Thermal Comfort 3000 manual Fuse blown at disconnect when primary power is connected

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E.Fuse blown at disconnect when primary power is connected

1.Voltage selection busbars connected incorrectly

a.Check and correct if necessary.

2.One leg of three-phase primary connected to chassis ground

a.Rewire input cable per Operating Manual.

3.Main transformer shorted

a.Replace main transformer

F.Fuse blown at disconnect when main contactor (W1 or W2) closes

1.Shorted input diode (D1-D6)

a.Refer to Section 4.05-E, Diode Check. Replace diode(s) as required.

2.Switching transistor (Q1) shorted to heatsink

a.Replace Q1, check heat-sink for possible dam- age. Refer to Section 4.05-M, Switching Con- trol Check (Q1).

3.Shorted input capacitor (C7-C12)

a.Replace capacitor if necessary

4.Shorted diode (D11-D14)

a.Check for proper 3-phase power at input termi- nal board, check diodes. Refer to Section 4.05- E, Diode Check.

5.Faulty Voltage Selection PC Board

a.If W1 and W2 come on simultaneously replace Voltage Selection PC Board.

6.Faulty main contactor (W1 or W2)

a.Check both contactors for welded contacts and replace contactor(s) if necessary

G.TEMP indicator on (red)

1.Unit overheated

a.Clean radiator and check for obstruction.

b.Excessive piloting; allow unit to cool

2.Faulty thermal sensor (TS1, TS2, or TS3)

a.Refer to Section 4.05-F, Thermal Sensing Circuit Circuit Check. Replace sensor(s) if necessary

3.Faulty Logic PC Board

a.Refer to Section 4.05-F, Thermal Sensing Circuit Check. Replace Logic PC Board if necessary

4.Faulty LED/Current Control PC Board

a.Refer to Section 4.05-F, Thermal Sensing Circuit Check. Replace LED/Current Control PC Board if necessary.

H.No GAS indicator; Motor and Pump operating; Other LED indicators normal; Both gases flow

1.Front panel RUN/SET/PURGE switch set to PURGE, or PURGE selected at Remote Control

a.Normal operation (purges plasma line only, sec- ondary pressure switch is not satisfied)

2.Gas pressure set too low

a.Adjust pressure

3.Faulty pressure switch (PS1 or PS2)

a.Jump switches one at a time and check for indi- cator to determine which has failed. Replace switch if necessary.

4.Faulty Logic PC Board

a.Refer to Section 4.05-G, Pressure Sensing Cir- cuit. Replace Logic PC Board if necessary

5.Faulty LED/Current Control PC Board

a.Refer to Section 4.05-G, Pressure Sensing Cir- cuit. Replace LED/Current Control PC Board if necessary.

6.Faulty SW3-B (secondary mode set to O2 or H2O )

a.With secondary mode set to O2 or H2O, check for continuity from wire #52 to #55 on SW3-B. If open, replace SW3-B.

7.If using Gas Control Option (GC3000) set for Water Secondary, faulty SW2-C in Gas Control.

a.With Merlin front panel secondary mode set to GAS and the Gas Control (GC3000) set to WATER, there should be continuity from wires #52 to #55. If not, SW2-C or connections to it are faulty.

I.GAS indicator off, plasma and/or secondary gas does not flow

1.Front panel RUN/SET/PURGE switch set to PURGE, or PURGE selected at Remote Control.

a.Normal operation (purges plasma line only, sec- ondary does not flow)

2.Secondary mode set to O2

a.No secondary flow is normal operation in O2 mode (but GAS indicator should be ON). Re- fer to symptom 'H' above.

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 Specifications & Design Features Section Introduction DescriptionGeneral Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 pilotTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits Coolant Flow Sensor Circuit CheckPower Supply Start Circuit Remote Control Start CircuitRefer to Appendix IX for Start Circuit Diagram 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 CSDPilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit DiagramOK-To-Move Tests 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 ReplacementCoolant Tank Replacement Flow Switch Assembly ReplacementConductivity Sensor 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 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 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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