Thermal Comfort 3000 manual Switch-Mode Power Supply Operation, Switching Control PC Board

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C. Switch-Mode Power Supply Operation

Primary three-phase power is rectified by the three- phase bridge diodes D1-D6. The resulting negative DC voltage (approximately -320 VDC) is applied to the switching transistor (Q1). The switching transis- tor controls the output current by pulse width modu- lation (PWM). PWM varies the duty cycle (or on-time versus off-time) of the switch. The greater the on-time, the higher the output current will be. Components D7-10, R2-3, C13-14, L1, and the Suppression PC Board are snubbers to limit voltage and current surges caused by switching Q1 on and off. D11-14 are free wheeling diodes. When Q1 is on, current flows through Q1 into the output network. When Q1 is off, D11-14 provide a path for current to continue flowing supported by energy that was stored in the output network during the time Q1 was on. The switching transistor output is a series of pulses which are filtered back into pure DC voltage by the output network. The output net- work consists primarily of the main inductor (L2A and L2B), resistor R13, and capacitor C23.

D. Switching Control PC Board

The Switching Control PC Board compares the shunt amp output with the current control pot setting and generates logic level PWM signals. The shunt and Shunt Amp PC Board are located between the input bridge positive and work lead to measure the output cutting current. The signals are sent to the driver PC board, where they are converted into the current and voltage levels needed to drive the switching transis- tor.

The Switching Control PC Board senses if the Remote Control (RC6010) is installed to route the current con- trol signal from the remote instead of the Merlin front panel control. The Switching Control PC Board routes the Shunt Amp signal to the remote’s current display, sends a torch voltage signal to the standoff control and supplies POT HI and POT LOW signals to set min and max output to both remote and front panel current controls. CSR (output greater than 25A) and over current shutdown (current greater than 175A) are sent to the Logic PC Board.

A relay on the Switching Control PC Board, controled by the Remote Control (RC6010) ENABLE switch or the ENABLE input on TB2, removes power from one side of the motor (MC) and main (W) contactors coils when the enable switch is off shutting off the coolant flow and DC power to allow changing torch parts.

E. Logic PC Board Functions

The Logic PC Board controls the timing and sequenc- ing of the system. It monitors the pressure, tempera- ture, and flow interlocks and controls the gas flow in

run, set, and purge modes by turning on the plasma and secondary solenoids. The Logic PC Board also controls pre-flow and post-flow durations, which are selectable by DIP switches on the board. The Logic PC Board drives the sequence status LED indicators and contains the circuit for measuring coolant con- ductivity.

After receiving the CNC (cutting machine controller) START signal from either the remote control, the standoff control, direct from the controller via the re- mote connector or TB2 the “simple” interface termi- nal strip, the Logic PC Board initiates gas preflow then energizes the main contactor, W1 or W2 (as deter- mined by the Voltage Selection PC Board).

The Logic PC Board closes the pilot contactor and sends enable signals to the Switching Control PC Board to start the PWM and turn on the main switch- ing circuits producing open circuit output voltage (OCV). When the Arc Starter Box senses OCV greater than 220 V between the Torch plus (+) and minus (-) it starts the CD (capacitor discharge) arc starting circuit to fire the spark gap producing the high voltage spark which starts the DC pilot arc. Once a constant DC pilot is established the torch voltage drops below 220 V and shuts off the CD circuit. When the Torch is close to the work the cutting arc “transfers” to the work.

The resulting current in the work lead is sensed by the Shunt Amp and the Switching Control PC Board sends the CSR signal to the Logic PC Board which opens the pilot contactor shutting off the pilot anf generating an “OK-To-Move” signal. OK-To-Move can be either contact closure or 24VAC through con- tacts selected by switch SW5 on the Logic PCB. OK- To-Move is sent to the remote control, the standoff control or directly to the cutting machine controller. It controls the optional High Flow Water Shield and the Arc Hour/Starts Counter.

F.LED/Current Control PC Board

The LED and current control PC board contains the sequence status LED indicators and the front panel current control pot.

G.Remote Control

The Remote Control allows remotely controlling the cutting current, setting reduced current for corner slowdown, and enabling gas purge and set functions. An ENABLE switch shuts down the power supply and coolant pump for changing torch consumables. The Digital Amperage display allows accurate setting and monitoring of the cutting current. Connections to the cutting machine controller (CNC) are electrically iso- lated to minimize interference. Both a rear panel con-

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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 WarrantyService Responsibilities General Service PhilosophySection Introduction Scope Of ManualIntroduction Specifications & Design Features Section Introduction DescriptionGeneral Description Theory Of Operation Input and Output PowerPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 energizedTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Pressure Sensing Circuit Thermal Sensing Circuit CheckGas Solenoid Circuits Coolant Flow Sensor Circuit CheckPower Supply Start Circuit Remote Control 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 TestPilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit DiagramOK-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 ReplacementCoolant Tank Replacement Flow Switch Assembly 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 installedRelay Replacement Amp REV Diode 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

3000 specifications

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