Thermal Comfort 3000 Blown Fuse F1 or F2, Motor Control Contactor Check MC1 or MC2, Diode Check

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work check continuity from TB2, wires 102 & 103, to J50-10 & 11. If correct, replace the Switching Control PC Board.

 

 

 

Merlin 3000, 6000

RC6010

 

or 6000GST

 

 

 

 

 

 

 

Switching

 

 

 

 

Control PCB

 

J37-17

J15-5

J50-12

+V1

 

 

J1-5

 

 

 

 

 

ON

 

 

 

J1-4

J37-27

J15-33

J50-10

K1

 

 

E3

 

 

 

 

 

ENABLE

TB2-1

 

E2

J37-26

J15-32

J50-11

 

To AMP/VOLT

TB2-2

 

 

 

 

Display Enable

 

 

A-01137

Enable Circuit Diagram

C.Blown Fuse (F1 or F2)

1.A shorted or frozen motor will cause F1 to fail. To check the motors, disconnect J20 (pump motor) and J39 (fan motor). Reconnect one at a time to determine which component is faulty. A shorted or open fan motor starting capacitor (C32) may also cause F1 to fail.

2.F2 fuses the 110 VAC circuit. MC1 or MC2, T2, T3 and the gas solenoids are energized when power is first applied. If shorted, any one of these com- ponents would cause F2 to fail. W1 or W2, and PCR energize after the torch switch or remote start switch is activated. Disconnect all components and reconnect one at a time to establish which compo- nent is faulty.

D.Motor Control Contactor Check (MC1 or MC2)

NOTE

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

120 VAC is supplied to the Motor Control Contactors (MC1 and MC2) from the Voltage Selection PC Board, which selects the proper tap on the Main Transformer (T1). The return path travels from wire #110 through the remote connector (J15) on the rear panel to the E- Stop switch (or if no remote is used, through K1 on

the Switching Control PC Board) to wire #8, through the ON/OFF switch (SW1A) to wire #9, through fuse F2 to wire #10 and T1.

Only one of the MC contactors should have voltage applied. If the red LED indicator (D18) on the volt- age selection board is lit, MC2 should be energized. If D18 is not lit, MC1 should be energized.

1.Check the voltage across the coil on the contactor for approximately 120 VAC. If voltage is present, replace the contactor. If it is not, perform the 120 VAC test (refer to test paragraph 'A' above) to check for a proper voltage supply from the volt- age selection board. If correct, continue to step 2 to isolate the problem in the return path.

2.With one meter lead on the supply side of the con- tactor coil (wire #3 for MC1 or wire #4 for MC2) measure to wires #8, 9, and 10 to determine where the return circuit is broken. On the return path, F2, SW1-A, and E-Stop can be measured for conti- nuity. K1 on the switching control board will nor- mally be open when power is off.

3.When the remote control cable is installed, a jumper between J15-26 and J15-27 pulls J7-20 on the switching control board to 0 V (board connector J7-19). When the jumper is not in place (remote cable is not plugged in) J7-20 measures +15 VDC and K1 should energize, bypassing the E-stop func- tion. If not, replace the switching control board.

E.Diode Check

There are fourteen diodes in the main heatsink area, including six large 150 amp input rectifier diodes (D1-

6)and eight small 70 amp diodes (snubbing diodes

D7-10 and freewheeling diodes D11-14). To measure the resistance of each diode use one of the following:

•An ohmeter set on the Rx1 or Rx10 scale

•Digital meter set to the diode function

Measure the resistance of each diode in both direc- tions. The readings should differ by at least a factor of ten. If the readings do not differ (both high or both low), disconnect one end of the diode and recheck. If the diode reading is not correct with one end discon- nected, then replace the diode. Check all diodes be- fore turning on power to the system.

If a diode fails, check the potential causes of diode failure to make sure the replacement diode will not also fail when it is installed:

1.Isolate and check each diode separately to deter- mine which individual diode has failed.

SERVICE TROUBLESHOOTING

24

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 LaborGeneral Service Philosophy Service ResponsibilitiesSection Introduction Scope Of ManualIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction 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 pilotEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits 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 presentCurrent Control, Display and CSD checks Tip Drag CircuitFront Panel Current Control 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 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 ReplacementFlow Switch Assembly Replacement Coolant Tank 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 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 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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