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

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INTRODUCES

(2)

November 9, 1998

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:

M

AXIMUM

F

LEXIBILITY

•

M

AXIMUM

P

ERFORMANCE

•

• 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 603-298-5711. Sincerely,

David R. Routhier

David R. Routhier DAVID R. ROUTHIER AUTOMATION SPECIALIST

THERMAL DYNAMICS CORPORATION

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784-2006 PHONE: 603-298-5711 FAX: 603-298-5720

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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

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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

30 - 100 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….

M

AXIMUM

F

LEXIBILITY

• • •

M

AXIMUM

P

ERFORMANCE

• • •

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MERLIN

®

1000

Plasma Cutting

System

Automation

at its Finest!

Maximum Productivity

Maximum Flexibility

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®

MERLIN

®

1000

AUTOMATION AT ITS FINEST

Multi-Gas Plasma — Multi-Application Flexibility

Conventional Plasma Application

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

• O2, N2, Air, Ar-H2 Plasma

• O2, N2, Air & Water Mist Secondary

• Exclusive Oxygen Plasma • Remote Arc Starter Option for

Longer Lead Lengths

The historical performance associated with the Merlin family of plasma systems shines again in the Merlin®_1000.

• When the application calls for quality cuts on car-bon 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}

stain-less steel and aluminum at 100 amps using H-35

(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.

Robotic Cutting

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

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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 deliv-ers benchmark quality cuts with minimal edge bevel and dross.

To achieve these results a high quality posi-tioning system, and a precision torch standoff control is required. ®

MERLIN

1000

AUTOMATION AT ITS FINEST

Multi-Gas Plasma — Multi-Application Flexibility

Advanced Plasma Applications

0 1000 800 600 400 200 0 5 10 15 20 25 30 35 40 45 50 1800 1600 1400 1200 2000

100 amp Air Plasma Consumable Parts Life

Cut Duration (seconds)

Liquid Cooled Torch Gas Cooled Torch

T

ypical Arc Star

ts

The Merlin® 1000 is a Single System Providing

Maximum Flexibility — Maximum Performance — Maximum Parts LIfe

The WMS™ (water mist secondary) process the water flow control, standard with all Merlin®

Exclusive Oxygen Plasma Process

WMS™ Water Mist Secondary

Superior Non-Ferrous Cutting

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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) 905-827-9777 Ph: (1) 905-827-1111 Ph: (44) 1257-261755 Ph: (60) 3-791-0086 Ph: (61) 3-9487-1234 Fax: (1) 905-827-9797 Fax: (1) 905-827-3648 Fax: (44) 1257-261756 Fax: (60) 3-791-0129 Fax: (61) 3-9487-1487

Thermadyne do Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Sao Paulo, Brazil Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan

U.S. CUSTOMER SERVICE: Industrial Park #2 • West Lebanon, NH 03784 800-752-7621 • FAX 800-221-4401

International Offices

®

WORLD HEADQUARTERS: 101 S. Hanley Road • St. Louis, MO 63105 • 314-721-5573 • FAX 314-746-2161

Merlin

®

1000

Automation at its Finest!

M

ERLIN®

1000 P

OWER

S

UPPLY

Output: 30-100 amps continuously variable Input: 208 vac 3-phase @ 65 amps

230 vac 3-phase @ 62 amps 380 vac 3-phase @ 37 amps 415 vac 3-phase @ 34 amps 460 vac 3-phase @ 31 amps Duty Cycle: 100% @ 100 amps @ 130 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)

Material Thickness Current Speed Speed

(Plasma / Secondary) (Amps) (IPM) (MPM) Mild Steel 1/16" (1.6mm) 50 350 8.9 (Air / Air) 1/8" (3.2mm) 50 165 4.2 1/4" (6.4mm) 100 120 3.0 1/2" (12.7mm) 100 60 1.5 Stainless Steel 1/16" (1.6mm) 50 250 6.3 (Air / Air) 1/8" (3.2mm) 100 210 5.3 Stainless Steel 1/8" (3.2mm) 100 200 5.1 (Nitrogen / Water Mist) 1/4" (6.4mm) 100 80 2.0 1/2" (12.7mm) 100 35 0.9

Aluminum 1/16" (1.6mm) 50 350 8.9 (Air / Air) 1/8" (3.2mm) 50 150 3.8

Aluminum 1/8" (3.2mm) 100 225 5.7 (Nitrogen / Water Mist) 1/4" (6.4mm) 100 80 2.0 1/2" (12.7mm) 100 25 0.6

S

PECIFICATIONS

M

AXIMIZER

™ 300 T

ORCH

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

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9-Nov-98

MERLIN

™

1000

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9-Nov-98

MERLIN

™

1000

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

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9-Nov-98

MERLIN

™

1000

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

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9-Nov-98

MERLIN

™

1000

•

Maximum Process Flexiblity

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9-Nov-98

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

MERLIN

™

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9-Nov-98

Maximum Performance

[ Conventional Oxygen Plasma / Air Secondary]

• 16ga Steel

O

2

plasma 50 amps

280 IPM

• 1.5 mm Steel O2 plasma 50 amps 7.11 MPM

• 1/8” Steel

O

2

plasma 50 amps

140 IPM

• 3 mm Steel O2 plasma 50 amps 3.56 MPM

• 1/4” Steel

O

2

plasma 100 amps

115 IPM

• 6 mm Steel O2 plasma 100 amps 2.92 MPM

• 1/2” Steel

O

2

plasma 100 amps

53 IPM

• 12.7 mm Steel O2 plasma 100 amps 1.35 MPM

MERLIN

™

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9-Nov-98

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

MERLIN

™

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9-Nov-98

Maximum Performance

[WMS

™

Water Mist Secondary]

• 1/8” Stainless N

2

plasma

100 amps 210 IPM

• 3 mm Stainless N2 plasma 100 amps 5.33 MPM

• 3/16” Stainless N

2

plasma

100 amps 125 IPM

• 4.5 mm Stainless N2 plasma 100 amps 3.18 MPM

• 1/4” Stainless N

2

plasma

100 amps 80 IPM

• 6 mm Stainless N2 plasma 100 amps 2.03 MPM

• 1/2” Stainless N

2

plasma

100 amps 35 IPM

• 12.7 mm Stainless N2 plasma 100 amps 0.89 MPM

MERLIN

™

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9-Nov-98

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

MERLIN

™

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9-Nov-98

Maximum Performance

[WMS

™

Water Mist Secondary]

• 1/8”

Aluminum N

2

plasma 100 amps 210 IPM

• 3 mm Aluminum N2 plasma 100 amps 5.33 MPM

• 3/16” Aluminum N

2

• 4.5 mm Aluminum N2 plasma 100 amps 3.81 MPM

• 1/4”

Aluminum N

2

• 6 mm Aluminum N2 plasma 100 amps 2.03 MPM

• 1/2”

Aluminum N

2

• 12.7 mm Aluminum N2 plasma 100 amps 0.89 MPM

MERLIN

™

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9-Nov-98

MERLIN

™

1000

•

Maximum Process Flexiblity

•

Maximum Performance

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9-Nov-98

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

MERLIN

™

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9-Nov-98

100 amp M erlin 1000

Consumable Parts Life

0 500 1000 1500 2000 2500 3000 0 5 10 15 20 25 30 35 40 45

Maximum Parts Life

MERLIN

™

1000

N

₂

Air

O

₂

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9-Nov-98

The ADVANTAGE

MERLIN

™

1000

N

₂

Air

O

₂

Manufacturer THERMAL DYNAMICS HYPERTHERM ESAB

Model Merlin 1000 1250XR Max-100 Max-100D ESP-100i

Feature

Output

Range 30 - 100 amps

35 / 70 / 105

amps 30 - 100 amps 30 - 100 amps 10 - 100 amps

Production Capacity ½" (12mm) ½" (12mm) ½" (12mm) ½" (12mm) ½" (12mm) Max. Travel Speed

@ Production Cap. 60 IPM (1.5 M/min) 40 IPM (1.0 M/min) 40 IPM (1.0 M/min) 45 IPM (1.1 M/min) 45 IPM (1.1 M/min) Maximum Torch Length 125' (38.1 M) 100' (30.5 M) 75' (22.9 M) 75' (22.9 M) 117' (35.6 M) Duty Cycle @ Max. Current 100% 80% 80% 80% 100% Remote

Arc Starter OPTIONAL No No No Optional

Liquid Cooled for

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Merlin

™

Advantage

Features & Benefits

(Automated - 1/2"

(12mm)

capacity)

Manufacturer THERMAL DYNAMICS HYPERTHERM ESAB Model Merlin 1000 Pak-10 1250XR HT 40C Max-100 Max-100D ESP-100i Feature

Availability Current Obsolete Current Obsolete Current Current Current

1998

List Price $8,495.00 N/A $5,418.00 N/A $6,250.00 $8,820.00 $6,814.00 Output

Range 30 - 100 amps 50 - 100 amps

35 / 70 / 105

amps 20 - 40 amps 30 - 100 amps 30 - 100 amps 10 - 100 amps

Input Power 200 - 575 vac 3 phase 220 - 575 vac 1 or 3 phase ‡ 200 - 460 vac 1 or 3 phase 220 - 575 vac 1 or 3 phase ‡ 208 - 600 vac 3 phase 208 - 600 vac 3 phase 220 - 575 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 Speed @ 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 Cycle @ Max. Current 100% 80% 80% 80% (1-phase) 100% (3-phase) 80% 80% 100%

Remote Arc Starter for More Reliable

Arc Starting

OPTIONAL No No No No No Optional

Liquid Cooled for

Enhanced Parts Life YES No No No No No No Plasma Gas Capabilities AIR - YES O2 - YES N2 - YES AR/H2 - YES 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* Secondary Capabilities# Air, O2, N2,

CO2 & WaterMist Air, N2, CO2 Air, N2, CO2 Air, N2 Air, N2 Air, N2, CO2 Air, N2, CO2 Dimensions 34½" 20½" 31" 87.6 cm 52.1 cm 78.8 cm 26" 24" 36" 66.0 cm 61.0 cm 91.4 cm 45½" 20" 27" 115.6 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 109.2 cm 29¼" 43¾" 29¼" 74.3 cm 111.1 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:

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THERMAL DYNAMICS

A THERMADYNE COMPANY

OPERATOR’S

COMPARISON

MERLIN

™

1000

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9-Nov-98

THERMAL DYNAMICS

Benefits of O

2

Plasma

Cutting Mild Steel

F

Excellent Weldability

– Essentially Nitride Free Cut Surface

u

Eliminate Nitride Related Welding Porosity

F

Eliminate Follow-on Processes

– Reduced Dross on WorkPiece

u

Eliminate Grinding and Chipping

u

Eliminate Cost of Grinding Labor & Abrasives

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9-Nov-98

THERMAL DYNAMICS

Benefits of N

2

Plasma / WMS

™

Secondary

Cutting Stainless Steel & Aluminum

F

Reduced Top-Edge Rounding

F

Excellent Weldability

F

Eliminate Follow-on Processes

– Reduced Dross on WorkPiece

u

Eliminate Grinding and Sanding

u

Eliminate Cost of Grinding Labor & Abrasives

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9-Nov-98

THERMAL DYNAMICS

Merlin

™

1000

• “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

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9-Nov-98

THERMAL DYNAMICS

Merlin

™

1000

• “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.”

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9-Nov-98

THERMAL DYNAMICS

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.”

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9-Nov-98

THERMAL DYNAMICS

Maximizer

™

300 Torch

“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.”

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HOW TO DEMO

CAN YOU REALLY “DEMO” AN AUTOMATED SYSTEM?

YES…..ABSOLUTELY!

•

P

RESENT

C

UT

S

AMPLES FROM

T

RAVEL

K

IT

•

V

ISIT

E

XISTING

C

USTOMER

S

ITES

•

R

EQUEST

C

USTOMER

R

EFERENCES

•

V

ISIT

TDC F

ACILITY IN

W

EST

L

EBANON

, NH

QUANTIFY THE MERLIN 1000’s

ABILITY TO IMPROVE THE CUSTOMER’S BUSINESS

•

F

OCUS ON

E

NTIRE

M

ETAL

H

ANDLING

P

ROCESS

•

C

OMPARE

C

OST OF

O

PERATION TO

E

XISTING

M

ETHODS

•

D

ISCUSS

M

ERLIN

’

S

M

ULTI

-A

PPLICATION

F

LEXIBILITY

•

E

XPLAIN

R

APID

R

ETURN ON

I

NVESTMENT

•

U

SE

TDC A

UTOMATION

S

ERVICE FOR

A

SSISTANCE

MERLIN

™

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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 208-240/460 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.

MERLIN

™

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Sales Tools

Cut Samples:

• Generic shape samples are available quickly from Thermal Dynamics Technical Service Department.

• Call 1-800-PLASMA-2 (800-752-7622) or (603) 298-5711

• Cold Rolled Carbon Steel, 16ga - ½” (1.5mm - 12.7mm)

• Stainless Steel, 16ga - ½” (1.5mm - 12.7mm)

• Aluminum, 16ga - ½” (1.5mm - 12.7mm)

• Customer supplied materials may also be sample cut on request, with certain limitations.

• Call 1-800-PLASMA-2 (800-752-7622) or (603) 298-5711

• 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 Specialist @ 1-800-PLASMA-2 (800-752-7622) or (603) 298-5711 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!

MERLIN

™

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Merlin

™

1000 System

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Merlin

™

1000 System

TABLE OF CONTENTS

Ordering Information:

Basic System w/o Remote Arc Starter --- 3

Basic System with Remote Arc Starter --- 4

Detailed Component Descriptions: Merlin 1000 Power Supply --- 5

Maximizer Torch & Leads--- 6

Remote Arc Starter & Leads --- 7

CNC Interface Cable --- 8

SC-11 Standoff Control --- 9

SC-11 Standoff Control Cables --- 10

Torch Consumable Parts and Maintenance Items: Replacement Torch Bodies --- 11

Torch Consumables --- 11

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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

1 - 9 0 0 0 1 - 9 0 0 1 1 - 9 0 0 2 1 - 9 0 0 3 1 - 9 0 0 4 1 - 9 0 0 5 Same as above Also including: SC-11 Standoff Control w/ 25’ (7.6m) Motor Cable 1 - 9 0 1 0 1 - 9 0 1 1

Interconnection of Basic System Interconnection of Basic System without Remote Arc Starter without Remote Arc Starter without SC-11 Standoff Control with SC-11 Standoff Control

Merlin™ 1000 Power Supply

Maximizer 300 Torch & Leads CNC Interface Cable CNC Controller Customer Supplied Merlin™ 1000 Power Supply

Maximizer 300 Torch & Leads SC-11 to Plasma Cable SC-11 Controller CNC Controller CNC Interface Cable

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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

1-9006-AB 1-9007-AB 1-9008-AB Same as above Also including: SC-11 Standoff Control w/ 25’ (7.6m) Motor Cable 1-9016-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 Interconnection of Basic System

with Remote Arc Starter with Remote Arc Starter

without SC-11 Standoff Control with SC-11 Standoff Control

Merlin™ 1000 Power Supply

Arc Starter Supply Leads

CNC Interface Cable

CNC Controller

Customer Supplied

Maximizer Torch & Leads Remote Arc Starter

Merlin™ 1000 Power Supply SC-11 to Plasma Cable SC-11 CNC CNC Interface Cable

Lifter Motor Cable Arc Starter Supply Leads

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Merlin

™

1000 System

1.

Merlin 1000 Power Supply

3-9000

30 - 100 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

3-9900

Same as Item 1, above. Also:

CE / EMC Compliant

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Merlin

™

1000 System

2.

Maximizer 300 Torch & Leads

(See Chart)

14 - 300 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: 963.0007 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) 2-9900 180º 15’ (4.6m) 2-9901 180º 20’ (6.1m) 2-9902 180º 25’ (7.6m) 2-9903 180º 50’ (15.2m) ** 2-9904 70º 10’ (3.0m) 2-9905 70º 15’ (4.6m) 2-9906 70º 20’ (6.1m) 2-9907 70º 25’ (7.6m) 2-9908 70º 50’ (15.2m) ** 2-9909 90º 10’ (3.0m) 2-9910 90º 15’ (4.6m) 2-9911 90º 20’ (6.1m) 2-9912 90º 25’ (7.6m) 2-9913 90º 50’ (15.2m) ** 2-9914

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Merlin

™

1000 System

3.

Remote Arc Starter

3-6825

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) 4-9000 2½” (65mm) Arc Starter Supply Leads 50’ (15.2M) 4-9001 2½” (65mm) 75’ (22.9M) 4-9002 2½” (65mm) 100’ (30.5M) 4-9003 2½” (65mm)

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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)

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.

Description Length Catalog

Number

Lead Diameter Connector Diameter

25’ (7.6M) 9-5651 ½” (12.7mm) 1¾” (45mm)

50’ (15.2M) 9-5652 ½” (12.7mm) 1¾” (45mm)

75’ (22.9M) 9-5653 ½” (12.7mm) 1¾” (45mm)

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Merlin

™

1000 System

7.

SC-11 High Speed Standoff Control

7-3900

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.

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Merlin

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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

Number

SC-11 10’ (3.0M) 9-4535 ½” (12.7mm) 1½” (38mm)

Lifter Motor Cable 15’ (4.6M) 9-4536 ½” (12.7mm) 1½” (38mm)

order: 20’ (6.1M) 9-4537 ½” (12.7mm) 1½” (38mm)

1 of correct length 25’ (7.6M) 9-4538 ½” (12.7mm) 1½” (38mm)

50’ (15.2M) 9-4539 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

Number

SC-11 to Plasma 25’ (7.6m) 9-9020 ½” (12.7mm) 1½” (38mm)

Power Supply Cable 50’ (15.2m) 9-9021 ½” (12.7mm) 1½” (38mm)

order: 75’ (22.9m) 9-9022 ½” (12.7mm) 1½” (38mm)

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Merlin

™

1000 System

Torch Consumables and maintenance parts

Description

Catalog

Number

REPLACEMENT TORCH BODIES

Maximizer Torch Body, 180º

9-6410

Maximizer Torch Body, 70º Robotic

9-6457

Maximizer Torch Body, 90º Robotic

9-6459

THERMAL ARC TORCH COOLANT

Standard, for temp's down to 0ºF

(per gallon)

7-2850

Super, for temp's down to -34ºF

(per gallon)

7-2959

CONVENTIONAL PLASMA ARC CONSUMABLES

Shield Cup Body

20-1002

Shield Cup End Cap, 50 amp

20-1003

20-1004

Tip, Cutting, 50 amp, O2, N2, Air

20-1030

Tip, Cutting, 100 amp, O2, N2, Air

20-1031

Tip, Cutting, 100 amp Argon-Hydrogen

20-1035

Gas Distributor, Cutting

20-0008

Electrode, Cutting, Oxygen

20-1016

Electrode, Cutting, Air

20-1018

Electrode, Cutting, Nitrogen

20-1023

Electrode, Cutting, Argon-Hydrogen

20-1025

SQUARE CUT, 50 AMP, O

2

-O

2

CONSUMABLES

Shield Cup Body

20-1002

20-1052

Tip, Cutting, 50 amp

20-1051

Gas Distributor, Cutting

20-0008

Electrode, Cutting, Oxygen

20-1050

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Ordering Information w/ Pricing

MERLIN

™

1000

Power Supply Torch Catalog # List Price Basic Systems

MERLIN 1000 Maximizer 180° torch / 25’ (7.6m) Leads 1-9000 8,495.00$ MERLIN 1000 Maximizer 70° Robotic torch / 25’ (7.6m) Leads 1-9002 8,495.00$ MERLIN 1000 Maximizer 90° Robotic torch / 25’ (7.6m) Leads 1-9004 8,495.00$ MERLIN 1000 Maximizer 180° torch / 50’ (15.2m) Leads 1-9001 8,495.00$ MERLIN 1000 Maximizer 70° Robotic torch / 50’ (15.2m) Leads 1-9003 8,495.00$ MERLIN 1000 Maximizer 90° Robotic torch / 50’ (15.2m) Leads 1-9005 8,495.00$

Systems with Remote Arc Starter

MERLIN 1000 Maximizer 180° Machine torch 1-9006-AB $ 9,595.00 MERLIN 1000 Maximizer 70° Robotic torch 1-9007-AB $ 9,595.00 MERLIN 1000 Maximizer 90° Robotic torch 1-9008-AB $ 9,595.00

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) 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 20-1002 92.55$ 1 3

Shield Cup End Cap, 50 amp 20-1003 22.40$ * 3 * * 10 * Shield Cup End Cap, 100 amp 20-1004 22.40$ * 3 * * 10 *

Tip, Cutting, 50 amp 20-1030 10.40$ * 20 * * 50 *

Tip, Cutting, 100 amp 20-1031 10.40$ * 20 * * 50 *

Gas Distributor, Cutting 20-0008 34.20$ 2 5

Electrode, Cutting, Oxygen 20-1016 18.15$ * 20 * * 50 * Electrode, Cutting, Air 20-1018 17.75$ * 20 * * 50 * Electrode, Cutting, Nitrogen 20-1023 16.95$ * 5 * * 10 * Electrode, Cutting, Argon-Hydrogen 20-1025 16.95$ * 5 * * 10 *

SQUARE CUT, 50 AMP, O2-O2 CONSUMABLES

Shield Cup Body 20-1002 92.55$ 1 3

Shield Cup End Cap, 50 amp 20-1052 23.00$ * 3 * * 10 *

Tip, Cutting, 50 amp 20-1051 12.50$ * 10 * * 25 *

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MERLIN 1000

Who to Contact at Thermal Dynamics

Customer Service

toll free _____________________________ 1-800-PLASMA-1

international__________________________ 1-603-298-5711

General Technical Service

toll free _____________________________ 1-800-PLASMA-2

international__________________________ 1-603-298-5711

Automated Applications Service

toll free _____________________________ 1-888-832-3477

international__________________________ 1-603-298-5711

Product Specialists

Automated Plasma Cutting ______________ David Routhier

Manual Plasma Cutting _________________ Robert (Bob) Brown

Torches & Consumable Parts ____________ Terry Raymond

Customer & Technical Service Manager

_____ Scott MacDonald

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THERMAL DYNAMICS

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 1

¼“

(31mm)

Merlin

™

6000GST

(Gas Stepping Technology Oxygen Plasma)

• Full featured Oxygen plasma system for production cutting up to 1

¼“

(31mm)

Pak

™

45

• High power plasma for machine cutting up to 3”

(76mm)