Thermal Comfort 3000 Theory Of Operation, Plasma Arc Cutting and Gouging, Input and Output Power

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5.Duty Cycle 100%

6.Pilot Modes

Auto-Restart, Pre-Flow Delay, Recycle

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

0.5gpm (2.2 lpm) with 150 feet (45.7m) 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 (8.8 liters)

Capable of handling a total of 150 feet (45.7m) of torch lead length

12.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)

13. Weight of Power Supply Only

678 lbs (308 kg)

3.04 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 the same process to remove material 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 selectable (2, 4, 7, or 10 second) gas pre-flow, followed by a uninterrupted DC pilot arc established between the electrode and tip. The pilot arc is initiated by a momentary high frequency pulse from the Arc 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 can auto- matically restart (factory set for No Auto-Restart) 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.

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 clamp connection.

INTRODUCTION & DESCRIPTION

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Contents Merlin October 6Page Table of Contents Table of Contents Important Safety Precautions Section General InformationPublications Fire and ExplosionPrecautions De Securite Importantes AvertissementChoc Electrique Documents De Reference BruitGeneral Information National Standard and Technical Specifications Declaration of ConformityStatement of Warranty LaborGeneral Service Philosophy Service ResponsibilitiesSection Introduction Scope Of ManualIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction System Theory Coolant Level and ConductivityDraining Coolant Circuit DescriptionSwitch-Mode Power Supply Operation Switching Control PC BoardRemote Control Logic PC Board FunctionsTroubleshooting Guide Troubleshooting and RepairAdvanced Troubleshooting Standoff ControlHow to use this Guide Fuse blown at disconnect when primary power is connected Temp indicator on redCoolant indicator off Coolant conductivity indicator offNo pilot arc Pilot indicator on PCR energized Weak or sputtering pilotEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRemote Control Start Circuit Power Supply Start CircuitRefer to Appendix IX for Start Circuit Diagram Switching Control Check Q1 Q1 LocationPilot Circuit Check High Voltage is presentCurrent Control, Display and CSD checks Tip Drag CircuitFront Panel Current Control Remote Current ControlVolt Bias Test Corner Slowdown CSDRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-To-Move Tests Service Troubleshooting Section Repairs & Replacement Procedures Anti-Static Handling ProceduresParts Replacement General Information ProcedureExternal Parts Replacement Handle ReplacementLeft/Right Side Panel Replacement Top Panel ReplacementAccess Panel Parts Replacement Front Panel/Chassis Parts ReplacementRear Panel Parts Replacement Three-Phase Contactor Replacement Voltage Selection PC Board ReplacementGas Solenoid Assembly Replacement Secondary Water Solenoid Valve Assembly ReplacementFlow Switch Assembly Replacement Coolant Tank ReplacementConductivity Sensor Assembly Replacement Base Assembly Parts Replacement Secondary Water Check Valve ReplacementDC Inductor L2 Assembly Replacement 29KVA Transformer T1 Assembly ReplacementUpper Chassis Parts Replacement Main Contactor W1 or W2 ReplacementMotor M1 Assembly Replacement Pump Assembly ReplacementBxbx Auxiliary Transformer T3 Assembly Replacement Do not damage HeatsinkPressure Gauge Replacement Coolant Pressure Gauge ReplacementPressure Switch Replacement Plasma or Secondary Gas Input Fitting ReplacementFuse F1 and F2 Replacement Plasma or Secondary Regulator Assembly ReplacementControl Logic PC Board Assembly Replacement Switching Control PC Board Assembly ReplacementMain Heatsink Assembly Parts Replacement Secondary Gas Check Valve 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 Section Parts Lists Parts List BreakdownOrdering Information ReturnsExternal Power Supply Replacement Parts List Item # Qty Description Catalog #Access 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 Appendix I Input Wiring Requirements LtsAppendix II Sequence of Operation Block Diagram ActionAppendix III Typical Mechanized System Cable Connections System With Standoff Control SC11 And Gas Control GC3000Remote 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 Appendix XII OK-TO-MOVE Circuit Diagram OK OUTXiii Hose BlockAppendix XIV System Schematic Appendix Daily Operational Checks or Every Six Arc Hours Weekly or Every 30 Arc HoursSix Months or Every 720 Arc Hours Twelve Months or Every 1500 Arc Hours

3000 specifications

Thermal Comfort 3000 is an innovative solution designed to enhance indoor climate by ensuring optimal thermal comfort for users. As the demand for energy efficiency and sustainable building practices grows, Thermal Comfort 3000 emerges as a key player in providing customizable and effective climate control systems.

One of the main features of Thermal Comfort 3000 is its advanced smart technology that allows for precise temperature regulation based on real-time data. It utilizes sensors that monitor indoor and outdoor temperatures, humidity levels, and even occupancy patterns. This data is then analyzed to optimize the heating and cooling systems, ensuring that energy is used efficiently. With its ability to automatically adjust to changing conditions, users can enjoy a consistent and comfortable environment without excessive energy consumption.

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In summary, Thermal Comfort 3000 represents the future of climate control technology. Its combination of smart features, user-centric design, and sustainability makes it an ideal solution for enhancing thermal comfort in any indoor environment. With its innovative approach, it not only ensures comfort but also promotes energy efficiency and environmental responsibility, making it a worthwhile investment for modern living.
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