Tweco 1000 Merlin(Sept1999) - Manual (Page 39)

Manual 0-2731 35 SERVICE
SECTION 5:
MAINTENANCE &
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
This section describes maintenance procedures, basic
troubleshooting and service performable by operating
personnel. No other adjustments or repairs are to be at-
tempted by other than Thermal Dynamics Trained per-
sonnel.
For major troubleshooting and parts replacement pro-
cedures refer to Merlin 1000 Power Supply Service
Manual 0-2732.
5.02 Recommended Routine
Maintenance Schedule
WARNING
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
This schedule applies to all types of water cooled plasma
cutting systems. Some systems will not have all the parts
listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to
be adjusted according tousage and the environment.
A. Daily Operational Checks or Every Six Arc
Hours:
1. Check torch parts, replace if damaged.
2. Check plasma and secondary supply and pressure/
flow.
3. Purge plasma gas line to remove any moisture
build-up.
4. Check deionizer bag/cartridge, replace if color is
predominantly yellow.
B. Weekly or Every 30 Arc Hours:
1. Blow or vacuum dust and dirt out of the entire
machine.
C. Six Months or Every 720 Arc Hours:
1. Remove and clean in-line filter screens.
2. Check cables and hoses for leaks or cracks, replace
if necessary.
3. Check all contactor points for severe arcing or pits,
replace if necessary.
4. Check all pillow blocks and bearings, clean and
lubricate if necessary.
5. Check fans, pumps and hoses for wear or cracking,
replace if necessary.
D. Twelve Months or Every 1500 Arc Hours:
1. Drain coolant, fill with distilled water, turn on main
power switch and let machine run for approxi-
mately 30 minutes.
Drain distilled water and replace with Thermal
Arc Coolant. Use Standard Mix Coolant (Catalog
# 7-2850) or Super Mix Coolant (Catalog # 7-2959)
for environments below +10° F (-12° C).
2. Check radiator fins, clean and comb out if neces-
sary.
3. Repeat six month maintenance.
5.03 General Maintenance
A. Power Supply Cleaning
To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The
unit should also be wiped clean. If necessary, solvents
that are recommended for cleaning electrical apparatus
may be used. Do NOT blow air into the power supply
during cleaning; make sure to always blow air out of the
unit. Blowing air into the unit can cause metal particles
to interfere with sensitive electrical components and cause
damge to the unit.
While the side panels are off, inspect the wiring in the
unit. Look for any frayed wires or loose connections that
should be corrected.
B. Coolant Filter Assembly
The filter screen should be cleaned periodically. Remove
the filter screen by unscrewing the filter holder from the
Coolant Filter Assembly on the rear panel. Clean the fil-
ter screen by rinsing with hot soapy water. Remove soap
residue by rinsing with clean hot water. Be sure that all
the soap has been removed and the screen is dry of water
before re-installing in the Coolant Filter Assembly.