Thermal Comfort 3000 Base Assembly Parts Replacement, Secondary Water Check Valve Replacement

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CAUTION

Handle and dispose of the used coolant per recom- mended procedures.

3.Remove the two wires from the Conductivity Sen- sor Assembly.

4.Remove the Conductivity Sensor Assembly from the Coolant Tank.

5.Install the replacement Conductivity Sensor As- sembly by reversing the above procedure.

6.Refill the Coolant Tank with the coolant removed or add fresh Thermal Arc Torch Coolant.

J.Secondary Water Check Valve Replacement

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

2.Disconnect the Secondary Gas/Water Hose Assem- bly from the Elbow Fitting connection at the Check Valve.

3.Carefully remove the Check Valve and Elbow Fit- ting from the Secondary Water Solenoid Assem- bly.

NOTE

The output of the replacement Check Valve should be pointing towards the rear of the unit when in- stalled. The output is designated by a symbol on the side of the part as shown in the following Fig- ure.

Check Valve

Symbol

Direction Of Flow

A-00370

4.Install the replacement Check Valve by reversing the above procedure and noting the following:

•Coat the threads of the Elbow Fitting with a teflon sealer before installing the replacement Check Valve.

5.08Base Assembly Parts Replacement

NOTE

Refer to Section 6.07, Base Assembly Replacement Parts, for parts list and overall detail drawing.

A. DC Inductor (L2) Assembly Replacement

WARNING

The removal of this Assembly requires the use of a mechanical lift.

1.Remove the Left and Right Side Panels per Section 5.04-B.

2.Disconnect all the wiring at the DC Inductor As- sembly.

3.Remove the six mounting bolts securing the DC Inductor Assembly to the Base.

4.Place a mechanical lift next to the left side of the Power Supply.

5.Carefully slide the DC Inductor Assembly out the left side of the unit and onto the mechanical lift.

6.Install the replacement DC Inductor Assembly by reversing the above procedure

B.29KVA Transformer (T1) Assembly Replacement

WARNING

The removal of this Assembly requires the use of a mechanical lift.

1.Remove the Left and Right Panels per Section 5.04- B.

2.Disconnect all the wireing at the Transformer As- sembly.

3.Remove the six bolts, star washers and flat wash- ers securing the Transformer Assembly to the Base.

4.Place a mechanical lift next to the left side of the Power Supply.

5.Carefully slide the Transformer Assembly out the left side of the unit and onto the mechanical lift.

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