Thermal Comfort 3000 manual Merlin, October 6

October 6 MerlinPage Table of Contents Table of Contents Section General Information Important Safety PrecautionsFire and Explosion PublicationsAvertissement Precautions De Securite ImportantesChoc Electrique Bruit Documents De ReferenceGeneral Information Declaration of Conformity National Standard and Technical SpecificationsLabor Statement of WarrantyService Responsibilities General Service PhilosophySection Introduction Scope Of ManualIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Theory Of Operation Input and Output PowerPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction Coolant Level and Conductivity System TheoryDraining Coolant Circuit DescriptionSwitching Control PC Board Switch-Mode Power Supply OperationRemote Control Logic PC Board FunctionsTroubleshooting and Repair Troubleshooting GuideAdvanced Troubleshooting Standoff ControlHow to use this Guide Temp indicator on red Fuse blown at disconnect when primary power is connectedCoolant conductivity indicator off Coolant indicator offWeak or sputtering pilot No pilot arc Pilot indicator on PCR energizedEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Pressure Sensing Circuit Thermal Sensing Circuit CheckGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRemote Control Start Circuit Power Supply Start CircuitRefer to Appendix IX for Start Circuit Diagram Q1 Location Switching Control Check Q1High Voltage is present Pilot Circuit CheckTip Drag Circuit Current Control, Display and CSD checksFront Panel Current Control Remote Current ControlCorner Slowdown CSD Volt Bias TestRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-To-Move Tests Service Troubleshooting Anti-Static Handling Procedures Section Repairs & Replacement ProceduresParts Replacement General Information ProcedureHandle Replacement External Parts ReplacementLeft/Right Side Panel Replacement Top Panel ReplacementFront Panel/Chassis Parts Replacement Access Panel Parts ReplacementRear Panel Parts Replacement Voltage Selection PC Board Replacement Three-Phase Contactor ReplacementGas Solenoid Assembly Replacement Secondary Water Solenoid Valve Assembly ReplacementFlow Switch Assembly Replacement Coolant Tank ReplacementConductivity Sensor Assembly Replacement Secondary Water Check Valve Replacement Base Assembly Parts ReplacementDC Inductor L2 Assembly Replacement 29KVA Transformer T1 Assembly ReplacementMain Contactor W1 or W2 Replacement Upper Chassis Parts ReplacementMotor M1 Assembly Replacement Pump Assembly ReplacementBxbx Do not damage Heatsink Auxiliary Transformer T3 Assembly ReplacementCoolant Pressure Gauge Replacement Pressure Gauge ReplacementPressure Switch Replacement Plasma or Secondary Gas Input Fitting ReplacementPlasma or Secondary Regulator Assembly Replacement Fuse F1 and F2 ReplacementControl Logic PC Board Assembly Replacement Switching Control PC Board Assembly ReplacementSecondary Gas Check Valve Replacement Main Heatsink Assembly Parts ReplacementAmp STR. Diode Replacement Diodes can overheat if not properly installedAmp REV Diode Replacement Relay ReplacementAmp STR Diode Replacement Hose Assembly Replacements Drain the coolant from the Coolant Tank per Sec- tion 4.02-F Replacement Procedures Replacement Procedures Parts List Breakdown Section Parts ListsOrdering Information ReturnsItem # Qty Description Catalog # External Power Supply Replacement Parts ListAccess Panel Replacement Parts Front Panel/Chassis Replacement Parts 01217 Rear Panel Replacement Parts 1323 Base Assembly Replacement Parts 00894 Upper Chassis Replacement Parts 01226 Main Heatsink Assembly Replacement Parts 00971 Power Supply Options And Accessories 01218 Parts Lists Lts Appendix I Input Wiring RequirementsAction Appendix II Sequence of Operation Block DiagramSystem With Standoff Control SC11 And Gas Control GC3000 Appendix III Typical Mechanized System Cable ConnectionsRemote Cables Appendix V CNC Interface Appendix VI 120 VAC Circuit Diagram Appendix VII Ladder Diagram 15 VDC Appendix Viii Signal Flow Block Diagram Appendix IX Start Circuit Diargram Appendix X Current Control / Display Circuit Diagram Appendix XI CSD Corner Slowdown Circuit Diagram OK OUT Appendix XII OK-TO-MOVE Circuit DiagramBlock Xiii HoseAppendix XIV System Schematic Appendix Weekly or Every 30 Arc Hours Daily Operational Checks or Every Six Arc HoursSix Months or Every 720 Arc Hours Twelve Months or Every 1500 Arc Hours