Thermal Comfort 3000 manual System Theory, Coolant Level and Conductivity, Draining Coolant

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hot soapy water. Remove 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-in- stalling in the Internal Filter Assembly.

E. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50mm) from the top of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity LED on the front panel must be ON for normal operation. If the LED is OFF then drain the old coolant from the Power Supply and torch leads and replace with new cool- ant. Check the condition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag.

F.Draining Coolant

Remove the old coolant from the Power Supply res- ervoir per the following procedure:

1.Remove the right side and top panels from the Power Supply.

2.Disconnect the coolant hose input to the rear panel filter assembly.

3.Carefully lower the hose out the right side of the Power Supply and drain the coolant into an ac- ceptable container.

CAUTION

Handle and dispose of the used coolant per recom- mended procedures.

A-01017

Coolant Hose

Coolant Hose

Connection

Figure 4-2 Draining Coolant From Reservoir

4.Reconnect the hose to the filter assembly.

5.Install new coolant and deionizer bag.

6.Reinstall the top and right side panels.

4.03 System Theory

A. Circuit Description

The Merlin 3000 system is designed for mechanized cutting only and consists of the Merlin 3000 plasma power supply, the Maximizer 300 Torch, Torch Leads Extension, and Arc Starter Box. An Optional Remote Control (RC6010), Standoff Control (SC10 or SC11, see notes) and Gas Control (GC3000) may be used in vari- ous combinations. Different interconnect and input/ output (I/O) cables may be used depending on which options are installed. An Optional Dual Meter, Arc Hours and Arc Starts Counter, may be included on the Power Supply front panel.

NOTES

The Standoff Control SC10 must be used with the Remote Control RC6010.

The Remote Control RC6010 is not used if the Standoff Control SC11 is used.

B. Input Voltage Selection

The main transformer (T1) has busbar connections to select one of three input voltage ranges. Each main transformer secondary has two taps. One secondary tap is automatically selected by the Voltage Selection PC board when primary power is applied. If input voltage is within the lower half of the selected volt- age range (for example, 380V or 415V in the 380/415/ 460V range), the higher voltage taps are selected. If input voltage is within the upper half of the selected voltage range (460V in the 380/415/460V range), the lower voltage taps are selected. This arrangement provides secondary voltages close to the optimum levels. When the lower voltage taps are selected a red indicator, D18, on the Voltage Selection PC Board will be ON.

The auxiliary voltage taps, 115 VAC and 28 VAC cir- cuits, are selected directly by relays on the Voltage Selection PC Board. The fan and pump motors are supplied by the Motor Control Contactors (MC1 and MC2). MC1 is for the high voltage tap and MC2 is for the low voltage tap. Three-phase primary power is controlled by one of the Main Contactors (W1 for the high voltage tap or W2 for the low voltage tap).

SERVICE TROUBLESHOOTING

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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 General Description Specifications & Design FeaturesSection Introduction Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 pilotVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRefer to Appendix IX for Start Circuit Diagram Power Supply Start CircuitRemote Control Start Circuit 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 CSDOK-To-Move Tests Pilot Resistor AdjustmentRefer to Appendix XII for OK-To-Move Circuit Diagram 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 STR Diode Replacement Relay ReplacementAmp REV 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

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