Thermal Comfort 3000 Three-Phase Contactor Replacement, Voltage Selection PC Board Replacement

Page 41

7.Locate and remove the four bolts and lock nuts securing the Fan Assembly to the Rear Panel As- sembly.

8.Carefully pull the Fan Assembly from the Rear Panel Assembly feeding the wiring through the hole.

9.Install the replacement Fan Assembly by reversing the above procedure.

B.Three-Phase Contactor Replacement

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

2.Note the orientation of all the wires and then dis- connect the input and output wiring from the Three-Phase Contactor Assembly.

3.Remove the two locking nuts securing the Three- Phase Contactor to the Rear Panel of the unit.

4.Install the replacement Three-Phase Contactor As- sembly by reversing the above procedure.

C.Voltage Selection PC Board Replacement

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

2.Disconnect all the wiring connections to the Volt- age Selection PC Board Assembly.

3.Remove the Voltage Selection PC Board from the four PC Board Standoffs.

4.Install the replacement Voltage Selection PC Board Assembly by reversing the above procedure.

D.Gas Solenoid Assembly Replacement

NOTE

The Plasma and Secondary Gas Solenoid Valve Assemblies are replaced in the same manner.

1.Remove the Top Panel per Section 5.04-B.

2.Disconnect the Gas Supply at the Rear Panel con- nection

3.Disconnect the internal Gas Hose Assembly con- nected to the elbow fitting on the Gas Solenoid Valve Assembly.

4.Disconnect the two wires connected to the Sole- noid Valve Assembly.

5.Remove the Panel Nut securing the assembly to the Rear Panel Assembly.

6.Pull the old Gas Solenoid Valve Assembly from the Rear Panel Assembly.

7.Install the replacement Solenoid Valve Assembly by reversing the above procedure and noting the following:

•Remove the fittings from the old assembly and install on the replacement assembly.

E.Secondary Water Solenoid Valve Assembly Replacement

1.Remove the water supply from the Secondary Water connection at the Rear Panel Assembly.

2.Remove the Top Panel per Section 5.04-B.

3.Disconnect the internal Hose Assembly connected to the elbow fitting on the Secondary Water Soleniod Valve Assembly inside the unit.

4.Carefully disconnect the two wire connector to the Secondary Water Solenoid Valve Assembly.

5.Remove the Panel Nut securing the assembly to the Rear Panel Assembly.

6.Pull the old Secondary Water Solenoid Valve As- sembly from the Rear Panel Assembly.

7.Install the replacement Secondary Water Solenoid Assembly by reversing the above procedure and noting the following:

•Remove the fittings and Check Valve from the old assembly and install on the replacement as- sembly.

F.Rear Panel Coolant Filter Assembly Replacement

The Coolant Filter Assembly is located on a bracket on the Rear Panel Assembly of the unit.

1.Remove the two Coolant Hose connections to the Coolant Filter Assembly.

2.Remove the two elbow fitting on each side of the Coolant Filter Assembly and remove the damaged assembly from the bracket.

3.Clean the old thread sealer from the threads of the elbow fittings.

4.Apply a thin coating of liquid teflon thread sealer to the threads of the elbow fittings.

5.Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings.

6.Reconnect the two Coolant Hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly (left side as viewed from the back).

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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 General Description Specifications & Design FeaturesSection Introduction Description Theory Of Operation Input and Output PowerPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 energizedVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Pressure Sensing Circuit Thermal Sensing Circuit CheckGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRefer to Appendix IX for Start Circuit Diagram Power Supply Start CircuitRemote Control Start Circuit 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 TestOK-To-Move Tests Pilot Resistor AdjustmentRefer to Appendix XII for OK-To-Move Circuit Diagram 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 STR Diode Replacement Relay ReplacementAmp REV 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.

Thermal Comfort 3000 is built with user convenience in mind. It comes equipped with a user-friendly interface that enables easy adjustments and programming. Through a dedicated mobile app, users can control their indoor climate remotely, providing flexibility for those with busy lifestyles. Furthermore, the system offers customizable settings that cater to individual preferences, ensuring that everyone in a space can enjoy their ideal thermal environment.

The technology behind Thermal Comfort 3000 incorporates sustainable practices, utilizing eco-friendly refrigerants and energy-efficient components. This not only reduces the carbon footprint of buildings but also lowers energy costs for users. The system can be integrated with renewable energy sources, such as solar panels, creating a truly sustainable heating and cooling solution.

Thermal Comfort 3000 also features advanced filtration systems that improve indoor air quality. By removing allergens, dust, and other pollutants from the air, it promotes a healthier living environment. This is especially beneficial for individuals with allergies or respiratory issues, making Thermal Comfort 3000 an excellent choice for homes and commercial spaces alike.

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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