Thermal Comfort 3000 manual Coolant Pressure Gauge Replacement, Pressure Switch Replacement

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C. Pressure Gauge Replacement

NOTE

Both the Plasma and Secondary gauges are replaced in the same manner

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

2.Disconnect the wiring tho the desired Pressure Switch.

3.Remove the Pressure Switch from the desired Pres- sure Gauge Assembly.

4.Disconnect the input gas Hose Assembly from the fitting at the Pressure Gauge.

5.Remove the fitting(s) from the Pressure Gauge.

6.Remove the nut and clamp Securing the Pressure Gauge Assembly to the Upper Chassis/Gauge Assembly.

7.Slide the Pressure Gauge out of the Upper Chas- sis/Gauge Assembly.

8.Reinstall the replacement Pressure Gauge Assem- bly by reversing the above procedure.

NOTE

Be sure that the Pressure Gauge orientation is cor- rect when installed. The 80 PSI mark should be at the twelve o'clock position.

D.Coolant Pressure Gauge Replacement

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

2.Disconnect the Coolant Hose Assembly from the fitting at the Pressure Gauge.

3.Remove the fitting(s) from the Pressure Gauge.

4.Remove the nut and clamp Securing the Pressure Gauge Assembly to the Upper Chassis/Gauge Assembly.

5.Slide the Pressure Gauge out of the Upper Chas- sis/Gauge Assembly.

6.Reinstall the replacement Pressure Gauge Assem- bly by reversing the above procedure.

NOTE

Be sure that the Pressure Gauge orientation is cor- rect when installed. The 80 PSI mark should be at the twelve o'clock position.

E. Pressure Switch Replacement

NOTE

Both the Plasma and Secondary Pressure Switches are replaced in the same manner

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

2.Disconnect the two wires connected to the Pres- sure Switch Assembly.

3.Remove the assembly from the T-fitting.

4.Install the replacement Pressure Switch Assembly by reversing the above procedure and noting the following:

•Apply pipe thread sealant to the fitting before reassembling.

F.Coolant Supply and Return Bulkhead Adapter Fitting Replacement

NOTE

Both the Coolant Supply and Return Bulkhead Fittings are replaced in the same manner.

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

2.Remove the Torch connection to the Bulkhead Adapter Fitting.

3.Disconnect the gas Hose Assembly from the fitting at the end of the Bulkhead Adapter Fitting.

4.Remove the fittings from the end of the Bulkhead Adapter Fitting.

5.Remove the first nut from the Bulkhead Adapter Fitting.

6.Remove the second nut securing the Bulkhead Adapter to the Upper Chassis/Gauge Assembly.

7.Pull the Bulkhead Adapter Fitting from the Upper Chassis/Gauge Assembly.

8.Install the replacement Bulkhead Adapter by re- versing the above procedure.

G.Plasma or Secondary Gas Input Fitting Replacement

NOTE

Both the Plasma and Secondary Gas fittings are replaced in the same manner

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

2.Disconnect the Torch connection to the fitting be- ing replaced at the Upper Chassis/Gauge Assem- bly.

Manual 0-2533

43

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 General Description Specifications & Design FeaturesSection Introduction Description Pilot Arc Input and Output PowerTheory Of Operation Plasma Arc Cutting and GougingOptions And Accessories Plasma/Secondary Gas Control Hour/Counter MetersIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 energizedVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Coolant Flow Sensor Circuit Check Thermal Sensing Circuit CheckPressure Sensing Circuit Gas Solenoid CircuitsRefer 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 CheckRemote Current Control Current Control, Display and CSD checksTip Drag Circuit Front Panel Current ControlCorner Slowdown CSD Volt Bias TestOK-To-Move Tests Pilot Resistor AdjustmentRefer to Appendix XII for OK-To-Move Circuit Diagram 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 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 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

3000 specifications

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