Thermal Comfort 3000 No pilot arc Pilot indicator on PCR energized, Weak or sputtering pilot

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M.DC indicator off (after pre-flow); Main contactor comes on momentarily; No pilot arc; No main arc transfer

1.Switching transistor (Q1) not turning on

a.Refer to Section 4.05-M, Switching Control Check (Q1).

N.No pilot arc; DC indicator on; Pilot indicator OFF; PCR not energized

1.Faulty Logic PC Board, Switching Control PC Board, or Shunt Amp PC Board.

a.Refer to Section 4.05-N, Pilot Circuit Check.

O.No pilot arc; PILOT indicator on; PCR energized

1.Faulty Arc Start Box

a.Refer to Section 4.05-N, Pilot Circuit Check.

2.Shorted torch

a.Refer to Section 4.05-N, Pilot Circuit Check.

P.Weak or sputtering pilot

1.Faulty torch consumable parts

a.Replace consumables as needed

2.Plasma gas pressure too high

a.Adjust pressure

3.Low OCV (normal 290-350) caused by improper con- nection of voltage selection bus bars

a.Check input voltage connections

4.Low OCV caused by faulty Voltage Selection PC Board

a.If three-phase input voltage is within the lower half of range (refer to Operating Manual Sec- tion 3.07, Input Voltage Selection), D18 on Volt- age Selection PC Board should be off. If D18 is on, replace the Voltage Selection PC Board.

5.Input voltage low

a.Adjust pilot resistor for less resistance. Refer to Section 4.05-R, Pilot Resistor Adjustment.

Q.No pilot; PILOT indicator on; Strong spark visible at spark gap points inside the Arc Starter Box

1.Electrode shorted against tip

a.Thread electrode securely into torch head or replace tip and electrode

2.Shorted torch head

a.Check and replace if necessary

3.Broken conductor in torch lead

a.Check and replace if necessary

4.Shorted torch lead

a.Check and replace if necessary

5.Dirty or wet torch lead

a.Clean and dry torch lead

R.Pilot arc on; No main arc transfer (torch brought within range of work)

1.Work cable not connected

a.Connect work cable securely

2.Defective current control pot (on front panel or remote)

a.If Remote Control is used, disconnect J15 and set current at power supply front panel. If trans- fer is correct or Remote Control is not used, re- fer to Section 4.05-O, Current Control, Display, and CSD Checks.

S.Main arc starts but goes out immediately; Main contactor (W1 or W2) goes off

1.Fault condition causes output greater than 175 amps

a.Shorted Q1 or faulty Switching Control PC Board. Refer to Section 4.05-M, Switching Con- trol Check (Q1).

T.Main arc transfers but doesn’t pierce through the plate or pierce is too slow

1.Corner slowdown (CSD) setting too low on Remote Control.

a.Most cutting machines activate CSD during piercing, if so CSD must be set at or near maxi- mum.

2.Cutting current too low

a.Set for higher current

b.Current control circuit defective. Refer to Sec- tion 4.05-O, Current Control, Display and CSD Checks.

3.Trying to pierce greater than 3/4 inch (19 mm) plate

a.Unit rated only for piercing upto 3/4 inch (19 mm)

4.Travel speed too high

a.Try a stationary pierce, if piercing is correct, then adjust travel speed

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 LaborSection Introduction General Service PhilosophyService Responsibilities Scope Of ManualIntroduction General Description Specifications & Design FeaturesSection Introduction Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 pilotVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit 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 presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit 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 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 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 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

Thermal Comfort 3000 is an innovative solution designed to enhance indoor climate by ensuring optimal thermal comfort for users. As the demand for energy efficiency and sustainable building practices grows, Thermal Comfort 3000 emerges as a key player in providing customizable and effective climate control systems.

One of the main features of Thermal Comfort 3000 is its advanced smart technology that allows for precise temperature regulation based on real-time data. It utilizes sensors that monitor indoor and outdoor temperatures, humidity levels, and even occupancy patterns. This data is then analyzed to optimize the heating and cooling systems, ensuring that energy is used efficiently. With its ability to automatically adjust to changing conditions, users can enjoy a consistent and comfortable environment without excessive energy consumption.

Thermal Comfort 3000 is built with user convenience in mind. It comes equipped with a user-friendly interface that enables easy adjustments and programming. Through a dedicated mobile app, users can control their indoor climate remotely, providing flexibility for those with busy lifestyles. Furthermore, the system offers customizable settings that cater to individual preferences, ensuring that everyone in a space can enjoy their ideal thermal environment.

The technology behind Thermal Comfort 3000 incorporates sustainable practices, utilizing eco-friendly refrigerants and energy-efficient components. This not only reduces the carbon footprint of buildings but also lowers energy costs for users. The system can be integrated with renewable energy sources, such as solar panels, creating a truly sustainable heating and cooling solution.

Thermal Comfort 3000 also features advanced filtration systems that improve indoor air quality. By removing allergens, dust, and other pollutants from the air, it promotes a healthier living environment. This is especially beneficial for individuals with allergies or respiratory issues, making Thermal Comfort 3000 an excellent choice for homes and commercial spaces alike.

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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