Thermal Comfort 3000 manual Auxiliary Transformer T3 Assembly Replacement, Do not damage Heatsink

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PTC Resistor Assembly

Q1

A-01089	Main Heatsink

17.Remove the four screws securing the Switching Transistor module to the Main Heatsink.

18.Pry between the Main Heatsink and the faulty Switching Transistor Assembly until it slides eas- ily.

19.Remove the faulty Switching Transistor Assem- bly from the unit by sliding it towards the center of the Main Heatsink.

CAUTION

DO NOT damage Heatsink.

20.If the transistor thermstrate was not removed with the transistor, it must be removed.

21.Clean the old transistor thermstrate from the tran- sistor mounting area. Verify that the Heatsink sur- face under the transistor is smooth and free of de- fects.

22.Install the replacement Transistor Thermstrate and the Switching Transistor Assembly by reversing the above procedure and noting the following:

•Place the replacement Transistor Thermstrate onto the Main Heatsink at the Switching Tran- sistor mounting location.

•Depending on the style of the replacement Switching Transistor connect the wires per one of the following Figures:

Wire #84

Wire #83

BX
E	B
	B
Q1
A-01086	Wire #82
	Wire #82

Wire Connections (Q1 With E Terminal)

Wire #83

BX

B

Wire #84

Q1

A-01087	Wire #82

Wire Connections (Q1 Without E Terminal)

•The metric screws supplied with the Switching Transistor are to be used for the transistor wire connections. Small metric screws are to be torqued to 12 in-lbs (1.4 Nm). Larger metric screws are to be torqued to 26 in-lbs (2.9 Nm).

B.Auxiliary Transformer (T3) Assembly Replacement

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

2.Disconnect the wiring connector from the wiring harness at the Auxiliary Transformer Assembly.

3.Remove the two mounting screws securing the Auxiliary Transformer Assembly to the Upper Chassis/Gauge Assembly.

4.Remove the Auxiliary Transformer Assembly from the unit.

5.Install the replacement Auxiliary Transformer As-

sembly by reversing the above procedure.

REPLACEMENT PROCEDURES

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Manual 0-2533

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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 LaborSection Introduction General Service PhilosophyService Responsibilities Scope Of ManualIntroduction Section Introduction Description Specifications & Design FeaturesGeneral Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlPeriodic Inspection & Procedures Section Service Troubleshooting DiagnosticsIntroduction Draining Coolant System TheoryCoolant Level and Conductivity Circuit DescriptionRemote Control Switch-Mode Power Supply OperationSwitching Control PC Board Logic PC Board FunctionsAdvanced Troubleshooting Troubleshooting GuideTroubleshooting and Repair 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 pilotEnable Circuit Tests Test ProceduresVoltage Selection PC Board Check Motor Control Contactor Check MC1 or MC2 Blown Fuse F1 or F2Diode Check Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit Coolant Flow Sensor Circuit CheckRemote Control Start Circuit Power Supply Start CircuitRefer to Appendix IX for Start Circuit Diagram Switching Control Check Q1 Q1 LocationPilot Circuit Check High Voltage is presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit Remote Current ControlVolt Bias Test Corner Slowdown CSDRefer to Appendix XII for OK-To-Move Circuit Diagram Pilot Resistor AdjustmentOK-To-Move Tests Service Troubleshooting Parts Replacement General Information Section Repairs & Replacement ProceduresAnti-Static Handling Procedures ProcedureLeft/Right Side Panel Replacement External Parts ReplacementHandle Replacement Top Panel ReplacementAccess Panel Parts Replacement Front Panel/Chassis Parts ReplacementRear Panel Parts Replacement Gas Solenoid Assembly Replacement Three-Phase Contactor ReplacementVoltage Selection PC Board Replacement Secondary Water Solenoid Valve Assembly Replacement Flow Switch Assembly Replacement Coolant Tank Replacement Conductivity Sensor Assembly Replacement DC Inductor L2 Assembly Replacement Base Assembly Parts ReplacementSecondary Water Check Valve Replacement 29KVA Transformer T1 Assembly ReplacementMotor M1 Assembly Replacement Upper Chassis Parts ReplacementMain Contactor W1 or W2 Replacement Pump Assembly ReplacementBxbx Auxiliary Transformer T3 Assembly Replacement Do not damage HeatsinkPressure Switch Replacement Pressure Gauge ReplacementCoolant Pressure Gauge Replacement Plasma or Secondary Gas Input Fitting ReplacementControl Logic PC Board Assembly Replacement Fuse F1 and F2 ReplacementPlasma or Secondary Regulator Assembly Replacement Switching Control PC Board Assembly ReplacementAmp STR. Diode Replacement Main Heatsink Assembly Parts ReplacementSecondary Gas Check Valve 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 Ordering Information Section Parts ListsParts List Breakdown 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 Six Months or Every 720 Arc Hours Daily Operational Checks or Every Six Arc HoursWeekly or Every 30 Arc Hours Twelve Months or Every 1500 Arc Hours