Thermal Comfort 3000 manual Upper Chassis Parts Replacement, Main Contactor W1 or W2 Replacement

Page 44

6.Install the replacement Transformer Assembly by reversing the above procedure.

C.Main Contactor (W1 or W2) Replacement

NOTE

The Main Contactors, W1 and W2, are replaced in the same manner.

1.Depending on which Main Contactor Assembly is to be replaced, remove the Left or Right Side Panel per Section 5.04-B.

2.Label all the wiring connected to the Main Contac- tor Assembly.

3.Disconnect the wires from the Main Contactor As- sembly terminals.

4.Remove the two screws and star washers securing the Main Contactor Assembly to the Base.

5.Install the replacement Main Contactor Assembly by reversing the above procedure.

D.Motor (M1) Assembly Replacement

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

2.Loosen the allen set screw securing the Coupling to the shaft of the Motor Assembly.

3.Remove the two bolts and nuts securing the Pilot Resistors, air cooled 4.5 ohms, to the left Pilot Re- sistor Mounting Support.

4.Remove the two bolts securing the Pilot Resistor Mounting Support to the Base.

5.Carefully suspend the free end of the Pilot Resis- tors with string to prevent damage to the resis- tors.

6.Disconnect the Motor Assembly wiring.

7.Remove the four bolts securing the Motor Assem- bly to the Base.

8.Remove the complete Motor Assembly out the left side of the unit.

9.Install the replacement Motor Assembly by revers- ing the above procedure.

E.Pump Assembly Replacement

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

2.Disconnect the two Hose Assemblies at the fittings on the Pump Assembly.

3.Loosen the allen set screw securing the Coupling to the Pump Assembly shaft.

4.Note the orientation of the Pump Assembly to the Pump Mounting Plate.

5.Remove the three nuts securing the Pump Assem- bly to the Pump Mounting Plate.

6.Remove the Pump Assembly from the unit.

7.Install the replacement Pump Assembly by revers- ing the above procedure and noting the follow- ing:

•Remove the Fittings from the old Pump Assem- bly and install on the replacement Pump As- sembly.

•Be sure to align the Pump Assembly to the Pump Mounting Plate as noted in Step 4 above.

5.09Upper Chassis Parts Replacement

NOTE

Refer to Section 6.08, Upper Chassis Replacement Parts, for parts list and overall detail drawing.

A. Power Driver PC Board Kit Replacement

The Power Driver PC Board Replacement Kit is a di- rect parts replacement for the failed Driver PC Board and Switching Transistor (Q1) Assemblies in the Power Supply.

WARNING

Disconnect primary power at the source before as- sembling or disassembling power supply, torch parts, or torch and leads assemblies.

1.Turn OFF main input power to the Power Supply both at the Power Supply ON/OFF switch and at the main power disconnect.

2.Wait at least two minutes to allow the input ca- pacitors to discharge.

3.Remove the top panel of the Power Supply. To remove the top panel of the Power Supply requires the removal of several phillips head screws. Care- fully remove all the screws before attempting to remove the top panel.

4.Locate the old Driver PC Board Assembly on the inside left side, behind the front panel, as viewed from the front of the unit.

REPLACEMENT PROCEDURES

40

Manual 0-2533

Page 43 Page 45
Image 44
Page 43 Page 45
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 LaborGeneral Service Philosophy Service ResponsibilitiesSection Introduction Scope Of ManualIntroduction General Description Specifications & Design FeaturesSection Introduction Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures System Theory Coolant Level and ConductivityDraining Coolant Circuit DescriptionSwitch-Mode Power Supply Operation Switching Control PC BoardRemote Control Logic PC Board FunctionsTroubleshooting Guide Troubleshooting and RepairAdvanced Troubleshooting 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 pilotVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits Coolant Flow Sensor Circuit CheckRefer to Appendix IX for Start Circuit Diagram Power Supply Start CircuitRemote Control Start Circuit Switching Control Check Q1 Q1 LocationPilot Circuit Check High Voltage is presentCurrent Control, Display and CSD checks Tip Drag CircuitFront Panel Current Control Remote Current ControlVolt Bias Test Corner Slowdown CSDOK-To-Move Tests Pilot Resistor AdjustmentRefer to Appendix XII for OK-To-Move Circuit Diagram Service Troubleshooting Section Repairs & Replacement Procedures Anti-Static Handling ProceduresParts Replacement General Information ProcedureExternal Parts Replacement Handle ReplacementLeft/Right Side Panel Replacement Top Panel ReplacementAccess Panel Parts Replacement Front Panel/Chassis Parts ReplacementRear Panel Parts Replacement Three-Phase Contactor Replacement Voltage Selection PC Board ReplacementGas Solenoid Assembly Replacement Secondary Water Solenoid Valve Assembly ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch Assembly Replacement Base Assembly Parts Replacement Secondary Water Check Valve ReplacementDC Inductor L2 Assembly Replacement 29KVA Transformer T1 Assembly ReplacementUpper Chassis Parts Replacement Main Contactor W1 or W2 ReplacementMotor M1 Assembly Replacement Pump Assembly ReplacementBxbx Auxiliary Transformer T3 Assembly Replacement Do not damage HeatsinkPressure Gauge Replacement Coolant Pressure Gauge ReplacementPressure Switch Replacement Plasma or Secondary Gas Input Fitting ReplacementFuse F1 and F2 Replacement Plasma or Secondary Regulator Assembly ReplacementControl Logic PC Board Assembly Replacement Switching Control PC Board Assembly ReplacementMain Heatsink Assembly Parts Replacement Secondary Gas Check Valve 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 Section Parts Lists Parts List BreakdownOrdering Information 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 Daily Operational Checks or Every Six Arc Hours Weekly or Every 30 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.
Top Page Image Contents