Thermal Comfort 3000 Test Procedures, Voltage Selection PC Board Check, Enable Circuit Tests

Page 27

U.Main arc transfers and pierces through the plate, but cutting machine doesn’t move

1.Incorrect or missing OK-To-Move signal.

a.Many cutting machines require an AC voltage to activate the motion input. Refer to Operat- ing Manuals for setting OK-To-Move signal.

b.Check for missing OK-To-Move signal. Refer to Section 4.05-Q, OK-To-Move Tests.

V.Standoff Control Not Working Correctly

Refer to Troubleshooting in the Standoff Control In- struction Manual.

W. Remote Control Not Working Correctly

Refer to Troubleshooting in the Remote Control In- struction Manual.

4.05 Test Procedures

The following tests are suggested for specific problems listed in the troubleshooting guide.

WARNING

Several of these tests involve voltage measurements that must be made with power on. Use extreme care when making these tests. Tests requiring volt- age measurements are marked with the warning symbol. Disconnect primary power to the system for all other tests.

A. Voltage Selection PC Board Check

When wall power is first turned on, the Voltage Se- lection PC senses the low voltage AC present at J6-20, J6-22, and J6-24 (center tap). The Voltage Selection PC Board determines whether the voltage is in the lower or higher part of the selected input voltage range. If the input voltage is within the upper part of the range, the board energizes K1, K4, and K5 relays (labeled ‘HV’ on the system schematic). If the input voltage is within the lower part of the range the board energizes the K2 and K3 relays (labeled ‘LV’ on the schematic). If HV is selected, the red LED indicator (D18) on the voltage selection board will be lit. The relays do not energize until SW1-B (one pole of the ON/OFF switch) is closed because the DC voltage to the coils passes through it.

28 VAC Test

1.Check the AC input from J6-24 to both J6-20 and J6-22 for 12 - 18 VAC.

2.Check the AC voltage from J6-24 to both J6-17 and J6-18 for 16 - 22 VAC.

3.If input voltages are correct, check output from J6- 24 to both J6-19 and J6-21 for 14 - 18 VAC.

4.If output is not present at J6-19 and J6-21, check between J6-24 (-) and both J6-16 and J6-23 (+) for 12 - 16 VDC. If voltage is present at both points or neither, replace the Voltage Selection PC Board. If voltage is found at J6-23 but not at J6-16, check SW1-B and all wiring and connections.

120 VAC Test

NOTE

Refer to Appendix VI for 120 VAC Circuit Dia- gram.

1.Check the voltage input from F2 (wire #10) to J6-9 for 100 - 120 VAC. Check the input from F2 to J6- 10 for 120 - 140 VAC.

2.If the voltage input is present, check the red LED indicator (D18) on the voltage selection board. If the indicator is lit, measure voltage output between F2 (wire #10) and J6-7. If the indicator is not lit, measure between F2 and J6-12. The voltage out- put at either point should measure 110 - 130 VAC.

3.If both or neither J6-7 or J6-12 have high voltage present, replace the voltage selection board. Check voltage between J6-21 and wire #10 on fuse F2 for 110 - 130 VAC. This supplies 120 VAC to the rest of the unit.

B.Enable Circuit Tests

Relay K1 on the Switching Control PC Board, along with SW1-A and F2, completes the 120VAC return path. K1 is energized by the ENABLE switch on the RC6010 remote or if the remote is not used by a switch connected to TB1-1 & 2.

Check for K1 being energized by measuring AC volts from F2 wire #10 to J7-22 and J7-24. It should be 0 v. If so, refer to Section 4.05-D, Motor Control Contactor Check (MC1 or MC2), to check motor contactors. If there is voltage, about 120v, at J7-24 circuit is open between J7-24 and F2 (F2 or SW1-A open). If there is no voltage at J7-24 but it is at J7-22 then K1 is not closed.

If K1 is not closing and the remote is being used tem- porarily jumper TB2 1 to 2. If the fan and pump come on the problem is in the remote’s enable circuit. Check continuity from TB2 back to the remote ENABLE switch to find the problem. If jumping TB2 did not

Manual 0-2533

23

SERVICE TROUBLESHOOTING

Page 26 Page 28
Image 27
Page 26 Page 28
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 Specifications & Design Features Section Introduction DescriptionGeneral Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 energizedTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsPower 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 CheckRemote Current Control Current Control, Display and CSD checksTip Drag Circuit Front Panel Current ControlCorner Slowdown CSD Volt Bias TestPilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit DiagramOK-To-Move Tests 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 ReplacementCoolant Tank Replacement Flow Switch Assembly ReplacementConductivity Sensor 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 ReplacementRelay 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 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

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.
Top Page Image Contents