Thermal Comfort 3000 manual Switching Control Check Q1, Q1 Location

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lem is in the Standoff Control (SC10) or the ribbon cable. Refer to Section 5, Customer/Operator Service, in the Standoff Control Instruction Manual.

If the Standoff Control (SC10) isn’t used or the Power Supply didn’t start with the ribbon cable disconnected, there are two approaches you can take. Either dis- connect the remote and see if the Power Supply will start without it or check if the start signal is getting to the Remote Control (RC6010). To check the Power Supply, remove the remote connector at J15 and con- nect a jumper TB2-1 to TB2-2 for ENABLE, then jump TB2-3 to TB2-4 for start. If it starts the problem is in the remote or CNC connections. If not refer to Sec- tion 4.05-K, Power Supply Start Circuit.

To check for start to the Remote Control (RC6010), open the Remote Control cover and see if indicator D103 comes ON. If so, problem is in Remote control (RC6010) or the remote cable. If indicator D103 is OFF, remove J29 (or the CNC start connections to J6) and jumper J29-3 to 4 or J6-3 to 4. Don’t jumper to the screw heads on J6 as they don’t always make electri- cal contact. If it starts (indicator D103 ON) with the jumper, the problem is in the CNC connections. If not, replace the Remote Control (RC6010).

M. Switching Control Check (Q1)

To produce DC output, the main switch (Q1) must be turned on and off rapidly. Power Supply output is controlled by the on-time. At the same time the Main Contactor (W1 or W2) closes, the Logic PC Board grounds pins 9 and 23 of the 34-pin ribbon cable (J3-9 on the Logic PC Board, J10-9 on the Switching Con- trol PC Board). This enables the pulse width modula- tor (PWM) on the Switching Control PC Board.

If no DC voltage is detected within 75 ms at J1-24 on the Logic PC Board, the enable signal on J10-9 is re- moved and the Main Contactor opens. Connecting TP4 to TP1 (ground) on the Logic PC Board disables this function for troubleshooting if no DC output is found.

Switching Transistor

Transistor/Coil

Bracket

Q1

 

Large Blue

A-01085

Capacitors

 

Q1 Location

To check for a defective Q1, first disconnect J27 from the Driver PC Board.

Rear of Front Panel

A-01083

Driver PC Board

Driver PC Board Location

On a X1 or X10 scale or with a digital meter set for diode, measure between “C” (collector) terminal, wire #83, and “E” (emitter) terminal, wire #84. Reverse the meter leads and measure again. It is normal to measure an open (high reading) one way and a lower reading the other. A low or zero measurement both ways means the Q1 is shorted and must be replaced.

If correct, measure from the “B” (base) terminal, wire #82, to “E” (emitter) terminal, wire #84. Normal read- ing is from about 50 to 150 ohms (digital meter on ohms not diode scale) a short (zero ohms) or an open indicates a defective Q1.

NOTE

If the Switching Control Q1 has failed, the Driver PC Board must also be replaced. Refer to Section 6.08, Item #2, for replacement parts.

Manual 0-2533

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SERVICE TROUBLESHOOTING

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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 Section Introduction Description Specifications & Design FeaturesGeneral Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction 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 energizedEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsRemote Control Start Circuit Power Supply 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 TestRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-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 ReplacementFlow Switch Assembly Replacement Coolant Tank 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 ReplacementAmp 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 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

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