Thermal Comfort 3000 manual How to use this Guide

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The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live mea- surements. It is helpful for solving many of the common problems that can arise with the Merlin 3000 Plasma Cut- ting System.

If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.

Follow all instructions as listed and complete each in the order presented.

Specific test procedures and LED status identification tables have been grouped together, and are referenced by the troubleshooting guide.

C. How to use this Guide

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. This guide is set up in the following manner:

1.Perform operational check(s) on the equipment to iso- late problem to possible circuit(s).

2.Determine symptom and isolate to defective assembly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1.Cause (Italic Type)

a. Check/Remedy (Text Type)

3.Locate your symptom in the appropriate Sub-Section.

4.Check the causes (easiest listed first) for the symptom.

5.Check the remedies listed for each cause.

6.Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTE

Many signals are transfered between Printed Circiut Board Assemblies on Ribbon Cables. If these cables become faulty they can then cause vari- ous problems. Do not forget about these cables when troubleshooting.

A.No front panel LED indicators ON; Fan and pump not operating

1.No primary power. Refer to symptoms C and D also.

a.Check for proper three-phase power at input terminal board

2.Faulty ON/OFF switch (SW1)

a.Disconnect primary power. Check each section for continuity. Replace switch if necessary

3.Faulty voltage selection board

a.Refer to Section 4.05-A, Voltage Selection PC Board Check. Replace Voltage Selection PC Board if necessary

B.AC indicator ON; Fan and pump not operating

1.ENABLE signal not ON

a.Remote ENABLE or ENABLE at TB2 must be on. Refer to Section 4.05-B, Enable Circuit Test.

2.Blown fuse (F1 or F2)

a.Check and replace fuse if necessary. Refer to Section 4.05-C, Blown Fuse (F1 or F2).

3.Faulty ON/OFF switch (SW1)

a.Disconnect primary power. Check each section for continuity. Replace switch if necessary

4.Faulty Voltage Selection PC Board

a.Refer to 4.05-A, Voltage Selection PC Board Check. Replace Voltage Selection PC Board if necessary

5.Faulty motor contactor (MC1 or MC2)

a.Refer to Section 4.05-D, Motor Control Contac- tor Check (MC1 or MC2). Replace contactor if necessary

6.Faulty ENABLE circuit

a.Refer to Section 4.05-B, Enable Circuit Test.

C.No indicators are on for the RC6010 or SC10 remotes.

1.No +48 VDC power to the remotes.

a.3 amp fuse blown on the Bias PCB, replace.

b.Defective Bias PCB, Refer to Section 4.05-P, 48 Volt Bias Test.

D.AMPS or VOLTS displays not on for RC6010 or SC10.

1.Normal if ENABLE not on.

a.Turn on ENABLE at RC6010 or TB2 (if RC6010 not used)

b.Defective ENABLE circuit, Refer to Section 4.05- B, Enable Circuit Test.

2.Faulty Remote Device

a.Replace as needed

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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 General Description Specifications & Design FeaturesSection Introduction Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 energizedVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsRefer to Appendix IX for Start Circuit Diagram Power Supply Start CircuitRemote Control Start Circuit 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 TestOK-To-Move Tests Pilot Resistor AdjustmentRefer to Appendix XII for OK-To-Move Circuit Diagram 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 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 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

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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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