Thermal Comfort 3000 manual Access Panel Parts Replacement, Front Panel/Chassis Parts Replacement

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2.Loosen the two screws of the Work Cable strain relief securing the Work Cable at the Front Panel.

3.Remove the nut (under the Horizontal Chassis Panel) securing the Work Cable connection to the Shunt Assembly.

4.Pull the Work Cable from the unit.

5.Install the replacement Work Cable by reversing the above procedure.

5.05Access Panel Parts Replacement

NOTE

Refer to Section 6.04, Access Panel Replacement Parts, for parts list and overall detail drawing.

A.CURRENT Knob Replacement

1.Turn the CURRENT adjustment fully counter clock- wise and note the location of the pointer on the knob.

2.Loosen the screw securing the Current Knob to the potentiometer shaft.

3.Remove the old knob.

4.Place the replacement Current Knob on to the po- tentiometer shaft with the location of the pointer the same as noted in step 1.

5.Tighten the screw to secure the knob to the poten- tiometer shaft.

B.ON/OFF Switch Replacement

1.Unlatch the Access Panel to gain access to the rear of the ON/OFF Switch.

2.Disconnect all the wiring to the ON/OFF Switch.

3.Squeeze the top and bottom of the switch while pulling it out of the Access Panel

4.Install the replacement ON/OFF Switch by revers- ing the above procedure.

C.RUN/SET/PURGE Switch Replacement

1.Unlatch the Access Panel to gain access to the rear of the RUN/SET/PURGE Switch.

2.Disconnect all the wiring to the RUN/SET/PURGE Switch.

3.Squeeze the top and bottom of the switch while pulling it out of the Access Panel

4.Install the replacement RUN/SET/PURGE Switch by reversing the above procedure.

D.LED/Current Control PC Board Assembly Replacement

1.Remove the Current Knob per paragraph 'A' above.

2.Unlatch the Access Panel to gain access to the LED/ Current Control PC Board.

3.Remove the four screws and washers securing the LED/Current Control PC Board to the Access Panel.

4.Disconnect the connector at J5 of the LED/Current Control PC Board.

5.Install the replacement LED/Current Control PC Board by reversing the above procedure.

E.Access Panel Replacement

1.Remove the Right Side Panel per Section 5.04-B.

2.Remove the following components from the Ac- cess Panel:

•Current Knob per paragraph 'A' above.

•ON/OFF Switch per paragraph 'B' above.

•RUN/SET/PURGE Switch per paragraph 'C' above.

•LED/Current Control PC Board per paragraph 'D' above.

3.Remove the four screws securing the Access Panel to the LED/Current Control PC Board standoffs.

4.Install the replacement Access Panel by reversing the above procedure.

5.06Front Panel/Chassis Parts Replacement

NOTE

Refer to Section 6.05, Front Panel/Chassis Replace- ment Parts, for parts list and overall detail draw- ing.

A. Internal Coolant Filter Replacement

The Internal Coolant Filter Assembly is located inside behind the Left Side Panel (viewed from the front of the unit). The filter is attached to the Radiator inside of the Lower Front Panel.

1.Remove the Left Side Panel from the Power Sup- ply per Section 5.04-B.

2.Locate the Internal Coolant Filter near the front of the unit.

Manual 0-2533

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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 WarrantyScope Of Manual General Service PhilosophyService Responsibilities Section IntroductionIntroduction Specifications & Design Features Section Introduction DescriptionGeneral Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 energizedTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsPower 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 CheckRemote Current Control Current Control, Display and CSD checksTip Drag Circuit Front Panel Current ControlCorner Slowdown CSD Volt Bias Test Pilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit Diagram OK-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 ReplacementCoolant Tank Replacement Flow Switch Assembly 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 ReplacementRelay 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 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
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