Thermal Dynamics MERLIN 6000 User manual

Manual No. 0-2568
October 6, 1999
MERLIN
®
6000
Plasma Cutting
Master Power Supply
Operating Manual
A-01497

WARNING
WARNING
Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Operating Manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
MERLIN 6000 Plasma Cutting Master Power Supply
Operating Manual Number 0-2568
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1997 by
Thermal Dynamics Corporation
All rights reserved.
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 liability
to any party for any loss or damage caused by any error or
omission in the MERLIN 6000 Plasma Cutting Master Power
Supply Operating Manual, whether such error results from
negligence, accident, or any other cause.
Printed in the United States of America
October 6, 1999

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions andWarnings ...................................................................... 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 ofWarranty ................................................................................... 8
SECTION 2:
INTRODUCTION & DESCRIPTION..................................................................................... 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description....................................................................................... 9
2.03 Specifications & Design Features ................................................................ 10
2.04 Theory Of Operation.................................................................................... 11
2.05 Options And Accessories ............................................................................ 12
SECTION 3:
INSTALLATION PROCEDURES ........................................................................................ 13
3.01 Introduction.................................................................................................. 13
3.02 Site Location................................................................................................ 13
3.03 Unpacking .................................................................................................... 13
3.04 Removing Skid ............................................................................................ 13
3.05 Filling Master Power Supply Coolant ........................................................... 14
3.06 Input Power Connections............................................................................. 14
3.07 Voltage Selection ......................................................................................... 15
3.08 Primary Power Cable Connections .............................................................. 16
3.09 Work Cable And Ground Connections ......................................................... 16
3.10 Plasma And Secondary Gas Connections................................................... 17
3.11 Connecting Torch Supply Leads .................................................................. 22
3.12 External Cable Connections ........................................................................ 24
3.13 Master/Slave Parallel Cable Connection ...................................................... 26
3.14 Lifting Options.............................................................................................. 26
3.15 Pilot Resistor Adjustment............................................................................. 27
SECTION 4:
OPERATION ...................................................................................................................... 31
4.01 Introduction.................................................................................................. 31
4.02 Functional Overview .................................................................................... 31
4.03 Front and Rear Panel Descriptions .............................................................. 31
4.04 Operating UnitWithout Gas Control Option ................................................. 34
4.05 Operating Unit With Gas Control Option ...................................................... 36
4.06 System Operation........................................................................................ 37
4.07 Optional Power Supply Settings................................................................... 38

TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE.................................................................................. 43
5.01 Introduction.................................................................................................. 43
5.02 General Maintenance .................................................................................. 43
5.03 Common Operating Faults........................................................................... 44
5.04 Troubleshooting ........................................................................................... 44
5.05 Basic Parts Replacement ............................................................................ 47
SECTION 6:
PARTS LISTS.....................................................................................................................49
6.01 Introduction.................................................................................................. 49
6.02 Ordering Information.................................................................................... 49
6.03 Complete Power Supply Replacement Parts List......................................... 50
6.04 Basic Component Replacement Parts List................................................... 51
6.05 Power Supply Options And Accessories...................................................... 52
APPENDIX I: INPUTWIRING REQUIREMENTS ...................................................................... 53
APPENDIX II: SEQUENCE OF OPERATION BLOCK DIAGRAM.............................................. 54
APPENDIX III: TYPICAL MECHANIZED SYSTEMWORK AND GROUND
CABLE CONNECTIONS.................................................................................................... 55
APPENDIX IV: TYPICAL MECHANIZED SYSTEM CABLE
INTERCONNECTION DIAGRAM....................................................................................... 56
APPENDIXV: QUICK REFERENCETO INTERCONNECTING CABLES AND HOSES ........... 58
APPENDIXVI: INTERFACE CABLE FOR REMOTE CONTROL (RC6010)............................... 59
APPENDIXVII: INTERFACE CABLE FOR STANDOFF CONTROL (SC11) .............................. 60
APPENDIXVIII: CNC INTERFACE CABLES ............................................................................. 61
APPENDIX IX: LADDER DIAGRAM - 120 VAC.......................................................................... 62
APPENDIX X: LADDER DIAGRAM - 15 VDC ............................................................................ 63
APPENDIX XI: PARALLEL CABLE ............................................................................................ 64
APPENDIX XII: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE
FOR WATER COOLED PLASMA CUTTING SYSTEMS .................................................... 65
APPENDIX XIII: SYSTEM SCHEMATIC - Rev 'B' or Earlier....................................................... 66
APPENDIX XIV: SYSTEM SCHEMATIC - Rev 'C' or Later ........................................................ 68

Date:6/22/99 1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
areused 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-
structionsbefore using theequipment. Call1-603-
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
•Alwaysreadthe 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 fumesand 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-
bustibleorexplosive gases or materials arelocated.
• 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.”
•Weardry gloves andclothing. 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 beforeperforming 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.
•Donot cut or weld on containers that may have held
combustibles.
• Providea firewatch when working in an areawhere
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
Noisecancausepermanenthearingloss. Plasmaarcpro-
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.
PLASMAARC RAYS
PlasmaArc Rayscaninjure your eyesandburn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesand burn your skin ifyouarenot properlyprotected.
• To protect your eyes, always wear a welding hel-
metorshield. 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
* Thesevaluesapply where the actual arcisclearly
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-
INGAND GAS WELDINGAND CUTTING, obtain-
able from the Superintendent of Documents, U.S.
GovernmentPrinting Office,Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATIONAND EDUCATIONAL EYEAND 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 fromAmerican 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 fromAmerican 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. NFPAStandard 70, NATIONALELECTRICALCODE,
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, 1900Arch Street, Philadelphia, PA19103
14. American Welding Society StandardAWSF4.1, 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.
Coupantà l’arcaujet de plasma produitde 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
lesavertissements, toutes lesprécautionsde 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
revêtementssetrouvantsur le métal etdes 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
provenantdes solvants et des produitsde 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, voiremortels, 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
Lesincendies et lesexplosionspeuvent résulterdesscories
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.
• Necoupezpas 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
vosyeux et brûler votrepeau. Le procédéà l’arcdeplasma
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
ouun écran de soudeur. Portez toujoursdeslunettes
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 suiventANSI/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’appliquentoul’arc actuelestobservé
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 protégervotreouïecontre lesbruitsforts, 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 ETAU 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’InstitutAméricaindes Normes Nationales(Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURESPROTECTRICES, 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 LACOUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITSCOMBUSTIBLES,disponible auprès de
laAmericanWelding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Pro-
tectioncontreles 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 ProtectionAssociation, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL,disponibleauprèsde la National FirePro-
tectionAssociation,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 CSAW117.2, 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 SURLASÉCURITÉ
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’AssociationAméricaine de
Soudage, RECOMMANDATIONS DE PRA-
TIQUES SURES POUR LAPRÉPARATIONÀLA
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.
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 StandardsAssociation) standard C22.2 number 60 forArc welding equipment.
* UL(Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* 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
ThermadyneUK
ChorleyEngland

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, atThermal’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

Manual0-2568 9 INTRODUCTION & DESCRIPTION
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.01 Scope of Manual
Thismanualcontains descriptions, operating instructions
and basic maintenance procedures for the Merlin 6000
Plasma Cutting Master Power Supply. Service of this
equipmentisrestricted to Thermal Dynamics trained per-
sonnel; 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. 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 General Description
The Master Power Supply contains all operator controls,
electrical and gas inputs and outputs, and the torch leads
receptacle. A Slave Power Supply may be connected in
parallel to double the the cutting capacity (amperage) of
theMasterPower Supply. All signal inputs/outputs, gas,
and torch connections are still connected to the Master
PowerSupplywhen the Slave Power Supply is used. The
Slave Power Supply has the same power circuits as the
MasterPowerSupply. The Master Power Supply can also
be connected to a second Master Power Supply and the
equipment will automatically be configured when the
parallel cable is installed. Many options and accessories
can be added to further improve the versatility of the
system.
NOTES
Refer to the Merlin 6000 Plasma Cutting Slave
Power Supply Operating Manual 0-2570 for more
information on the Slave Power Supply.
The Merlin 6000 Slave Power Supply requires a
Merlin 6000 Master Power Supply for proper op-
eration and torch connections.
A-01497
Figure 2-1 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
canbe used in areaswheretheambienttemperature drops
to -34° F (-36° C).
A typical system configuration will contain the follow-
ing:
• One or two Power Supplies with Running Gear
• Arc Starter Box
• Maximizer 300 Machine Torch with Leads and
MountingAssembly
• Torch Supply Leads
• Maximizer 300 Spare Parts Kit
• 25 ft (7.6 m) Work Cable and Ring Lug
• Optional Air Line Filter Assembly (or) High Pres-
sure Regulators
NOTE
Refer to Section 2.05 for complete list of Power
Supply Options and Accessories.

INTRODUCTION & DESCRIPTION 10 Manual0-2568
2.03 Specifications & Design
Features
The following apply to the Master Power Supply only:
1. Controls
ON/OFF Switch, Output Current Control, RUN/
SET/PURGE Switch, Secondary Gas Regulator,
Plasma Gas Regulator, Secondary Mode Switch, Sec-
ondary Water Flowmeter/Regulator, Optional Arc
Hour/Counter Meters
2. Control Indicators
LED Indicators:
AC , TEMP, GAS, DC, PILOT, COOLANT PRES, and
COOLANT COND
Gauges:
Secondary, Plasma, and Coolant Pressure Gauges
3. Input Power
Voltage Frequency Phase Amperage
200 50 or 60 Hz 3 98
220 50 or 60 Hz 3 89
230 50 or 60 Hz 3 85
380 50 or 60 Hz 3 51
415 50 or 60 Hz 3 47
460 50 or 60 Hz 3 42
500 50 or 60 Hz 3 40
575 50 or 60 Hz 3 34
NOTE
Refer to Appendix I for recommended input wir-
ing size, current ratings, and circuit protection re-
quirements.
Amps depends on input voltage (Refer to Appendix
I).
4. Output Power
Master Power Supply:
Continuouslyadjustable by potentiometer from50
to 150 amps
With Slave Power Supply:
Continuously adjustable by potentiometer from
100 to 300 amps
5. Duty Cycle
100%
6. Pilot Modes
Auto-Restart, Pre-Flow Delay, "Recycle Required"
7. CNC Signals
Enable, Start/Stop, OK-To-Move, Pilot Sensing Relay
(PSR), Full CNC Available with Remote
8. 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 (2.6 lpm)
9. Coolant Flow Rate
0.5 gpm (2.2 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.
10. Cooling Capacity
4,000 to 10,000 BTU
NOTE
Maximum value based on “free flow” condition.
11. Coolant Reservoir Capacity
2 gallons
Capable of handling a total of 150 feet of torch lead
length
12. Secondary Water
Tap water can be used as a secondary gas and must
be capable of delivering the following minimums:
• Water pressure of 50 psi (3.5 BAR)
• Flow of 8 gph (35.2 lph)
NOTES
Tap water should only be used as a secondary gas
on machine torches.
The tap water source does not need to be deionized,
but in water systems with extremely high mineral
content a water softener is recommended.

Manual0-2568 11 INTRODUCTION & DESCRIPTION
13. Power Supply Dimensions
Enclosure Only -
Width: 24.12 in (0.61 m)
Height: 38.38 in (0.98 m)
Depth: 34.25 in (0.87 m)
Fully Assembled -
Width: 28.50 in (0.72 m)
Height: 43.38 in (1.10 m)
Depth: 43.75 in (1.11 m)
14. Weight of Power Supply Only
678 lbs (308 kg)
2.04 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. Plasma arc gouging uses
thesameprocess to removematerial to a controlled depth
and width.
With a simple change of torch parts, the system can also
be used for plasma arc gouging. Plasma arc gouging is
used to remove material to a controlled depth and width.
B. Input and Output Power
The Power Supply accepts input voltages from 200 to
575V, 50 or 60 Hz, three-phase. Input voltages are set by
an internal changeover in the unit. 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 two second gas pre-
flow,followed by a uninterruptedDC pilot arcestablished
between the electrode and tip. The pilot arc is initiated
by a momentary high voltage pulse from theArc Starter
Box. The pilot creates a path for the main arc to transfer
to the work. When the main arc is established, the pilot
arc shuts off. The pilot automatically restarts when the
main arc stops, as long as the torch remains activated.
NOTE
For the arc to restart automatically, AUTO RE-
START must be enabled at switch settings inside
the Power Supply (Refer to Section 4.07).
D. Main Cutting Arc
The Power Supply accepts 50 or 60 Hz three-phase line
input. An internal changeover switches input line volt-
ages in three ranges, for 200/220/230V, 380/415/460V,
or 500/575V operation. The power supply 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. The positive output is
connected to the workpiece 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 inter-
lockthatpreventsaccidental torch starting when torch
parts are not properly installed. Aflow 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.
2. Gas Pressure Interlock
A pressure switch acts as an interlock for the plasma
gas supply. If the supply pressure falls below mini-
mum requirements the pressure switch will open,
shutting off the power to the contactors, and the GAS
indicator will go out. When adequate supply pres-
sure is available the pressure switch will close, allow-
ing power to be resumed for cutting.
3. Thermal Interlock
Thermal overload sensors are located in the trans-
former, pilot resistors,andmainheatsinkinthepower
supply. If one of these components is overheated the
appropriate switch will open, causing the tempera-
ture light to turn from green to red and shutting off

INTRODUCTION & DESCRIPTION 12 Manual0-2568
power to the main contactor. When the overheated
componentcools down the switch will close againand
allow operation of the system.
G. PlasmaTorches
Plasma torches are similar in design to the common au-
tomotive spark plug. They consist of negative and posi-
tive sections which are separated by a center insulator.
Inside the torch, the pilot arc is initiated in the gap be-
tweenthenegativelychargedelectrodeand the positively
charged tip. Once the pilot arc has ionized the plasma
gas, the superheated column of gas flows through the
smallorificein the torch tip, which is focusedonthemetal
to be cut.
The Maximizer 300 Torch uses an internal closed-loop
cooling system. Deionized coolant is distributed from a
reservoir in the Power Supply through the coolant sup-
ply lead. At the torch, the coolant is circulated through
the torch tip and electrode, where the extra cooling helps
to prolong parts life. Coolant then circles back to the
power supply through the return lead. The Maximizer
300 also can use secondary gases such as compressed air,
nitrogen (N2), water, and carbon dioxide (CO2).
2.05 Options And Accessories
These items can be used to customize a standard system
for a particular application or to further enhance perfor-
mance. Torch accessories are listed in the separate Torch
Instruction Manual.
NOTE
Refer to Section 6, Parts Lists, for ordering infor-
mation.
A. RC6010 Remote Control
Formechanized systems, thislowprofileunit provides
full CNC capability and allows the operator to con-
trol all system functions from a remote location.
B. SC-10 or SC11 Standoff Controls
Formachine torchsystems,the StandoffControlauto-
matically finds height and maintains torch standoff
with a high speed torch lifter motor.
NOTES
Standoff Control SC10 must be used with the Re-
mote Control RC6010.
Standoff Control SC11 can be used without Re-
mote Control RC6010.
C. Computer Control Cable Kits
For interfacing the power supply with a computer or
auxiliary control device. Available in various cable
lengths.
D. High Pressure Regulators
Available for air, oxygen, argon/hydrogen, nitrogen,
CO2, and water.
E. High Flow Water Shield (HFWS) Assembly
Reduces arc glare, noise, and fumes during the cut-
ting process.
F. Two Stage Air Line Filter
Removes damaging contaminants as small as 5 mi-
cronsfromthe plasma streamwhen using compressed
air.
G. Hour/Counter Meters
Meter assembly containing two meters. One meter
indicates the total number of hours and minutes that
the main cutting arc has been on to a maximum of
99999-59 (hours-minutes). The second meter counts
the number of times that the cutting arc has been
started to a maximum of 99999999 starts. Both meters
can be reset to zero.
H. Plasma/Secondary Gas Control (GC 3000)
A remote control to select one of various plasma and
secondary gases that can be connected to the Power
Supply. This allows one-time plumbing connections
ofvariousgas/water supplies. The operator has com-
plete flexibility to quickly select the best plasma and
secondary gas combinations for the metal to be cut.

Manual 0-2568 13 INSTALLATION PROCEDURES
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This Section describes installation of the Master Power
Supply. These instructions apply to the Master Power
SupplyAssembliesonly; installation proceduresforSlave
Power Supply, Options and Accessories 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. Internal power selection
c. Work cable
b. Gas connections
d. Torch Installation
e. Connecting auxiliary devices
4. Grounding
5. Operator training
3.02 Site Location
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
The Master Power Supply is cooled by air flow through
the front, rear, and side panels. Air flow must not be ob-
structed. At least 2 feet (0.61 m) of clearance should be
provided on all sides.
NOTE
When using the Slave Power Supply in parallel
with the Master Power Supply the supplies should
be placed next to each other. Placing one Power
Supply behind the other will cause heated air to be
drawn into the rear Power Supply. This condition
may lower the duty cycle of the system.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Eachcomponent of the system is packaged separatelyand
protected with a carton and packing material to prevent
damage during shipping. Components are packaged as
follows:
A. Power Supply
The power supply is skid-mounted and protected with a
carton and padding material to prevent damage during
shipment. The power supply with work cable are fac-
tory-assembledand packaged together. Alsopacked with
the system are:
• Torch and torch leads
• Torch Supply Leads
• Spare parts kit for the torch
• Coolant deionizing bag
• Arc Starter Box
• Operating Manual for Power Supply
B. Torches
Torches and leads are packaged with the Power Supply.
Spare parts for new torches are packed in a spare parts
box. Separate instruction manual is provided with each
torch.
C. Options and Accessories
Options and Accessories are packaged separately from
the Power Supply.
D. Unpacking Procedure
1. Unpack each item and remove all packing mate-
rial.
2. Locate the packing list(s) and use the list to iden-
tify and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor before
proceeding with installation.
3.04 Removing Skid
ThePower Supply is mounted ontheskid with two brack-
ets. Remove the Power Supply from the skid per the fol-
lowing procedure:
1. Remove the six bolts connecting the brackets to the
base of the Power Supply.

INSTALLATION PROCEDURES 14 Manual 0-2568
A-01498
Three Bolts
(Each Side)
Shipping Brackets
Shipping Pallet
Figure 3-1 Skid Removal From Power Supply
2. Roll the Power Supply off the skid backwards (rear
wheels first).
3.05 Filling Master Power Supply
Coolant
NOTE
Only the Master Power Supply requires coolant.
DO NOT install coolant in the Slave Power Sup-
ply or the second Master Power Supply if used.
The ambient temperature of the environment where the
Power Supply will be located determines the coolant to
be used. The Standard Torch Coolant supplied with the
system can be used in ambient temperatures down to 10°
F (-12° C).
Optional Super Torch Coolant should be used in areas
where the ambient temperature drops down to -34° F (-
36° C).
CAUTION
Use only Thermal Arc Torch Coolant. Use of any
other coolant can result in torch damage, insuffi-
cient thermal protection, and/or pilot arc interfer-
ence.
1. Locate the coolant deionizer bag and remove from
the plastic shipping bag.
2. Remove the coolant filler cap from the reservoir at
the top rear of the Power Supply.
3. Place the deionizer bag into the basket in the cool-
ant reservoir.
Coolant Reservoir
Filler Cap
Deionizer
Bag
Basket
Coolant Level Indicator
A-00872
Figure 3-2 Coolant Reservoir
4. Carefully pour enough of the supplied Thermal
Arc Torch Coolant into the reservoir to fill it to the
FULL mark on the rear panel.
NOTE
After operating the system more coolant may need
to be added. Allow the pump to operate for ten
minutes to properly purge any air from the coolant
lines before using the system.
4. Reinstall the reservoir coolant filler cap.
3.06 Input Power Connections
The Power Supply accepts input voltages from 200V to
575V, 50 or 60 Hz, three-phase power. Every Power Sup-
ply is factory wired for 460V input. For any other input
voltage, the Power Supply must be reset.
NOTE
Refer to Section 3.07, Voltage Selection.
A. Electrical Connections
The power source must conform to local electric code and
the recommended circuit protection and wiring require-
ments shown in Appendix I.

Manual 0-2568 15 INSTALLATION PROCEDURES
B. Input Voltage Selection
EveryPower Supply isfactory-wiredfor460V three-phase
input. For any other input voltage, the Power Supply
must be changed using the procedures in Section 3.07.
C. Opening Power Supply Enclosure
The left side panel (viewed from the front) of the Power
Supply must be removed to make electrical connections
and to select the proper input voltage.
WARNING
Disconnect primary power at the source before as-
sembling or disassembling power supply, torch
parts, or torch and leads assemblies.
1. Remove the ten screws which secure the left side panel
(viewed from the front) to the Power Supply .
Left Side Panel
Screws
(10 Places)
A-01535
Figure 3-3 Opening Power Supply
2. Remove the left side panel from the Power Supply.
3.07 Voltage Selection
The Power Supply can be wired to use input voltages
from 200 - 575 VAC. Power Supply is factory-wired for
460 VAC, three-phase input. Voltage selection is accom-
plished by switching busbar connections on the input
voltage terminal board inside the Power Supply.
1. Locate the input voltage terminal board on the left
side of the power supply.
Input Voltage
Terminal Board
L1
L2
L3
Busbars
A-00985
Extra Busbar
Storage Location
Figure 3-4 Input Voltage Terminal Board Location
NOTE
Extra busbars are attached (stored) to the top side
of the power transformer assembly.
2. Check the busbar configuration on the input volt-
age terminal board . The busbar configuration
must correspond with the available line voltage
per the following figure and the label inside the
unit:

INSTALLATION PROCEDURES 16 Manual 0-2568
200, 208,
220, or 230
11 12
L3 13
15 14
67
L2 8
10 9
12
L1 3
54
380, 415,
or 460
11 12
L3 13
15 14
67
L2 8
10 9
12
L1 3
54
500, or 575
11 12
L3 13
15 14
67
L2 8
10 9
12
L1 3
54
Busbar Connections For Input Voltages
A-00904
Figure 3-5 Busbar Connections
If necessary, reposition the busbars to correspond to
the available line voltage.
3.08 Primary Power Cable
Connections
WARNING
Disconnectprimarypoweratthesourcebeforecon-
necting the primary power cable to the power sup-
ply.
The primary power cable must be supplied by the end
user and installed to the Power Supply assembly. Rec-
ommended cable sizes are specified in Appendix I.
NOTE
Three-phase operation requires a 3-conductor cable
with ground.
1. Route the primary power cable through the strain
relief fitting in the rear panel of the Power Supply
and tighten strain relief screws.
Input Voltage
Terminal Board
L1
L2
L3
Primary Power
Cable
Strain Relief
Fitting
Ground
Connection
Busbars
A-00893
Figure 3-6 Input Voltage Connections
2. Connect the electrical ground wire to the ground
lug on the base of the unit.
WARNING
The electrical ground wire must be connected to
the ground lug in the base of the unit for proper
grounding.
3. Connect the three line leads to the input voltage
terminal board per the following:
• Line 1 to terminal L1.
• Line 2 to terminal L2.
• Line 3 to terminal L3.
4. Tighten all nuts.
3.09 Work Cable And Ground
Connections
NOTE
Refer to Appendix III for a block diagram of a typi-
cal mechanized system work and ground cable con-
nections.
A. Electromagnetic Interference (EMI)
High frequency pilot arc initiation generates a certain
amountofelectromagneticinterference(EMI), commonly
called RF noise. This RF may interfere with other elec-
tronic equipment such as CNC controllers, etc. The sys-