INTRODUCES MERLIN 1000 MAXIMUM FLEXIBILITY MAXIMUM PERFORMANCE MAXIMUM PARTS LIFE. Literature # Dec-98

Transcription

1 INTRODUCES MERLIN 1000 MAXIMUM FLEXIBILITY MAXIMUM PERFORMANCE MAXIMUM PARTS LIFE Literature # Dec-98

2 DAVID R. ROUTHIER AUTOMATION SPECIALIST November 9, 1998 THERMAL DYNAMICS CORPORATION INDUSTRIAL PARK #2 WEST LEBANON, NH PHONE: FAX: Subject: New Product Introduction Dear Thermal Dynamics Distributor: Thermal Dynamics is pleased to announce the release of the Merlin 1000, our latest addition to the Merlin family of Automated Plasma Cutting Systems. The traditional reliability of the Merlin systems is combined with the proven performance of the Maximizer torch, providing metal fabricators around the world with an extremely cost effective high performance plasma system for cutting all thickness of metals from gauge up to ½ (12mm). The Merlin 1000 s built-in water cooling system and multiple gas capabilities provide low operating costs, maximum cutting performance and multi-process flexibility; allowing customers full utilization of their system and a prompt Return On Investment. In addition to the Merlin 1000 s obvious benefits as a conventional plasma system, the inclusion of Thermal Dynamics new Square Cut Oxygen Plasma process allows the Merlin 1000 to achieve high tolerance style cut quality with a simple change of torch consumable parts; providing: MAXIMUM FLEXIBILITY MAXIMUM PERFORMANCE Maximum Parts Life We appreciate the opportunity to present the Merlin 1000 and thank you for choosing Thermal Dynamics as your source for automated plasma cutting equipment. For further information on the Merlin 1000 or any other Thermal Dynamics products, please feel free to contact Thermal Dynamics Sales Support directly at 800-PLASMA-1 or Sincerely, David R. Routhier David R. Routhier Automation Specialist

3 MERLIN 1000 Table of Contents Tab System Description I Sales Presentation II Title Description Features & Benefits Applications Competitive Comparison (features) III Operator s Comparison IV How to Demo V Ordering Information VI Who to Contact at Thermal Dynamics VII Other Thermal Dynamics Products VIII 9-Oct-98

4 MERLIN 1000 System Description The Merlin 1000 plasma cutting system creates the new world standard for low power automated plasma cutting. The historical performance of Merlin plasma systems, combined with the proven technology of Thermal Dynamics XL inverter power supplies has resulted in a amp system that is unparalleled for performance, flexibility and cost of operation in the gauge to ½ market. The proven performance of the Maximizer 300 Torch has been further enhanced with the introduction of the exclusive Square Cut Oxygen Plasma consumable parts. By simply changing three torch consumables, the Merlin 1000 system can be converted from a conventional plasma system to a high precision Square Cut performer. The proven technology of the Merlin 1000 power supply, teamed with the multi-process flexibility of the Maximizer Torch and the exclusive Square Cut Oxygen Plasma process provides. MAXIMUM FLEXIBILITY MAXIMUM PERFORMANCE MAXIMUM PARTS LIFE

5 MERLIN 1000 Plasma Cutting System Automation at its Finest! Maximum Productivity Maximum Flexibility Maximum Parts Life Liquid Cooled Torch Production Cutting Gauge to 1/2"(12.7mm)

6 MERLIN 1000 AUTOMATION AT ITS FINEST The Merlin 1000 is a Single System Providing Maximum Flexibility Maximum Performance Maximum Parts Life 1/2" (12.7mm) Production Capacity 100% Duty Cycle Maximum Torch Parts Life Multi-Process Flexibility Multi-voltage Input Power O 2, N 2, Air, Ar-H 2 Plasma O 2, N 2, Air & Water Mist Secondary Exclusive Oxygen Plasma Remote Arc Starter Option for Longer Lead Lengths Multi-Gas Plasma Multi-Application Flexibility Conventional Plasma Application The historical performance associated with the Merlin family of plasma systems shines again in the Merlin When the application calls for quality cuts on carbon steel and economy is the primary requirement, the Merlin 1000 is able to use low-cost shop air plasma. If edge weldability of carbon steel is the primary concern, the Merlin 1000 can be quickly set up to use oxygen plasma with a quick change of the torch electrode. The Merlin 1000 is also capable of cutting stainless steel and aluminum at 100 amps using H-35 Robotic Cutting (argon-hydrogen) plasma gas. Again with a simple change of the torch electrode. When the application calls for thinner stainless steel or aluminum, once again a change of torch electrode allows the use of low-cost nitrogen plasma gas. Merlin 1000 Basic System Includes Merlin 1000 Power Supply Maximizer 300 Torch and Leads CNC Interface Cable Maximizer 300 Torch Spare Parts Kit Optional: SC11 Stand-off Control with 25'(7.6m) Motor Cable Remote arc Starter X-Y Coordinate Plate Cutting

7 The Merlin 1000 is a Single System Providing Maximum Flexibility Maximum Performance Maximum Parts LIfe 100 amp Air Plasma Consumable Parts Life MERLIN 1000 AUTOMATION AT ITS FINEST Typical Arc Starts Liquid Cooled Torch Gas Cooled Torch Cut Duration (seconds) Multi-Gas Plasma Multi-Application Flexibility Advanced Plasma Applications Exclusive Oxygen The new Thermal Dynamics Square Cut Oxygen Plasma process allows carbon steel fabricators to achieve the highest quality cuts on materials from gauge thickness up to 1/4"(6.4mm).The Merlin 1000 and Maximizer torch can accommodate the Square Cut process by simply changing the torch consumable parts. The Square Cut Process consistently delivers benchmark quality cuts with minimal edge bevel and dross. To achieve these results a high quality positioning system, and a precision torch standoff control is required. Plasma Process High Quality Plasma Cutting WMS Water Mist Secondary Superior Non-Ferrous Cutting The WMS (water mist secondary) process is included for outstanding cut quality on nonferrous materials up to 1/2(12.7mm)" production capacity.the process uses nitrogen plasma gas with the Thermal Dynamics' exclusive WMS.Ordinary tap water is regulated using the water flow control, standard with all Merlin 1000 systems.the water is then aerated around the plasma arc, causing a reaction in the cut area which reduces much of the oxides present, resulting in superior cut quality and reduced top edge rounding.

8 Merlin 1000 Automation at its Finest! SPECIFICATIONS MERLIN 1000 POWER SUPPLY Output: amps continuously variable Input: 208 vac 65 amps 230 vac 62 amps 380 vac 37 amps 415 vac 34 amps 460 vac 31 amps Duty Cycle: vdc Open Circuit Voltage: 350 volts DC Dimensions: H 42" (106.6cm) W 20 1/2" (52.1cm) D 31" (78.7cm) Weight: 250lbs.(114Kg) MAXIMIZER 300 TORCH Gas: Plasma: Air, O2, N2, Ar-H2 Secondary:Air, N2, O2, Water Mist Gas Pressure:Plasma:100 PSI (6.9 BAR) Secondary 50 PSI (3.5 BAR) Configuration: 180 Machine Mount w/ 1 3/8"(35mm) Mounting Tube 70 Robotic w/ 2"(50mm) Tube & 45mm Mount 90 Robotic w/ 2"(50mm) Tube & 45mm Mount Torch Lead Lengths: 25' (7.6m) 50' (15.2m) 75' (22.9m) w/ Remote Arc Starter Option 100' (30.5m) w/ Remote Arc Starter Option 125' (38.1m) w/ Remote Arc Starter Option Material Thickness Current Speed Speed (Plasma / Secondary) (Amps) (IPM) (MPM) Mild Steel 1/16" (1.6mm) (Air / Air) 1/8" (3.2mm) /4" (6.4mm) /2" (12.7mm) Stainless Steel 1/16" (1.6mm) (Air / Air) 1/8" (3.2mm) Stainless Steel 1/8" (3.2mm) (Nitrogen / Water Mist) 1/4" (6.4mm) /2" (12.7mm) Aluminum 1/16" (1.6mm) (Air / Air) 1/8" (3.2mm) Aluminum 1/8" (3.2mm) (Nitrogen / Water Mist) 1/4" (6.4mm) /2" (12.7mm) CSA Approved WORLD HEADQUARTERS: 101 S. Hanley Road St. Louis, MO FAX U.S. CUSTOMER SERVICE: Industrial Park #2 West Lebanon, NH FAX International Offices International Customer Service Thermadyne Canada Thermadyne Europe Thermadyne Asia Sdn. Bhd. Cigweld Australia Oakville, Canada Oakville, Canada Lancashire, England Kuala Lumpur, Malaysia Melbourne, Australia Ph: (1) Ph: (1) Ph: (44) Ph: (60) Ph: (61) Fax: (1) Fax: (1) Fax: (44) Fax: (60) Fax: (61) Thermadyne do Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Sao Paulo, Brazil Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan Ph: (55) Ph: (971) Ph: (52) Ph: (81) Fax: (55) Fax: (971) Fax: (52) Fax: (81) Form No.xx-xxxx (x/xx) Thermal Dynamics Corp., Printed in U.S.A.

9 MERLIN 1000 Maximum Process Flexiblity The Merlin 1000 Advantage

10 MERLIN 1000 Maximum Process Flexibility CONVENTIONAL PLASMA High Speed Plasma Cutting Carbon Steel Stainless Steel Aluminum Plasma Gases Air, O 2, N 2, Ar-H 2 Secondary Gases Air, N 2, CO 2 Gauge - 1/2 (12.7mm) capacity The Merlin 1000 Advantage

11 MERLIN 1000 Maximum Process Flexibility NITROGEN PLASMA with WMS SECONDARY Maximum Cut Quality Stainless Steel Aluminum Minimize Dross & Bevel Low Water Flow Rate less than 8 gph Gauge - 1/2 (12.7mm) capacity The Merlin 1000 Advantage

12 MERLIN 1000 Maximum Process Flexiblity Maximum Performance The Merlin 1000 Advantage

13 MERLIN 1000 Maximum Performance Manufacturers using CARBON STEEL: Prefabricated Galvanized Ducting Vehicle Exhaust Components Contour Pipe Cutting (fixtured or robotic) Prefab Building Exteriors Horse Trailers Car Haulers Farm Equipment The Merlin 1000 Advantage

14 MERLIN 1000 Maximum Performance [ Conventional Oxygen Plasma / Air Secondary] 16ga Steel O 2 plasma 50 amps 280 IPM 1.5 mm Steel O 2 plasma 50 amps 7.11 MPM 1/8 Steel O 2 plasma 50 amps 140 IPM 3 mm Steel O 2 plasma 50 amps 3.56 MPM 1/4 Steel O 2 plasma 100 amps 115 IPM 6 mm Steel O 2 plasma 100 amps 2.92 MPM 1/2 Steel O 2 plasma 100 amps 53 IPM 12.7 mm Steel O 2 plasma 100 amps 1.35 MPM The Merlin 1000 Advantage

15 MERLIN 1000 Maximum Performance Manufacturers using STAINLESS STEEL: Food Processing / Restaurant Equipment Dairy & Food Tanker Trailers Chemical Processing Equipment Pharmaceutical Equipment Brewery & Winery Equipment Vehicle Exhaust Components The Merlin 1000 Advantage

16 MERLIN 1000 Maximum Performance [WMS Water Mist Secondary] 1/8 Stainless N 2 plasma 100 amps 210 IPM 3 mm Stainless N 2 plasma 100 amps 5.33 MPM 3/16 Stainless N 2 plasma 100 amps 125 IPM 4.5 mm Stainless N 2 plasma 100 amps 3.18 MPM 1/4 Stainless N 2 plasma 100 amps 80 IPM 6 mm Stainless N 2 plasma 100 amps 2.03 MPM 1/2 Stainless N 2 plasma 100 amps 35 IPM 12.7 mm Stainless N 2 plasma 100 amps 0.89 MPM The Merlin 1000 Advantage

17 MERLIN 1000 Maximum Performance Manufacturers using ALUMINUM: Pleasure Boats Lightweight Camper Trailers Aircraft Components Automobile Body Components Road and Business Signs Dump Truck Bodies Freight Box & Tanker Trailers The Merlin 1000 Advantage

18 MERLIN 1000 Maximum Performance [WMS Water Mist Secondary] 1/8 Aluminum N 2 plasma 100 amps 210 IPM 3 mm Aluminum N 2 plasma 100 amps 5.33 MPM 3/16 Aluminum N 2 plasma 100 amps 150 IPM 4.5 mm Aluminum N 2 plasma 100 amps 3.81 MPM 1/4 Aluminum N 2 plasma 100 amps 80 IPM 6 mm Aluminum N 2 plasma 100 amps 2.03 MPM 1/2 Aluminum N 2 plasma 100 amps 35 IPM 12.7 mm Aluminum N 2 plasma 100 amps 0.89 MPM The Merlin 1000 Advantage

19 MERLIN 1000 Maximum Process Flexiblity Maximum Performance Maximum Parts Life The Merlin 1000 Advantage

20 MERLIN 1000 Maximum Parts Life Liquid Cooled System Proven Maximizer 300 Torch 100% Duty Cycle Tip Protected with Shield End Cap Maximized Electrode Life, including O 2 Plasma The Merlin 1000 Advantage

21 MERLIN 1000 Maximum Parts Life 100 amp Merlin 1000 Consumable Parts Life N Air 500 O 2 0 The 0 5 Advantage Cut Duration (seconds) 40 45

22 MERLIN 1000 The ADVANTAGE Manufacturer THERMAL DYNAMICS HYPERTHERM ESAB Model Merlin XR Max-100 Max-100D ESP-100i Feature Output amps 35 / 70 / amps amps amps Range Production Capacity Max. Travel Production Cap. Maximum Torch Length Duty Max. Current Remote Arc Starter Liquid Cooled for Enhanced Parts Life Merlin 1000 ½" (12mm) 60 IPM (1.5 M/min) 125' (38.1 M) amps ½" (12mm) 40 IPM (1.0 M/min) 100' (30.5 M) ½" (12mm) 40 IPM (1.0 M/min) 75' (22.9 M) ½" (12mm) 45 IPM (1.1 M/min) N 2 75' (22.9 M) Air ½" (12mm) 45 IPM (1.1 M/min) 117' (35.6 M) 100% 80% 80% 80% 100% OPTIONAL No No No O 2 Optional YES No No No No

23 Merlin Advantage Features & Benefits (Automated - 1/2" (12mm) capacity) Manufacturer THERMAL DYNAMICS HYPERTHERM ESAB Model Merlin 1000 Pak XR HT 40C Max-100 Max-100D ESP-100i Feature Availability Current Obsolete Current Obsolete Current Current Current 1998 List Price $8, N/A $5, N/A $6, $8, $6, Output Range amps amps 35 / 70 / 105 amps amps amps amps amps Input Power vac 3 phase vac 1 or 3 phase vac 1 or 3 phase vac 1 or 3 phase vac 3 phase vac 3 phase vac 3 phase Pierce Capacity ½" (12mm) 3/8" (9 mm) ½" (12mm) ¼" (6mm) 5/8" (15mm) 5/8" (15mm) 1" (25mm) Production Capacity ** ½" (12mm) ½" (12mm) ½" (12mm) ¼" (6mm) ½" (12mm) ½" (12mm) ½" (12mm) Max. Travel Production Cap. 60 IPM (1.5 M/min) 45 IPM (1.1 M/min) 40 IPM (1.0 M/min) 50 IPM (1.3 M/min) 40 IPM (1.0 M/min) 45 IPM (1.1 M/min) 45 IPM (1.1 M/min) Maximum Capacity 1¼" (30mm) 1" (25mm) 1¼" (30mm) ½" (12mm) 1¼" (30mm) 1¼" (30mm) 1½" (36mm) Maximum Torch Length 125' (38.1 M) 100' (30.5 M) 100' (30.5 M) 50' (15.2 M) 75' (22.9 M) 75' (22.9 M) 117' (35.6 M) Duty Max. Current 100% 80% 80% 80% (1-phase) 100% (3-phase) 80% 80% 100% Remote Arc Starter for More Reliable Arc Starting Liquid Cooled for Enhanced Parts Life Plasma Gas Capabilities Secondary Capabilities# Dimensions OPTIONAL No No No No No Optional YES No No No No No No AIR - YES O2 - YES N2 - YES AR/H2 - YES Air, O2, N2, CO2 & WaterMist 34½" 20½" 31" 87.6 cm 52.1 cm 78.8 cm Air - No O2 - No N2 - Yes Ar/H2 - Yes Air - Yes O2 - No N2 - Yes Ar/H2 - Yes Air - Yes O2 - No N2 - Yes Ar/H2 - No Air - Yes O2 - No N2 - Yes Ar/H2 - No Air - Yes O2 - No N2 - Yes Ar/H2 - Yes ## Air -Yes* O2 - No N2 - Yes* Ar/H2 - Yes* Air, N2, CO2 Air, N2, CO2 Air, N2 Air, N2 Air, N2, CO2 Air, N2, CO2 26" 24" 36" 66.0 cm 61.0 cm 91.4 cm 45½" 20" 27" cm 50.8 cm 68.6 cm 36" 19" 16" 91.4 cm 48.2 cm 40.6 cm 31¾" 26½" 43" 80.6 cm 67.3 cm cm 29¼" 43¾" 29¼" 74.3 cm cm 74.3 cm 32" 28" 22" 81.3 cm 71.1 cm 55.9 cm Weight 250 lbs 114 kg 615 lbs 280 kg 285 lbs 130 kg 200 lbs 91 kg 420 lbs 191 kg 435 lbs 198 kg 380 lbs 173 kg NOTES: 1-phase only available on 220 vac model * N2 and Ar/H2 are for use with the PT-25XL torch. In order to use Air plasma you must change to the PT-20AM torch ** Production Capacities are defined by the ability of the system to pierce and cut at minimum 40 Inches per Minute. # WaterMist provides significantly enhanced cut edge quality on non-ferrous metals compared to "dry" secondary gases. ## The use of Argon/Hydrogen with the Hypertherm Max-100D requires the addition of an external gas mixing station and hose package. This is included in the list price shown above. 29-Oct-98

24 THERMAL DYNAMICS A THERMADYNE COMPANY MERLIN 1000 OPERATOR S COMPARISON

25 THERMAL DYNAMICS A THERMADYNE COMPANY Benefits of O 2 Plasma Cutting Mild Steel Excellent Weldability Essentially Nitride Free Cut Surface Eliminate Nitride Related Welding Porosity Eliminate Follow-on Processes Reduced Dross on WorkPiece Eliminate Grinding and Chipping Eliminate Cost of Grinding Labor & Abrasives Streamlined Plate Processing / Faster Throughput

26 THERMAL DYNAMICS A THERMADYNE COMPANY Benefits of N 2 Plasma / WMS Secondary Cutting Stainless Steel & Aluminum Reduced Top-Edge Rounding Excellent Weldability Eliminate Follow-on Processes Reduced Dross on WorkPiece Eliminate Grinding and Sanding Eliminate Cost of Grinding Labor & Abrasives Streamlined Plate Processing / Faster Throughput

27 THERMAL DYNAMICS A THERMADYNE COMPANY Merlin 1000 Maximize Cut Quality The Merlin 1000 consistently delivers high quality, precision cuts on jobs up to ½ (12mm) thickness. We easily achieve high tolerance cuts at a fraction of the cost of other plasma systems.

28 THERMAL DYNAMICS A THERMADYNE COMPANY Merlin 1000 Multi-Process Flexibility The Merlin 1000 gives the operator the ability to quickly change between Air, O 2, N 2 and H-35 plasma gases. It allows the ability to easily maximize quality, cutting speed and weldability for the particular metal being cut.

29 THERMAL DYNAMICS A THERMADYNE COMPANY Merlin 1000 System Maximum Torch Parts Life The LIQUID COOLED torch provides maximum parts life with maximum simplicity. The Torch End Cap protects the tip from damage, even when piercing at maximum capacity.

30 THERMAL DYNAMICS A THERMADYNE COMPANY Maximizer 300 Torch Maximize Return on Investment The Maximizer Torch is very easy to work with. The consumable parts life is exceptional and they can be changed quickly with a single tool. This helps to maximize machine utilization and minimize downtime.

31 MERLIN 1000 HOW TO DEMO CAN YOU REALLY DEMO AN AUTOMATED SYSTEM? YES..ABSOLUTELY! PRESENT CUT SAMPLES FROM TRAVEL KIT VISIT EXISTING CUSTOMER SITES REQUEST CUSTOMER REFERENCES VISIT TDC FACILITY IN WEST LEBANON, NH QUANTIFY THE MERLIN 1000 s ABILITY TO IMPROVE THE CUSTOMER S BUSINESS FOCUS ON ENTIRE METAL HANDLING PROCESS COMPARE COST OF OPERATION TO EXISTING METHODS DISCUSS MERLIN S MULTI-APPLICATION FLEXIBILITY EXPLAIN RAPID RETURN ON INVESTMENT USE TDC AUTOMATION SERVICE FOR ASSISTANCE

32 MERLIN 1000 MERLIN 1000 SALES REQUIREMENTS Customer application requirements and product demonstration. It is very important to understand the customer s application and cutting requirements prior to offering examples of the Merlin 1000 s cutting performance. The following guide can assist in conducting a professional and quality presentation which will enhance the finalization of the sale. Customer s Application Requirements: Material type and thickness most often to be cut- The pierce and production capacity of the Merlin 1000 is ½ (12mm) thickness material. Maximum thickness to be cut- The maximum capacity of the Merlin 1000 is 1 (12.7mm) thickness material. Cut requirements Cut quality - determines gas selection, travel speeds, cut bevel angle, dross & surface finish Desire to use Square Cut Oxygen Plasma process Application must be reviewed by a Thermal Dynamics Automation representative Requires High Precision Torch Standoff Control Requires a very stable cutting machine in good condition Metal weldability after being cut - determines gas selection Piercing or edge starts Dry cutting or in a water table - affects capacity, travel speed, cut quality and work environment Bevel cutting - cut capacity now must include the cut face thickness, rather than the plate thickness. Motion Control System to be used - ie., Cutting Table / CNC, Robot, Pipe Beveller, etc. New Installation or Retrofit? If Retrofit, what is the current plasma system? Who will perform the installation? TDC personnel, distributor, customer, other? Size of Cutting System - Required to determine lead lengths and necessity for Remote Arc Starter Actual Layout of System - Required to determine lead lengths and necessity for Remote Arc Starter Equipment Requirements: Available input power The Merlin 1000 is a 3-phase only machine capable of operating /460 or 380/415 VAC. The high and low range inputs are configured internally and can be changed on-site. Gases - what gases required, pressure and flow requirements, air-line filter, regulators if cylinder gases used Accessories - Standoff Control (TDC SC-11, Innerlogic RSVP, other) Note: The Thermal Dynamics SC-11 is ideal for all conventional plasma cutting applications, but is not recommended for use with the Square Cut Oxygen Plasma process.

33 MERLIN 1000 Sales Tools Cut Samples: Generic shape samples are available quickly from Thermal Dynamics Technical Service Department. Call PLASMA-2 ( ) or (603) Cold Rolled Carbon Steel, 16ga - ½ (1.5mm mm) Stainless Steel, 16ga - ½ (1.5mm mm) Aluminum, 16ga - ½ (1.5mm mm) Customer supplied materials may also be sample cut on request, with certain limitations. Call PLASMA-2 ( ) or (603) Speak with Automation Product Specialist to discuss material, cutting requirements and capabilities Generally 1-2 week turn-around from receipt of material Testimonials: There are many satisfied users of Thermal Dynamics automated plasma systems. Call your local Thermal Dynamics District Manager, or Call TDC Automation Product PLASMA-2 ( ) or (603) to Visit Existing Customer Sites Conference Call with Existing Customers Visit the Thermal Dynamics demonstration area in West Lebanon, NH Finalize the sale: Re-emphasize the products capabilities and strengths Emphasize your Value added Product availability Service & Support Overcome any customers objections Pricing & Return on Investment Desires to look at other competitive units before purchasing Got to get quotes Ask for the order Be prepared to offer immediate delivery Thank the Customer For their valuable time For the order!

34 Merlin 1000 System Ordering Worksheet: 0

35 Merlin 1000 System TABLE OF CONTENTS Ordering Information: Basic System w/o Remote Arc Starter Basic System with Remote Arc Starter Detailed Component Descriptions: Merlin 1000 Power Supply Maximizer Torch & Leads Remote Arc Starter & Leads CNC Interface Cable SC-11 Standoff Control SC-11 Standoff Control Cables Torch Consumable Parts and Maintenance Items: Replacement Torch Bodies Torch Consumables Thermal Arc Coolant Nov-98

36 Merlin 1000 System BASIC SYSTEMS WITHOUT REMOTE ARC STARTER The Merlin 1000 Plasma Cutting System is designed for operation in many different fabrication environments. In applications where the Merlin power supply can be located within 50 (15.2m) of the cutting head the Merlin s built-in pilot arc circuit can be used to initiate the cutting arc. Examples where this might be the case are on Plasma-Punch Combination machines, Robotic Cutting Cells and small X-Y Coordinate Cutting Tables. The Merlin 1000 Basic Systems listed below can be easily configured for new installation or retrofit on to many of these types of equipment. 180 Machine Torch 70 Robotic Torch 90 Robotic Torch Merlin 1000 Basic System 25 (7.6m) 50 (15.2m) 25 (7.6m) 50 (15.2m) 25 (7.6m) 50 (15.2m) includes: Merlin 1000 Power Supply Maximizer 300 Torch and Leads CNC Interface Cable Maximizer Torch Spare Parts Kit Same as above Also including: SC-11 Standoff Control w/ 25 (7.6m) Motor Cable Interconnection of Basic System without Remote Arc Starter without SC-11 Standoff Control Interconnection of Basic System without Remote Arc Starter with SC-11 Standoff Control Maximizer 300 Torch & Leads Maximizer 300 Torch & Leads Merlin 1000 Power Supply CNC Interface Cable Merlin 1000 Power Supply SC-11 to Plasma Cable Lifter Motor Cable CNC Interface Cable CNC Controller Customer Supplied CNC Controller SC-11 Controller 3 Customer Supplied 25-Nov-98

37 Merlin 1000 System REMOTE ARC STARTER The addition of a Remote Arc Starter to the Merlin 1000 system allows operations up to a total lead length of 125 (38.1m). As shown below the Remote Arc Starter is typically located as near to the torch head as possible to help assure prompt and consistent arc starting regardless of the system length. 180 Machine Torch 70 Robotic Torch 90 Robotic Torch Merlin 1000 Systems w/ Remote Arc Starter includes: Merlin 1000 Power Supply Remote Arc Starter Merlin 1000 Supply Leads Maximizer 300 Torch and Leads CNC Interface Cable Maximizer Torch Spare Parts Kit Same as above Also including: SC-11 Standoff Control w/ 25 (7.6m) Motor Cable AB AB AB AB Suffix A denotes the length of Supply Leads and Interface Cable 1: 35 (10.7m) 3: 75 (22.9m) 2: 50 (15.2m) 4: 100 (30.5m) Suffix B denotes the length of the Maximizer Torch & Leads: 1: 10 (3.0m) 3: 20 (6.1m) 2: 15 (4.6m) 4: 25 (7.6m) Interconnection of Basic System with Remote Arc Starter without SC-11 Standoff Control Interconnection of Basic System with Remote Arc Starter with SC-11 Standoff Control Arc Starter Supply Leads Remote Arc Starter Arc Starter Supply Leads Remote Arc Starter Merlin 1000 Power Supply CNC Interface Cable Maximizer Torch & Leads Merlin 1000 Power Supply SC-11 to Plasma Cable Lifter Motor Cable CNC Controller CNC Interface Cable Customer Supplied CNC Controller SC-11 Controller Customer Supplied 4 25-Nov-98

38 Merlin 1000 System 1. Merlin 1000 Power Supply amps cutting current ½ Production Capacity ½ Piercing Capacity 1 Maximum Capacity Universal 3Ø Input Power Standard Plasma Gas Flow Control Standard Gas Secondary Pressure Control Standard Square Cut Gas Secondary Flow Control Standard Water Mist Secondary Flow Control This Merlin 1000 Power Supply acts as the central connection point for all remote control devices and cabling. It also provides a connection point for all incoming gas and power connections. 1(a). Merlin 1000 Power Supply Same as Item 1, above. Also: CE / EMC Compliant For use with 380 / 415 Input Voltage 5 25-Nov-98

39 Merlin 1000 System 2. Maximizer 300 Torch & Leads (See Chart) amp rated 100% Duty Cycle Liquid Cooled Shielded Leads Plasma Gases: - Shop Air - Oxygen - Nitrogen - Argon-Hydrogen Secondary: - Shop Air - Oxygen - Nitrogen - Carbon Dioxide - Water Mist Standard 180º Machine Head Optional 70 º & 90º Robotic Heads Available Mounts using standard Binzel p/n: Clamp Torch Assembly, 45mm The Maximizer 300 torch and leads are connected from the Remote Arc Starter to the actual cutting area of the system. It is within the Maximizer 300 torch that the plasma gas is converted to the high temperature plasma cutting arc which is then used to cut the metal workpiece. Torch Head Torch Leads Catalog Number 180º 10 (3.0m) º 15 (4.6m) º 20 (6.1m) º 25 (7.6m) º 50 (15.2m) ** º 10 (3.0m) º 15 (4.6m) º 20 (6.1m) º 25 (7.6m) º 50 (15.2m) ** º 10 (3.0m) º 15 (4.6m) º 20 (6.1m) º 25 (7.6m) º 50 (15.2m) ** ** Note: Torches with 50 (15.2m) leads cannot be used with Remote Arc Starter Option Nov-98

40 Merlin 1000 System 3. Remote Arc Starter Reliable arc initiation at total lead lengths up to 125 (38.1m) Weight: approx. 13 lb (5.9 kg) Dimensions: 17 x 8½ x 7 (43.2cm x 21.6cm x 17.8cm) Optional for Merlin 1000 systems Requires interconnecting Arc Starter Supply cables The Remote Arc Starter is an optional component, available for all Merlin 1000 systems. The Remote Arc Starter provides the high voltage starting energy required to initiate the plasma cutting arc at the torch. It also provides the connection point between the Arc Starter Supply Leads and the Maximizer 300 torch leads. 4. Merlin 1000 Arc Starter Supply Leads (See Chart) The Merlin 1000 Torch Supply Leads provide all of the connections between the Merlin 6000 Master Power Supply and the Remote Arc Starter. These leads include a plasma gas supply hose, secondary supply hose, torch coolant supply and return hoses and a Remote Arc Starter control cable. Both the torch positive (+) and negative (-) power connections are integrated into the gas and coolant hoses to provide the smallest diameter total lead package possible. Description Length Catalog Number Lead Diameter 35 (10.7M) ½ (65mm) Arc Starter Supply Leads 50 (15.2M) ½ (65mm) 75 (22.9M) ½ (65mm) 100 (30.5M) ½ (65mm) 7 25-Nov-98

41 Merlin 1000 System 5. CNC Interface Cable (See Chart) Provides Input/Output connections for the following features: Plasma Arc Start / Stop Plasma Arc Sense (Current Sense Relay) Description Length Catalog Lead Diameter Connector Diameter 25 (7.6M) Number ½ (12.7mm) 1¾ (45mm) 50 (15.2M) ½ (12.7mm) 1¾ (45mm) 75 (22.9M) ½ (12.7mm) 1¾ (45mm) 100 (30.5M) ½ (12.7mm) 1¾ (45mm) Cable is configured with a 14-Pin AMP style connector on the Power Supply end, with bare wire connections on the CNC end. The appropriate CNC interface connector is to be supplied by the customer Nov-98

42 Merlin 1000 System 7. SC-11 High Speed Standoff Control Includes: SC-11 Operator s Control Panel High Speed Lifter Motor SC-11 48vdc Power Supply Featuring: Remote Arc Voltage Control Digital Voltage Display Preview Voltage Actual Cutting Voltage AutoHeight Regulation During Cut Find Height for Initial Start Manual Mode / SC-11 Off Selectable Lifter Speed, High / Lo Pierce Height Control (0-12mm) Pierce Delay Control (0-3 seconds) Adjustable End of Cut Retract Height Reduces Total Cycle Time Single Cable Connection The SC-11 High Speed Torch Standoff Control provides the system operator with the ability to automatically control the torch height during the cutting process. Control of this parameter then allows the process to achieve the greatest cut quality and consumable parts life possible. Electronic connections for the SC-11 are made directly to the Plasma Power Supply and the CNC Controller Nov-98

43 Merlin 1000 System 7(a). SC-11 Lifter Motor Cable (See Chart) This cable is required for use with the SC-11 Standoff Control operator s station to the SC-11 High Speed Lifter Motor assembly. Description Length Catalog Lead Diameter Connector Diameter SC Number (3.0M) ½ (12.7mm) 1½ (38mm) Lifter Motor Cable 15 (4.6M) ½ (12.7mm) 1½ (38mm) order: 20 (6.1M) ½ (12.7mm) 1½ (38mm) 1 of correct length 25 (7.6M) ½ (12.7mm) 1½ (38mm) 50 (15.2M) ½ (12.7mm) 1½ (38mm) 7(b). SC-11 to Plasma Power Supply Cable (See Chart) This cable is required for use with the SC-11 Standoff Control to connect the operator s station to the plasma power supply. Description Length Catalog Lead Diameter Connector Diameter SC-11 to Plasma 25 (7.6m) Number ½ (12.7mm) 1½ (38mm) Power Supply Cable 50 (15.2m) ½ (12.7mm) 1½ (38mm) order: 75 (22.9m) ½ (12.7mm) 1½ (38mm) 1 of correct length 100 (30.5m) ½ (12.7mm) 1½ (38mm) Nov-98

44 Merlin 1000 System Torch Consumables and maintenance parts Description Catalog Number REPLACEMENT TORCH BODIES Maximizer Torch Body, 180º Maximizer Torch Body, 70º Robotic Maximizer Torch Body, 90º Robotic THERMAL ARC TORCH COOLANT Standard, for temp's down to 0ºF (per gallon) Super, for temp's down to -34ºF (per gallon) CONVENTIONAL PLASMA ARC CONSUMABLES Shield Cup Body Shield Cup End Cap, 50 amp Shield Cup End Cap, 100 amp Tip, Cutting, 50 amp, O2, N2, Air Tip, Cutting, 100 amp, O2, N2, Air Tip, Cutting, 100 amp Argon-Hydrogen Gas Distributor, Cutting Electrode, Cutting, Oxygen Electrode, Cutting, Air Electrode, Cutting, Nitrogen Electrode, Cutting, Argon-Hydrogen SQUARE CUT, 50 AMP, O 2 -O 2 CONSUMABLES Shield Cup Body Shield Cup End Cap, 50 amp Tip, Cutting, 50 amp Gas Distributor, Cutting Electrode, Cutting, Oxygen Nov-98

45 MERLIN 1000 Ordering Information w/ Pricing Power Supply Torch Catalog # List Price Basic Systems MERLIN 1000 Maximizer 180 torch / 25 (7.6m) Leads $ 8, MERLIN 1000 Maximizer 70 Robotic torch / 25 (7.6m) Leads $ 8, MERLIN 1000 Maximizer 90 Robotic torch / 25 (7.6m) Leads $ 8, MERLIN 1000 Maximizer 180 torch / 50 (15.2m) Leads $ 8, MERLIN 1000 Maximizer 70 Robotic torch / 50 (15.2m) Leads $ 8, MERLIN 1000 Maximizer 90 Robotic torch / 50 (15.2m) Leads $ 8, Systems with Remote Arc Starter MERLIN 1000 Maximizer 180 Machine torch AB $ 9, MERLIN 1000 Maximizer 70 Robotic torch AB $ 9, MERLIN 1000 Maximizer 90 Robotic torch AB $ 9, Suffix A denotes the length of Supply Leads and Interface Cable 1: 35 (10.7m) 3: 75 (22.9m) 2: 50 (15.2m) 4: 100 (30.5m) Suffix B denotes the length of the Maximizer Torch & Leads: 1: 10 (3.0m) 3: 20 (6.1m) 2: 15 (4.6m) 4: 25 (7.6m) CONSUMABLES AND MAINTENANCE PARTS Description Catalog Number List Price Suggested Initial End-User Order per System Suggested Initial Distributor Order per System CONVENTIONAL PLASMA ARC CONSUMABLES Shield Cup Body $ Shield Cup End Cap, 50 amp $ * 3 * * 10 * Shield Cup End Cap, 100 amp $ * 3 * * 10 * Tip, Cutting, 50 amp $ * 20 * * 50 * Tip, Cutting, 100 amp $ * 20 * * 50 * Gas Distributor, Cutting $ Electrode, Cutting, Oxygen $ * 20 * * 50 * Electrode, Cutting, Air $ * 20 * * 50 * Electrode, Cutting, Nitrogen $ * * * 10 * Electrode, Cutting, Argon-Hydrogen $ * * * 10 * SQUARE CUT, 50 AMP, O 2 -O 2 CONSUMABLES Shield Cup Body $ Shield Cup End Cap, 50 amp $ * 3 * * 10 * Tip, Cutting, 50 amp $ * 10 * * 25 * Gas Distributor, Cutting $ Electrode, Cutting, Oxygen $ * 10 * * 25 * * Actual orders should be customized to the customer's specific application * 29-Oct-98

46 MERLIN 1000 Who to Contact at Thermal Dynamics Customer Service toll free PLASMA-1 international General Technical Service toll free PLASMA-2 international Automated Applications Service toll free international Product Specialists Automated Plasma Cutting David Routhier Manual Plasma Cutting Robert (Bob) Brown Torches & Consumable Parts Terry Raymond Customer & Technical Service Manager Scott MacDonald Director of Sales Support Steve Brown

47 THERMAL DYNAMICS A THERMADYNE COMPANY Thermal Dynamics Automated Plasma Products PakMaster 75XL & 100XL High speed air plasma systems for production cutting up to 5/16 (7.5mm) Merlin 1000 High performance multi-gas system for production cutting up to 1/2 (12.7mm) Merlin 6000 High performance full featured system for production cutting up to 1¼ (31mm) Merlin 6000GST (Gas Stepping Technology Oxygen Plasma) Full featured Oxygen plasma system for production cutting up to 1¼ (31mm) Pak 45 High power plasma for machine cutting up to 3 (76mm) non-ferrous metals TA-500/1000 High power plasma for machine cutting up to 6 (150mm) non-ferrous metals