Thermal Comfort 3000 manual Current Control, Display and CSD checks, Tip Drag Circuit

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If 24 VAC is not present, remove J14 control connec- tor at the torch bulkhead and measure for 24 VAC be- tween pins 5 and 8 of the receptacle. The 24 VAC comes from T3, is fused by F3, 1A 250v, and passes through the filter FL1 to J14. If voltage is not present at J14 the most likely fault is the fuse. T3 and the FL1 are other possibilities. If F3 is blown replace it and leave J14 disconnected. If it doesn’t blow, then recon- nect J14. If fuse blows again then the Arc Starter PC Board is defective or there is a short in the torch leads between J14 and the Arc Starter PC Board.

O. Current Control, Display and CSD checks

1. Tip Drag Circuit

The Merlin 3000 has a circuit that monitors the torch tip voltage to reduce cutting current to 40- 50 amps reducing consumable parts wear if the tip voltage is less than -20 volts indicating double arcing or the tip contacting the work. Wire #7 from the torch bulkhead (+) connection connects to the Logic PC Board at terminal W7. If the voltage there is less than -20 VDC the Logic PC Board puts a low on J3-25 (can measure at TP5 on the Logic PC Board) causing the Switching Control PC Board (J10-25) to reduce the current. When piloting or cutting the tip voltage at W7 should be greater than -20 volts, if so and Logic TP5 is low the Logic PC Board is defective.

2. Front Panel Current Control

If the Remote Control (RC6010) is being used the front panel control is inactive, go to next step.

The front panel current control receives it’s high level (10 VDC) on J10-17 and it’s low level (3.3 VDC) on J10-13. Verify those voltages (with re- spect to TP1 on the Switching Control PC Board) then measure the pot’s wiper between J10-15 and TP1. It should vary from 3.3 to 10 VDC as the control is moved from minimum to maximum. If it does not vary or is less than 3.3 VDC, then the control pot in the LED PC Board is faulty or the ribbon cable is faulty. If the high and low (3.3 VDC and 10 VDC) are incorrect, the Switching Control PC Board is faulty or the ribbon cable is shorted.

3.Remote Current Control

NOTE

Refer to Appendix X for Current Control Display Circuit Diagram.

The Remote Control (RC 6010) has front panel controls for OUTPUT AMPS and CSD. The up- per and lower limits of the current control range are set by the POT HI (+10 VDC) and POT LOW

(+3.3 VDC) signals from J50-8 and J50-6 on the Switching Control PC Board sent to the remote via the remote cable.

The CSD control upper limit is set by the wiper of the OUTPUT AMPS control thus the CSD range is a percentage (%) of the main output. The wiper of the main pot is sent through the normally closed CSD relay contact out the remote cable to J7-18 on the Switching Control PC Board. If CSD is en- abled, indicated by illuminating the 3 decimals in the display, then the CSD wiper provides the cur- rent control signal to J7-18.

NOTE

Refer to Appendix XI for Corner Slowdown (CSD) Circuit Diagram.

If the OUTPUT AMPS control or the CSD control have no effect on current level see if the panel con- trol does, if so, there may be a poor connection in the REMOTE INSTALLED circuit between the re- mote and Switching Control PC Board. Check TP1 to J7-20, if it does not measure less than 2v there is a faulty connection, otherwise the Switching Con- trol PC Board is faulty.

If the front panel control had no effect (which it shouldn’t) measure from TP1 to J7-18 while mov- ing the OUTPUT AMPS control from min to maxi- mum.

The voltage at J7-18 should vary from 3.3v to 10 v. If it does the Switching Control PC Board is faulty.

If voltage is incorrect at J7-18, check J50-8 for 10 v and J50-6 for 3.3 v. If OK then the remote is defec- tive or the connections (remote cable or Merlin) harness are open.

4. Remote AMPS Display

The AMPS display shows control pot setting (pre- view) and actual cutting amps. The decimal points indicate when CSD (standoff inhibit) is on by light- ing all 3 decimals and when OK-To-Move is not on by lighting the left hand decimal.

The AMPS display is driven by a signal from the Merlin Switching Control PC Board J7-2.

NOTE

Refer to Appendix X for Display Circuit Diagram.

Positive 3.3 to 10 volts at J37-1 gives a display from 50 to 150 AMPS. Prior to cutting arc transfer the display signal is in the “preview” mode as indi- cated by the left hand decimal being on. The dis- play is indicating the current control pot setting.

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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 WarrantyService Responsibilities General Service PhilosophySection Introduction Scope Of ManualIntroduction Specifications & Design Features Section Introduction DescriptionGeneral Description Theory Of Operation Input and Output PowerPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction Coolant Level and Conductivity System TheoryDraining Coolant Circuit DescriptionSwitching Control PC Board Switch-Mode Power Supply OperationRemote Control Logic PC Board FunctionsTroubleshooting and Repair Troubleshooting GuideAdvanced Troubleshooting Standoff ControlHow 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 Pressure Sensing Circuit Thermal Sensing Circuit CheckGas Solenoid Circuits Coolant Flow Sensor Circuit CheckPower 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 CheckTip Drag Circuit Current Control, Display and CSD checksFront Panel Current Control Remote Current ControlCorner Slowdown CSD Volt Bias TestPilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit DiagramOK-To-Move Tests Service Troubleshooting Anti-Static Handling Procedures Section Repairs & Replacement ProceduresParts Replacement General Information ProcedureHandle Replacement External Parts ReplacementLeft/Right Side Panel Replacement Top Panel ReplacementFront Panel/Chassis Parts Replacement Access Panel Parts ReplacementRear Panel Parts Replacement Voltage Selection PC Board Replacement Three-Phase Contactor ReplacementGas Solenoid Assembly Replacement Secondary Water Solenoid Valve Assembly ReplacementCoolant Tank Replacement Flow Switch Assembly ReplacementConductivity Sensor Assembly Replacement Secondary Water Check Valve Replacement Base Assembly Parts ReplacementDC Inductor L2 Assembly Replacement 29KVA Transformer T1 Assembly ReplacementMain Contactor W1 or W2 Replacement Upper Chassis Parts ReplacementMotor M1 Assembly Replacement Pump Assembly ReplacementBxbx Do not damage Heatsink Auxiliary Transformer T3 Assembly ReplacementCoolant Pressure Gauge Replacement Pressure Gauge ReplacementPressure Switch Replacement Plasma or Secondary Gas Input Fitting ReplacementPlasma or Secondary Regulator Assembly Replacement Fuse F1 and F2 ReplacementControl Logic PC Board Assembly Replacement Switching Control PC Board Assembly ReplacementSecondary Gas Check Valve Replacement Main Heatsink Assembly Parts ReplacementAmp STR. Diode 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 Parts List Breakdown Section Parts ListsOrdering Information ReturnsItem # 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 Weekly or Every 30 Arc Hours Daily Operational Checks or Every Six Arc HoursSix Months or Every 720 Arc Hours Twelve Months or Every 1500 Arc Hours

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