Thermal Comfort 3000 manual Volt Bias Test, Corner Slowdown CSD

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The display signal at J7-2 should be equal to the control pot wiper voltage at J7-18 measured in Step 3 above.

If this is not correct, the Switching Control PC Board is defective.

After arc transfer the display signal switches to represent actual cutting current as monitored by the Shunt Amp and Switching Control PC Boards. At the same time OK-To-Move is sent to the re- mote shutting off the left hand decimal, refer to Section 4.05-Q, OK-To-Move Tests. The output of the Shunt Amp at J9-5 of the Switching Control PC Board is 5.45 volts for 150 Amps. The display signal at J7-2 should be 10 volts. If the shunt volt- age is correct and the display signal is not then the Switching PC Board is defective.

If the remote display and the shunt amp voltage at J9-5 is correct but the cutting current is low (mea- sured with separate ampmeter) then the Shunt Amp may be faulty but first check step 1 of this section.

5. Corner Slowdown (CSD)

Corner Slowdown (CSD), a CNC signal, is also referred to as standoff inhibit or corner current reduction. The CNC signal comes from the cut- ting machine controller to inhibit the standoff con- trol when cutting speed reduction is desired. Spped reduction may be needed for cutting around corners where high speeds would ad- versely affect the standoff regulation. It also can be used to reduce cutting current when the cut speed is lowered.

A contact closure between J29-7 and 8 or J6-7 and 8 of the Remote Control (RC 6010) sends an active low signal to the Standoff Control (SC10) via J5- 21 which turns OFF the Standoff Control THC ACTIVE indicator, turns ON the three decimals in the VOLTS display and prevents the Standoff Control (SC10) from changing torch height.

NOTE

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

At the same time, the CSD relay in the Remote Control (RC6010) closes switching current control from the OUTPUT AMPS control to the CSD con- trol and turning on the three decimals in the AMPS display. Turning ON switch SW1-1, a dip switch on the Remote Control PC Board inside the Re- mote Control (RC6010), will reverse the logic so a closure is required at the CSD input for normal operation and an open for CSD.

For the Standoff Control (SC11) used without the Remote Control (RC6010), the CNC input for CSD is through J40-10 and J40-11 or J11-1 and J11-2 of the Standoff Control (SC11). For the Power Sup- ply, corner current reduction is only available when using the Remote Control (RC6010). The CSD relay output at J42 is not used with the Power Supply.

If the problem is the CSD on all the time or none of the time disconnect the CSD input from the cutting machine, set Remote Control (RC6010) in- ternal switch SW1-1 OFF and jumper the CSD in- put pins at either J6 or J29 (J42 or J11 for Standoff Control (SC11). If CSD is on (display indicates three decimals) when the jumper is connected and off when the jumper is not connected, the prob- lem is with the cutting machine or the CNC cable. If jumping the CSD does not work, the Remote Control (RC6010) or Standoff Control (SC11) is faulty. If while using the Remote Control (RC6010) and Standoff Control (SC10) together, CSD works in the Remote Control (RC6010) but not the Stand- off Control (SC10) check for a low, less than 3 VDC., on the ribbon cable at J5-21. If not low, with CSD on, the Remote Control (RC6010) is faulty. If J5-21 is low, either the Standoff Control (SC10) is faulty or the ribbon cable is open.

P. 48 Volt Bias Test

1.Remove the remote cable from the Remote Control (RC6010), or the Standoff Control (SC11). Tempo- rally jumper TB2-1 to TB2-2 for enable.

For the Remote Control (RC 6010), measure for +48 +/-5 VDC from J37-16, 35 and 37 (+) to J37- 15,34 and 36 (-). If correct, Remote Control RC6010 is faulty.

For the Standoff Control (SC11), measure J41-3 and 4 (+) to J41-1 and 2 (-). If correct, Standoff Control (SC11) is faulty.

2.If the 48 VDC is not correct, go the Power Supply and measure for +48 +/- 5 VDC at J31-1 to 2 of the Bias PC Board. If correct, check for open in the Power Supply harness to J15 or the remote cable.

If 48 VDC is not correct, remove J31 from the Bias PC Board as and measure again (on the Bias PC Board). If correct, check for a short in the wiring harness of remote cable.

3.If 48 VDC is still incorrect check for 115 VAC at J30- 1 to J30-3 at the Bias PC Board. If correct, replace Bias PC Board. Also, check Fuse (F1), 3A 250v, on the Bias PC Board.

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 Section Introduction Description Specifications & Design FeaturesGeneral Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction 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 pilotEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit 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 presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit 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 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 ReplacementFlow Switch Assembly Replacement Coolant Tank 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 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 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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