Thermal Comfort 3000 Section Repairs & Replacement Procedures, Anti-Static Handling Procedures

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SECTION 5:

REPAIRS & REPLACEMENT

PROCEDURES

5.01 Introduction

This Section describes parts replacement procedures and all repairs which may be performed on the Merlin 3000 Power Supply.

Under no circumstances are field repairs to be attemped on Printed Circuit Boards or other Subassemblies of this unit. Evidence of unauthorized repairs may void the fac- tory warranty.

5.02Anti-Static Handling Procedures

A. General

CAUTION

PC boards can be irreparably damaged by improper handling due to electrostatic discharge (ESD).

Replacement PC boards are shipped in a protective en- closure to prevent damage from electrostatic discharge (ESD) during shipping. Included with each replacement board is a ground strap to prevent static damage during installation.

WARNINGS

Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov- ing the replacement PC board from its protective enclosure.

Disconnect primary power to the system before dis- assembling the torch, torch leads, or power supply enclosure.

Do not operate the equipment or test equipment under power while wearing the grounding wrist strap.

B.Procedure

1.Open the wrist strap and unwrap the first two folds of the band. Wrap the adhesive side firmly around your wrist.

2.Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

3.Attach the copper foil to a convenient and exposed electrical ground.

4.Connect the equipment primary cable ground to the same electrical ground as the wrist strap.

5.Open the equipment enclosure (see instruction manual for the appropriate equipment) and re- move the failed PC board.

6.Carefully open the ESD protective bag and remove the replacement PC board.

7.Install the replacement PC board in the equipment and make all necessary connections.

8.Place the failed PC board in the ESD protective bag and seal for return shipping.

9.Reassemble the equipment enclosure (see instruc- tion manual for the appropriate equipment).

10.Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment.

5.03Parts Replacement - General Information

The parts replacement procedures described in this manual, except for Rear Panel Coolant Filter and exter- nal Fuse(s) replacement, require that the Power Supply be disassembled. Depending on the part to be replaced will determine to what extent the Power Supply must be disassembled.

NOTES

Before removing any electrical connection mark each wire with the connection designation. When reassembling this makes sure the wires go to the proper terminals.

Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit.

Turn OFF all gas inputs to the Power Supply at the source before diconnecting any gas Hose As- semblies.

Each Subsection is referenced to Section 6 for parts lists and overall detailed drawing.

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REPLACEMENT PROCEDURES

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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 Section Introduction Description Specifications & Design FeaturesGeneral Description Theory Of Operation Input and Output PowerPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction 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 energizedEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Pressure Sensing Circuit Thermal Sensing Circuit CheckGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRemote 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 CheckTip Drag Circuit Current Control, Display and CSD checksFront Panel Current Control Remote Current ControlCorner Slowdown CSD Volt Bias TestRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-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 ReplacementFlow Switch Assembly Replacement Coolant Tank 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 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 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

3000 specifications

Thermal Comfort 3000 is an innovative solution designed to enhance indoor climate by ensuring optimal thermal comfort for users. As the demand for energy efficiency and sustainable building practices grows, Thermal Comfort 3000 emerges as a key player in providing customizable and effective climate control systems.

One of the main features of Thermal Comfort 3000 is its advanced smart technology that allows for precise temperature regulation based on real-time data. It utilizes sensors that monitor indoor and outdoor temperatures, humidity levels, and even occupancy patterns. This data is then analyzed to optimize the heating and cooling systems, ensuring that energy is used efficiently. With its ability to automatically adjust to changing conditions, users can enjoy a consistent and comfortable environment without excessive energy consumption.

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In summary, Thermal Comfort 3000 represents the future of climate control technology. Its combination of smart features, user-centric design, and sustainability makes it an ideal solution for enhancing thermal comfort in any indoor environment. With its innovative approach, it not only ensures comfort but also promotes energy efficiency and environmental responsibility, making it a worthwhile investment for modern living.
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