Thermal Comfort 3000 manual Troubleshooting Guide, Standoff Control, Gas Control

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nector and an internal terminal strip are provided for CNC connections. The remote includes internal con- nections to interface to the SC10 standoff control so the single remote cable works for both.

A Merlin 3000 system may include the following:

•No Remote Control (RC6010)

•Remote Control Only (RC6010)

•Remote Control Only (RC6010) With Standoff Control (SC10)

When an RC6010 is included the CNC signals are con- nected to the RC6010 through the rear panel CNC connector, J29, or may be wired directly to J6, a termi- nal strip inside the RC6010. All CNC inputs are opti- cally isolated to reduce noise interference. The RC6010 allows remotely controlling the cutting current, set- ting reduced current for corner slowdown and select- ing gas PURGE and SET functions. A digital AMPS display allows accurate setting and monitoring of the output current. An ENABLE switch shuts down the power supply and coolant pump for changing torch consumables.

H. Standoff Control

1. Model SC10 Standoff Control

The Standoff Control (SC10) includes an ARC VOLTS display, a control to set the desired arc voltage as well as PIERCE HEIGHT, PIERCE DE- LAY and END OF CUT RETRACT (%). There are also manual UP and DOWN switches. The Stand- off Control operates a lifter motor assembly mov- ing the torch vertically to control torch tip to work distance.

When used with the Remote Control (RC6010) all inputs and outputs to the Standoff Control (ex- cept lifter motor drive) is via an internal ribbon cable between Remote Control (RC6010) J5 and Standoff Control (SC10) J7. No additional con- nections are required between Standoff Control and Power Supply.

2. Model SC11 Standoff Control

Standoff Control (SC11) is used without a Remote Control (RC6010). The Standoff Control has ad- ditional connectors on the rear panel, J40 for CNC, J41 for EXT PWR and J42 for plasma (labeled PL). A remote cable connects from the Power Supply J15 to both J41 and J42 carrying power and sig- nals to the Standoff Control. Connector J40 ac- cepts the same CNC cable as the Remote Control (RC6010) and like the Remote Control it has an internal terminal strip, J11. Connections J40 and J11 have only START/STOP, CSD, and OK-To-

Move signals which are optically isolated. A re- mote cable connects from the Power Supply to connector J41 supplying the Standoff Control power. The cable connected to J42 supplies con- trol signals between Power Supply and the Stand- off Control. Refer to the individual Instruction Manuals supplied with the equipment for more detailed information.

The Power Supply must have an enable switch connected to the terminal strip, TB2, inside the Power Supply when the Standoff Control (SC11) is used.

NOTE

Refer to Appendix VIII for a Signal Flow Block Diagram of the main functions.

I. Gas Control

The Gas Control (GC3000) consists of additional gas solenoids mounted on the Power Supply rear panel. A remote switch box is used to select the desired Plasma and Secondary gases. Up to four plasma and three secondary gases can be connected to the mani- folds and selected by the Gas Control. The secondary water input to the Power Supply may also be selected from the Gas Control.

4.04 Troubleshooting Guide

A. Troubleshooting and Repair

Troubleshooting and repairing the this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot- ing techniques.

B. Advanced Troubleshooting

NOTE

For basic troubleshooting and parts replacement procedures refer to Merlin 3000 Power Supply Op- erating Manual 0-2532.

SERVICE TROUBLESHOOTING

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Manual 0-2533

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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 LaborSection Introduction General Service PhilosophyService Responsibilities Scope Of ManualIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction Draining Coolant System TheoryCoolant Level and Conductivity Circuit DescriptionRemote Control Switch-Mode Power Supply OperationSwitching Control PC Board Logic PC Board FunctionsAdvanced Troubleshooting Troubleshooting GuideTroubleshooting and Repair 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 Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit 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 presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit 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 Parts Replacement General Information Section Repairs & Replacement ProceduresAnti-Static Handling Procedures ProcedureLeft/Right Side Panel Replacement External Parts ReplacementHandle Replacement Top Panel ReplacementAccess Panel Parts Replacement Front Panel/Chassis Parts ReplacementRear Panel Parts Replacement Gas Solenoid Assembly Replacement Three-Phase Contactor ReplacementVoltage Selection PC Board Replacement Secondary Water Solenoid Valve Assembly ReplacementFlow Switch Assembly Replacement Coolant Tank ReplacementConductivity Sensor Assembly Replacement DC Inductor L2 Assembly Replacement Base Assembly Parts ReplacementSecondary Water Check Valve Replacement 29KVA Transformer T1 Assembly ReplacementMotor M1 Assembly Replacement Upper Chassis Parts ReplacementMain Contactor W1 or W2 Replacement Pump Assembly ReplacementBxbx Auxiliary Transformer T3 Assembly Replacement Do not damage HeatsinkPressure Switch Replacement Pressure Gauge ReplacementCoolant Pressure Gauge Replacement Plasma or Secondary Gas Input Fitting ReplacementControl Logic PC Board Assembly Replacement Fuse F1 and F2 ReplacementPlasma or Secondary Regulator Assembly Replacement Switching Control PC Board Assembly ReplacementAmp STR. Diode Replacement Main Heatsink Assembly Parts ReplacementSecondary Gas Check Valve 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 Ordering Information Section Parts ListsParts List Breakdown 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 Six Months or Every 720 Arc Hours Daily Operational Checks or Every Six Arc HoursWeekly or Every 30 Arc Hours Twelve Months or Every 1500 Arc Hours

3000 specifications

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