVICE 5-30 Manual 0-22515.12 SERVICE AND TEST PROCEDURES (continued)If a diode fails, check the potential causes of diode failure

Manual 0-2251 5-31 CUSTOMER/OPERATOR SERVICE5.12 SERVICE AND TEST PROCEDURES (continued)F. Pressure Sensing Circuit(continued)G. Gas Solenoid Circuit

CUSTOMER/OPERATOR SERVICE 5-32 Manual 0-22515.12 SERVICE AND TEST PROCEDURES (continued)J. Main Contactor Circuit(W1 and W2)Only one of the two main

Manual 0-2251 5-33 CUSTOMER/OPERATOR SERVICE5.12 SERVICE AND TEST PROCEDURES (continued)1. If the start LED (D57) does not light, use the negativevol

CUSTOMER/OPERATOR SERVICE 5-34 Manual 0-22515.12 SERVICE AND TEST PROCEDURES (continued)K. Switching TransistorCheck (continued)The PWM compares shun

Manual 0-2251 5-35 CUSTOMER/OPERATOR SERVICE5.12 SERVICE AND TEST PROCEDURES (continued)M. Current Control CheckThe current control pot receives its

CUSTOMER/OPERATOR SERVICE 5-36 Manual 0-2251

Manual 0-2251 6-1 PARTS LISTSSECTION 6: PARTS LISTS6.1 ABOUT THE PARTS LISTSection 6.2 System Components and AccessoriesSection 6.3 Access Panel Com

Date: January 27, 2004 1-5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous p

PARTS LISTS 6-2 Manual 0-22516.2 SYSTEM COMPONENTS AND ACCESSORIESItem Qty. Catalog DescriptionNo. Number1 1 3-2752 PAK 15XC Power Supply With Runnin

Manual 0-2251 6-3 PARTS LISTSA-009661235648791011121314151716

PARTS LISTS 6-4 Manual 0-2251Item Qty. Catalog Description ReferenceNo. Number Designator1 8-3257 Access Panel Assembly (Complete)1 1 8-3308 Access Pa

Manual 0-2251 6-5 PARTS LISTS6.4 FRONT PANEL/CHASSIS COMPONENTSItem Qty. Catalog Description ReferenceNo. Number Designator1 1 8-3305 Front Panel (wi

PARTS LISTS 6-6 Manual 0-22516.5 REAR PANEL COMPONENTSItem Qty. Catalog Description ReferenceNo. Number Designator1 1 8-5574 Rear Panel2 1 8-6312 Fan

Manual 0-2251 6-7 PARTS LISTS123456789101112131415161718192021222324252627282930311818202120203A-00969

PARTS LISTS 6-8 Manual 0-22511 1 8-5145 Base2 2 8-5578 Caster3 2 8-5579 Wheel4 1 9-1243 Axle5 2 9-5539 Retaining Ring6 1 8-6143 Inductor Base Mat7 1 8

Manual 0-2251 6-9 PARTS LISTS9101211123413145615167817181920212223242120A-0089426259

PARTS LISTS 6-10 Manual 0-22511 1 9-1302 Upper Chassis/Gauge Panel2 1 9-4381 Current Driver PC Board Assembly (See NOTE)3 2 9-1054 PC Board Guide4 1 9

Manual 0-2251 6-11 PARTS LISTS12345678910111213141516171819202122232425262829303132333436373940414243223341252430353810930272233337A-00970272844

GENERAL INFORMATION 1-6 Date: January 27, 20049. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection As

PARTS LISTS 6-12 Manual 0-22511 1 9-1404 Main Heatsink2 4 9-1303 Capacitor - 550 mfd, 400VDC C7-103 1 8-4521 Capacitor/Heatsink Bracket4 1 8-2176 Air

Manual 0-2251 6-13 PARTS LISTS12345691011121314151617181920212223242526282930313233111892221717111127Art # A-0605431313131313178(J1)

PARTS LISTS 6-14 Manual 0-22516.9 TORCH COMPONENTSItem Qty. Catalog DescriptionNo. Number1 2-2380 PCH-150 70° Hand Torch with Air Parts1 2-2381 PCH-1

Manual 0-2251 6-15 PARTS LISTSA-00972211234567891011121316141718191520

PARTS LISTS 6-16 Manual 0-22516.10 TORCH ACCESSORIES1 1 9-1063 Handle2 1 9-1246 Switch Assembly3 1 9-1064 Switch Retaining Sheath4 1 8-2158 Adaptor5

Manual 0-2251 A-1 APPENDIXAPPENDIX 1: LADDER DIAGRAM - 120 VAC5A, 250 VACACT1MC1MC2W1W2PCRK1-AK5K3K4K2HFWS110110932424LOGIC BOARD23505T3 HIGH FREQPSR

APPENDIX A-2 Manual 0-2251APPENDIX 2: LADDER DIAGRAM - 15 VDC3LOGIC CONTROL BOARD131119152117597241112181420164862212K4K3K2K5K1PLASMASECONDARYGASCONT

Manual 0-2251 A-3 APPENDIXAPPENDIX 3: DIGITAL CURRENT CONTROL INTERFACEA-01579

APPENDIX A-4 Manual 0-2251APPENDIX 4: CNC INTERFACEA-01580

Manual 0-2251 A-5 APPENDIXAPPENDIX 5: POWER SUPPLY TO REMOTE CONTROLCABLE INTERFACEA-01581

Date: January 27, 2004 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest

APPENDIX A-6 Manual 0-2251APPENDIX 6: REMOTE CONTROL CHASSIS SCHEMATICA-01582

Manual 0-2251 A-7 APPENDIXAPPENDIX 7: ROUTINE MAINTENANCE SCHEDULEThis recommended schedule applies to all types of water cooled plasma cutting syste

APPENDIX A-8 Manual 0-2251APPENDIX 8: SYSTEM SCHEMATICArt # A-05857

Manual 0-2251 A-9 APPENDIXArt # A-05857

GENERAL INFORMATION 1-8 Date: January 27, 20041.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warr

Manual 0-2251 2-1 INTRODUCTION & DESCRIPTIONSECTION 2: INTRODUCTION & DESCRIPTION2.1 SYSTEM DESCRIPTION• PAK 15XC 150 Amp Power Supplywith R

INTRODUCTION & DESCRIPTION 2-2 Manual 0-22512.2 POWER SUPPLY SPECIFICATIONSVoltage Frequency Phase Amperage200/220/230 50 or 60 Hz 3 84/76/73380/

Manual 0-2251 2-3 INTRODUCTION & DESCRIPTION2.3 TORCH SPECIFICATIONS• PCH-150 90° Hand Torch• PCH-150 70° Hand Torch• PCM-150 Machine TorchStanda

INTRODUCTION & DESCRIPTION 2-4 Manual 0-22512.3 TORCH SPECIFICATIONS (continued)Figure 2-C PCH/M-150 Torch Dimensions3.81 in(97 mm)1.62 in(41 mm

Manual 0-2251 2-5 INTRODUCTION & DESCRIPTION2.4 OPTIONS AND ACCESSORIESPower Supply Optionsand Accessories• Remote Control Panel - For machine to

INTRODUCTION & DESCRIPTION 2-6 Manual 0-22512.5 THEORY OF OPERATIONFigure 2-D Theory of OperationPlasma Arc Cutting andGougingPlasma is a gas wh

Manual 0-2251 2-7 INTRODUCTION & DESCRIPTION2.5 THEORY OF OPERATION (continued)Plasma Gas Flow(continued)By forcing the plasma gas and arc throug

INTRODUCTION & DESCRIPTION 2-8 Manual 0-22512.5 THEORY OF OPERATION (continued)The system has several built-in interlocks to provide safeand effi

Manual 0-2251 3-1 INSTALLATION PROCEDURESSECTION 3: INSTALLATION PROCEDURES3.1 UNPACKING THE SYSTEMFigure 3-A Unpacking the SystemThe power supply

INSTALLATION PROCEDURES 3-2 Manual 0-2251Compressed air, oxygen (O2), nitrogen (N2), or argon/hydrogen (Ar/H2).Pressure 50 psi (3.5 bar)Flow 22 - 28 s

Manual 0-2251 3-3 INSTALLATION PROCEDURES3.3 PLASMA AND SECONDARY CONNECTIONS (continued)Input Gas Connections(Air Operation)Systems that are set up

INSTALLATION PROCEDURES 3-4 Manual 0-22513.3 PLASMA AND SECONDARY CONNECTIONS (continued)5. Connect one side of the Y-hose assembly into the othersid

Manual 0-2251 3-5 INSTALLATION PROCEDURES3.3 PLASMA AND SECONDARY CONNECTIONS (continued)Secondary WaterConnections1. The water source must be capabl

INSTALLATION PROCEDURES 3-6 Manual 0-2251The PAK 15XC power supply is designed to accept avariety of input voltages:• 200/220/230 VAC• 380/415/460 VAC

Manual 0-2251 3-7 INSTALLATION PROCEDURESVoltage Power Input Current Frequency Phase Recommended(Volts) (kVA) (Amps) (Hz) Fuse Size Wire Size200 29 84

Record the following information for Warranty purposes:Where Purchased: _______________________________________Purchase Date: ________________________

INSTALLATION PROCEDURES 3-8 Manual 0-22513.5 WORK AND GROUND CONNECTIONSMachine torch systems are equipped with shielded torchleads to minimize RF in

Manual 0-2251 3-9 INSTALLATION PROCEDURESFigure 3-F Coolant Reservior and De-ionizing CartridgeRefer to Figure 3-F and:1. Locate the coolant de-ioniz

INSTALLATION PROCEDURES 3-10 Manual 0-2251Remote Operator ControlPanel InstallationThe Remote Operator Control Panel consists of the controlpanel encl

Manual 0-2251 3-11 INSTALLATION PROCEDURES3.7 AUXILIARY CONNECTIONS (continued)Figure 3-G Typical Mechanized System Installation and Cable Interconn

INSTALLATION PROCEDURES 3-12 Manual 0-22513.8 LIFTING THE POWER SUPPLYFigure 3-H Lifting the Power SupplyWARNING Do not lift the power supply by the

Manual 0-2251 4-1 OPERATIONSECTION 4: OPERATION4.1 OPERATING CONTROLSFunctionON position activates all system control circuits.OFF position deactiva

OPERATION 4-2 Manual 0-22514.1 OPERATING CONTROLS (continued)FunctionAdjusts secondary gas pressure. Pull knob out and turnclockwise to increase seco

Manual 0-2251 4-3 OPERATION4.1 OPERATING CONTROLS (continued)FunctionImmediately de-activates pump, motor, and all controlcircuits (logic circuit and

OPERATION 4-4 Manual 0-22514.2 PRE-OPERATION SET-UPThe pre-operation set-up procedure should be followed atthe beginning of each shift:1. Check the c

Manual 0-2251 4-5 OPERATION4.2 PRE-OPERATION SET-UP (continued)4.3 TORCH PARTS SELECTIONWARNINGDisconnect primary power to the system beforedisassem

TABLE OF CONTENTSSECTION 1: GENERAL INFORMATION ... 1-11.01 Notes, Cau

OPERATION 4-6 Manual 0-2251WARNINGDisconnect primary power to the system beforedisassembling the torch, leads, or power supply.4.3 TORCH PARTS SELECT

Manual 0-2251 4-7 OPERATION4.3 TORCH PARTS SELECTION (continued)Cutting GougingAir Plasma Oxygen Plasma Nitrogen Plasma Argon/Hydrogen Air or Multi-

OPERATION 4-8 Manual 0-22514.4 GAS SELECTION FOR PLASMA CUTTING• Air plasma is normally used with air secondary.• Only clean, dry air is recommended

Manual 0-2251 4-9 OPERATION4.4 GAS SELECTION FOR PLASMA CUTTING (continued)• Air secondary is normally used when operating with airplasma and occasio

OPERATION 4-10 Manual 0-22514.4 GAS SELECTION FOR PLASMA CUTTING (continued)Cut Quality Cut quality requirements differ depending on application.For

Manual 0-2251 4-11 OPERATION4.4 GAS SELECTION FOR PLASMA CUTTING (continued)Cut Characteristics:Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice

OPERATION 4-12 Manual 0-22514.5 PLASMA CUTTING OPERATIONBe sure the operator is equipped with proper gloves,clothing, eye and ear protection and tha

Manual 0-2251 4-13 OPERATION4.5 PLASMA CUTTING OPERATION (continued)The auto-restart function provides an immediate pilot arcrestart during post-flow

OPERATION 4-14 Manual 0-22514.5 PLASMA CUTTING OPERATION (continued)Four two-pole DIP switches located on the control logic PCboard control the auto-

Manual 0-2251 4-15 OPERATION4.5 PLASMA CUTTING OPERATION (continued)Figure 4-G Control Logic PC Board - Setting Auto-Restart Options

TABLE OF CONTENTS (continued)SECTION 5: CUSTOMER/OPERATOR SERVICE ... 5-15.1 TORCH

OPERATION 4-16 Manual 0-22514.6 HAND TORCH OPERATIONFigure 4-H Cutting with a Hand TorchBe sure the operator is equipped with proper gloves,clothing

Manual 0-2251 4-17 OPERATIONHand Torch Operation(continued)2. To positively locate the line of the cut, position the torchover the workpiece, resting

OPERATION 4-18 Manual 0-22514.7 MACHINE TORCH OPERATIONCutting with aMachine Torch1. A machine torch should be aligned perpendicular tothe surface of

Manual 0-2251 4-19 OPERATIONCutting with aMachine Torch(continued)4.7 MACHINE TORCH OPERATION (continued)5. Cut with a standoff of 1/8 - 3/8 in (3 -

OPERATION 4-20 Manual 0-2251The corner slowdown feature provides an output currentreduction in to correspond with the reduction in torchtravel speed

Manual 0-2251 4-21 OPERATIONFigure 4-K Piercing with a Hand Torch4.8 PIERCINGIn some cutting operations, it may be desirable to start thecut within

OPERATION 4-22 Manual 0-22514.9 GOUGING OPERATIONFigure 4-L Gouging with a Hand TorchWARNINGCAUTIONBe sure the operator is equipped with proper glov

Manual 0-2251 4-23 OPERATION4.9 GOUGING OPERATION (continued)Gouging performance depends on the torch travel speed,the current level, the angle at wh

OPERATION 4-24 Manual 0-22514.9 GOUGING OPERATION (continued)Standoff DistanceThe tip to work distance affects gouge quality and depth.A standoff of

Manual 0-2251 4-25 OPERATION4.10 COMMON OPERATING ERRORSListed below are common cutting problems followed byprobable causes of each. If the problems

OPERATION 4-26 Manual 0-2251This Section contains information on cutting speeds for handand automated applications with PCH/M-150 Torch. Theinformati

Manual 0-2251 4-27 OPERATIONA. Hand Cutting Speeds50 Amps 100 Amps 150 Amps1/8 150 (3.81)3/16 110 (2.79)1/4 65 (1.65) 90 (2.29) 150 (3.81)1/2 48 (1.2

OPERATION 4-28 Manual 0-2251Hand Cutting Speeds (continued)50 Amps 100 Amps 150 Amps1/8 130 (3.30) 225 (5.7)3/161/4 65 (1.65) 100 (2.54) 160 (4.06)3/8

Manual 0-2251 4-29 OPERATIONFigure 4-P Cutting Speeds - Nitrogen Plasma on Stainless SteelHand Cutting Speeds (continued)50 Amps 100 Amps 150 Amps1/8

OPERATION 4-30 Manual 0-2251Figure 4-Q Cutting Speeds - Argon/Hydrogen Plasma on Stainless SteelHand Cutting Speeds (continued)50 Amps 100 Amps 150 A

Manual 0-2251 4-31 OPERATIONFigure 4-R Cutting Speeds - Air Plasma on AluminumHand Cutting Speeds (continued)50 Amps 100 Amps 150 Amps1/8 150 (3.81)

OPERATION 4-32 Manual 0-2251Figure 4-S Cutting Speeds - ArH2 Plasma/Nitrogen Secondary on AluminumHand Cutting Speeds (continued)50 Amps 100 Amps 150

Manual 0-2251 4-33 OPERATIONB. Automated Cutting SpeedsMild SteelAir Plasma / Air SecondaryGeneral purpose cuttingPlasma @ 60 psi (4.1 bar)Secondary

OPERATION 4-34 Manual 0-2251Automated Cutting Speeds (continued)Stainless SteelAir Plasma / Air SecondaryGeneral purpose cuttingPlasma @ 60 psi (4.1 b

Manual 0-2251 4-35 OPERATIONAutomated Cutting Speeds (continued)NOTES:1. Kerf widths are listed as the width of the cut at the bottom of the plate.2.

Date: January 27, 2004 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions,

OPERATION 4-36 Manual 0-2251Automated Cutting Speeds (continued)AluminumAir Plasma / Air SecondaryGeneral purpose cuttingPlasma @ 60 psi (4.1 bar)Seco

Manual 0-2251 4-37 OPERATIONAutomated Cutting Speeds (continued)NOTES:1. Kerf widths are listed as the width of the cut at the bottom of the plate.2.

OPERATION 4-38 Manual 0-22514.12 SEQUENCE OF OPERATIONFigure 4-T Sequence of OperationA-01016ACTIONClose externaldisconnect switchRESULT• Power to

Manual 0-2251 5-1 CUSTOMER/OPERATOR SERVICE12345678910111213161417181915SECTION 5: CUSTOMER/OPERATOR SERVICE5.1 TORCH MAINTENANCERefer to Figure 5-A

CUSTOMER/OPERATOR SERVICE 5-2 Manual 0-22515.1 TORCH MAINTENANCE (continued)Hand Torch HeadReplacement5.2 HAND TORCH HEAD REPLACEMENTWARNINGDisconne

Manual 0-2251 5-3 CUSTOMER/OPERATOR SERVICE5.2 HAND TORCH HEAD REPLACEMENT (continued)Hand Torch HeadReplacement (continued)4. With a twisting motion

CUSTOMER/OPERATOR SERVICE 5-4 Manual 0-22515.3 MACHINE TORCH HEAD REPLACEMENTMachine Torch LeadsReplacementWARNINGDisconnect primary power to the sys

Manual 0-2251 5-5 CUSTOMER/OPERATOR SERVICEFigure 5-D Machine Torch Head ReplacementMake sure the insulating tab completely separates thecoolant supp

CUSTOMER/OPERATOR SERVICE 5-6 Manual 0-22515.4 HAND TORCH SWITCH REPLACEMENTHand Torch HeadReplacementWARNINGDisconnect primary power to the system b

Manual 0-2251 5-7 CUSTOMER/OPERATOR SERVICE5.5 HAND TORCH LEADS REPLACEMENTDisconnect primary power to the system beforedisassembling the torch, lead

GENERAL INFORMATION 1-2 Date: January 27, 2004• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcirc

CUSTOMER/OPERATOR SERVICE 5-8 Manual 0-22515.5 HAND TORCH LEADS REPLACEMENT (continued)To minimize coolant leaks during torch head replacement,perfor

Manual 0-2251 5-9 CUSTOMER/OPERATOR SERVICE5.6 MACHINE TORCH LEADS REPLACEMENTWARNINGDisconnect primary power to the system beforedisassembling the t

CUSTOMER/OPERATOR SERVICE 5-10 Manual 0-22515.6 MACHINE TORCH LEADS REPLACEMENT (continued)10. Position the nylon outer sleeving over the shieldedinn

Manual 0-2251 5-11 CUSTOMER/OPERATOR SERVICE5.7 LEADS EXTENSION KITS - HAND TORCHLeads extension packages are available in 25 ft (7.6 m) or50 ft (15.

CUSTOMER/OPERATOR SERVICE 5-12 Manual 0-22515.7 LEADS EXTENSION KITS - HAND TORCH (continued)7. Thread the coolant supply insulator on the leadsexten

Manual 0-2251 5-13 CUSTOMER/OPERATOR SERVICELeads extension packages are available in 25 ft (7.6 m) or50 ft (15.2 m) lengths. Leads can be extended up

CUSTOMER/OPERATOR SERVICE 5-14 Manual 0-22515.8 LEADS EXTENSION KITS - MACHINE TORCH (continued)Connect Existing Leads toLeads ExtensionConnect Cool

Manual 0-2251 5-15 CUSTOMER/OPERATOR SERVICE5.8 LEADS EXTENSION KITS - MACHINE TORCH (continued)19. Thread the plasma insulator on the leads extensi

CUSTOMER/OPERATOR SERVICE 5-16 Manual 0-2251The fan motor and pump in the power supply should beoiled twice per year or once for each 100 hours of ope

Manual 0-2251 5-17 CUSTOMER/OPERATOR SERVICE5.10 TROUBLESHOOTING THEORYThe main transformer (T1) has buss bar connections toselect one of three input

Date: January 27, 2004 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from Am

CUSTOMER/OPERATOR SERVICE 5-18 Manual 0-22515.10 TROUBLESHOOTING THEORY (continued)Switching Control Board(continued)Logic Board FunctionsLED/Current

Manual 0-2251 5-19 CUSTOMER/OPERATOR SERVICE5.10 TROUBLESHOOTING THEORY (continued)Figure 5-H Major System Components - Front View

CUSTOMER/OPERATOR SERVICE 5-20 Manual 0-22515.10 TROUBLESHOOTING THEORY (continued)Figure 5-I Major System Components - Rear View

Manual 0-2251 5-21 CUSTOMER/OPERATOR SERVICE5.11 TROUBLESHOOTING GUIDESYMPTOM POSSIBLE CAUSE REMEDYA. No front panel LEDindicators lit. Fan andpump of

CUSTOMER/OPERATOR SERVICE 5-22 Manual 0-22515.11 TROUBLESHOOTING GUIDE (continued)1. Voltage selection bus barsconnected incorrectly2. One leg of thr

Manual 0-2251 5-23 CUSTOMER/OPERATOR SERVICE5.11 TROUBLESHOOTING GUIDE (continued)SYMPTOM POSSIBLE CAUSE REMEDYF. No GAS indicator(continued)G. GAS i

CUSTOMER/OPERATOR SERVICE 5-24 Manual 0-22515.11 TROUBLESHOOTING GUIDE (continued)SYMPTOM POSSIBLE CAUSE REMEDYH. COOLANT indicator offI. Coolant con

Manual 0-2251 5-25 CUSTOMER/OPERATOR SERVICE5.11 TROUBLESHOOTING GUIDE (continued)SYMPTOM POSSIBLE CAUSE REMEDYL. No pilot arc. DC indicatoron, PCR n

CUSTOMER/OPERATOR SERVICE 5-26 Manual 0-22515.11 TROUBLESHOOTING GUIDE (continued)SYMPTOM POSSIBLE CAUSE REMEDYP. Pilot arc on, no main arctransfer (

Manual 0-2251 5-27 CUSTOMER/OPERATOR SERVICE5.12 SERVICE AND TEST PROCEDURESThe following tests are suggested for specific problemslisted in the trou