Thermal Comfort 3000 manual Power Supply Start Circuit, Remote Control Start Circuit

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2.If the coolant conductivity indicator is not lit with the probe disconnected, measure between the Logic PC Board common (TP1) and J3-1. If the voltage measures below +12 VDC, replace the LED PC board. If the voltage measures above +12 VDC, replace the Logic PC Board.

K.Power Supply Start Circuit

NOTE

Refer to Appendix IX for Start Circuit Diagram.

The start signal enters the Merlin at J15-24(sig) and J15-25 (return) or if no remote is used it could be wired to TB2-3 & 4. From there it goes directly to the Logic PC Board. For troublshooting remove any remote con- nections from either J15 or TB2. Connect a jumper from TB2-1 to TB2-2 to enable the Merlin.

The RUN (D1) and READY (D2) leds on the Logic PC Board should be on. If The front panel TEMP led is green and the COOLANT PRESSURE led is on but READY is not on, the Logic PC Board is defective. If READY is on and RUN isn’t, check that RUN/SET/ PURGE is set to run. Measure for less than 1 VDC on the Logic PC Board J1-13 to J1-12. If correct the Logic PC Board is defective. If greater than 1 VDC, the RUN/SET/PURGE switch or wire connections to it are defective.

If RUN and READY are on, connect a jumper from TB2-3 to TB2-4. Logic PC Board START led, D3, should come on and gases start flowing. If not, check for less than 1 VDC at J1-19 to J1-18. If correct, Logic PC Board is defective. If greater that 1 V, wiring from TB2 to J1 is defective.

After the gases flow for the selected preflow time the W ON led should light and both the main contactor (W1 or W2) and PCR contactor should come on. If W ON does not light, even momentarly, the Logic PC Board is defective.

If W ON is on for a moment then off but neither W1 or W2 comes on even momentarly do the following:

The Logic PC Board has a circuit to monitor the power supply output voltage. If the circuit doesn't sense voltage in 75 ms, if the contactor doesn’t come on, it shuts off the power to the contactor which makes it hard to troublshoot. Connecting a jumper between TP4 and TP1 on the Logic PC Board disables the volt- age sensing circuit so W ON led stays on.

On the Logic PC Board, K2, sends 120 VAC to the Volt- age Selection PC Board (refer to Appendix VI). Relay K5 directs that voltage to either W1 or W2 depending on the level of incoming line voltage. If high, LED D38 on the Voltage Selection PC Board will be ON

and the 120 VAC should go to W2 otherewise it goes to W1. The first step is to measure for 120 VAC from Logic PC Board J2-9 to wire #110 (PCR coil, MC1 or MC2 coils). If no voltage, the Logic PC Board is faulty. If about 120 VAC is present, measure the voltage at the W contactor coil (W2 if LED on Voltage Selection PC Board is ON, or else W1). If about 120 VAC is present the contactor is faulty. If no voltage, check from wire #110 to J6-1 and J6-3 on the Voltage selec- tion PC Board. One of the two should have about 120VAC, if not check J6-5. If it measures 120VAC re- place the voltage selection PC Board. If there is no voltage at J6-5 but was on J2-9, there is a faulty con- nection (wire #23).

L. Remote Control Start Circuit

NOTE

Refer to Appendix IX for Start Circuit Diagram.

The start signal from the cutting machine controller enters the RC6010 at J29 or J6 and may be either a momentary closure (J29-1) or sustained closure (J29- 3). It passes through optical isolation circuits and, if the ENABLE is on and the station select input is ac- tive, lights internal led D103. If the Standoff Control (SC10) is not used, start goes to the remote cable at J37-9.

If the Standoff Control (SC10) is connected, then the start signal goes to it, active low at J5-13, lights inter- nal indicator D79 and starts the find height sequence. Once height is found the front panel PLASMA ON inicator comes ON. If FIND HT is not ON, the find height function is by passed and PLASMA ON comes on immediately. The start signal then is returned to the Remote Control (RC6010), active low on J7-17, and to the remote cable on J37-9 to the Power Supply re- mote connector J15-24 and TB2-3 and on to the Power Supply Logic PC Board.

If the Standoff Control (SC10) is installed and the sys- tem won’t find height the problem is in the Standoff Control (SC10), Remote Control (RC6010) or the in- terconnections to the cutting machine. Set FIND HT off, it the torch starts now the problem is in the Stand- off Control (SC10).

NOTE

Refer to Section 5, Customer/Operator Service, in the Standoff Control Instruction Manual.

If it doesn’t start open the cover of either the Standoff Control (SC10) or Remote Control (RC6010), which- ever one is on top, and disconnect the ribbon cable at J5 or J7. Then if the Power Supply will start the prob-

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 Specifications & Design Features Section Introduction DescriptionGeneral Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 pilotTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit 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 presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit 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 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 ReplacementCoolant Tank Replacement Flow Switch Assembly ReplacementConductivity Sensor 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 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 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

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