Thermal Comfort 3000 manual Section Service Troubleshooting Diagnostics, Introduction

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SECTION 4:

SERVICE

TROUBLESHOOTING

DIAGNOSTICS

4.01 Introduction

This Section provides service diagnostics for the Merlin 3000 Power Supply, allowing the Technician to islolate any faulty Subassemblies. Refer to Section 5, Repairs & Replacement Procedures, for parts replacement instruc- tions.

Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other Subassemblies of this unit. Evidence of unauthorized repairs will void the fac- tory warranty.

NOTE

The troubleshooting contained in this manual is for the Merlin 3000 Power Supply only. Trouble- shooting other parts of the system is covered in the separate manuals for that product.

4.02Periodic Inspection & Procedures

NOTE

Refer to Appendix XV for a recommended mainte- nance schedule for water cooled plasma cutting systems.

This subsection describes inspection procedures which should be performed at periodic intervals as required.

A. Fan Motor and Pump Lubrication

The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation. To oil the motor, remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor.

NOTE

Some units may utilize a sealed motor design which does not require lubrication.

B. Routine Maintenance

The only other routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

To clean the unit, first make sure that the power is disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air especially from the radiator. The unit should also be wiped clean. If necessary, solvents that are recom- mended for cleaning electrical apparatus may be used.

While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected.

C. Coolant Filter Assembly (Rear Panel)

The rear panel filter screen should be cleaned peri- odically. Remove the filter screen by unscrewing the filter holder from the Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Re- move 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 Cool- ant Filter Assembly.

Coolant Filter Assembly

Filter Screen

A-01018

Filter Holder

Figure 4-1 Coolant Filter Assembly (Rear Panel)

D. Internal Filter Assembly

The internal filter screen should be cleaned periodi- cally. To gain access to the Internal Filter Assembly remove the Left Side Panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing the filter holder from the Internal Fil- ter Assembly. Clean the filter screen by rinsing with

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SERVICE TROUBLESHOOTING

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Contents 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 WarrantyScope Of Manual General Service PhilosophyService Responsibilities Section IntroductionIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction Circuit Description System TheoryCoolant Level and Conductivity Draining CoolantLogic PC Board Functions Switch-Mode Power Supply OperationSwitching Control PC Board Remote ControlStandoff Control Troubleshooting GuideTroubleshooting and Repair Advanced TroubleshootingHow 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 Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsRemote 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 CheckRemote Current Control Current Control, Display and CSD checksTip Drag Circuit Front Panel Current ControlCorner Slowdown CSD Volt Bias TestRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-To-Move Tests Service Troubleshooting Procedure Section Repairs & Replacement ProceduresAnti-Static Handling Procedures Parts Replacement General InformationTop Panel Replacement External Parts ReplacementHandle Replacement Left/Right Side Panel ReplacementFront Panel/Chassis Parts Replacement Access Panel Parts ReplacementRear Panel Parts Replacement Secondary Water Solenoid Valve Assembly Replacement Three-Phase Contactor ReplacementVoltage Selection PC Board Replacement Gas Solenoid Assembly ReplacementFlow Switch Assembly Replacement Coolant Tank ReplacementConductivity Sensor Assembly Replacement 29KVA Transformer T1 Assembly Replacement Base Assembly Parts ReplacementSecondary Water Check Valve Replacement DC Inductor L2 Assembly ReplacementPump Assembly Replacement Upper Chassis Parts ReplacementMain Contactor W1 or W2 Replacement Motor M1 Assembly ReplacementBxbx Do not damage Heatsink Auxiliary Transformer T3 Assembly ReplacementPlasma or Secondary Gas Input Fitting Replacement Pressure Gauge ReplacementCoolant Pressure Gauge Replacement Pressure Switch ReplacementSwitching Control PC Board Assembly Replacement Fuse F1 and F2 ReplacementPlasma or Secondary Regulator Assembly Replacement Control Logic PC Board Assembly ReplacementDiodes can overheat if not properly installed Main Heatsink Assembly Parts ReplacementSecondary Gas Check Valve Replacement Amp STR. Diode ReplacementAmp 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 Returns Section Parts ListsParts List Breakdown Ordering InformationItem # 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 Twelve Months or Every 1500 Arc Hours Daily Operational Checks or Every Six Arc HoursWeekly or Every 30 Arc Hours Six Months or Every 720 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.

Thermal Comfort 3000 is built with user convenience in mind. It comes equipped with a user-friendly interface that enables easy adjustments and programming. Through a dedicated mobile app, users can control their indoor climate remotely, providing flexibility for those with busy lifestyles. Furthermore, the system offers customizable settings that cater to individual preferences, ensuring that everyone in a space can enjoy their ideal thermal environment.

The technology behind Thermal Comfort 3000 incorporates sustainable practices, utilizing eco-friendly refrigerants and energy-efficient components. This not only reduces the carbon footprint of buildings but also lowers energy costs for users. The system can be integrated with renewable energy sources, such as solar panels, creating a truly sustainable heating and cooling solution.

Thermal Comfort 3000 also features advanced filtration systems that improve indoor air quality. By removing allergens, dust, and other pollutants from the air, it promotes a healthier living environment. This is especially beneficial for individuals with allergies or respiratory issues, making Thermal Comfort 3000 an excellent choice for homes and commercial spaces alike.

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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