Thermal Comfort 3000 Fuse F1 and F2 Replacement, Control Logic PC Board Assembly Replacement

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3.Disconnect the gas Hose Assembly from the fitting at the end of the Gas Input Fitting.

4.Remove the fitting screwed into the end of the Gas Input Fitting.

5.Remove the first nut from the Gas Input Fitting.

6.Remove the second nut securing the Gas Input Fit- ting to the Upper Chassis/Gauge Assembly.

7.Pull the fitting from the Upper Chassis/Gauge As- sembly.

7.Reinstall the replacement Plasma or Secondary Gas Input Fitting Assembly by reversing the above pro- cedure.

H.Fuse (F1 and F2) Replacement

1.Open the hinged cover at the Front Panel torch leads connection area.

2.Locate and remove the cap from the fuse holder.

3.Pull the faulty Fuse from the fuse holder.

4.Install the replacement Fuse by reversing the above procedure.

I.Plasma or Secondary Regulator Assembly Replacement

NOTE

Both the Plasma and Secondary Regulator Assem- blies are replaced in the same manner

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

2.Carefully remove the input and output gas Hose Assemblies to the Regulator Assembly.

3.On the Upper Ghassis/Gauge Assembly remove the securing nut for the Regulator Assembly.

4.Slide the Regulator Assembly.out of rear of the Upper Ghassis/Gauge Assembly.

5.Remove the fittings from the old Regulator Assem- bly.

6.Reinstall the replacement Regulator Assembly by reversing the above procedure.

J.Control Logic PC Board Assembly Replacement

1.Open the front panel access panel cover at the front of the Power Supply.

2.Fasten the access cover open with string or rubber band.

3.Note where each connector is located on the old Control Logic PC Board.

4.Disconnect the three connectors from the old Con- trol Logic PC Board.

5.Note the orientation of the old Control Logic PC Board.

6.Remove the old Control Logic PC Board.

7.On the new Control Logic PC Board set the switches, SW1 through SW5, the same as the old Control Logic PC Board.

8.Install the replacement Control Logic PC Board by reversing the above procedure.

K.Switching Control PC Board Assembly Replacement

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

2.Note the orientation of the old Switching Control PC Board.

3.Remove the Switching Control PC Board from the rear of the Upper Chassis/Gauge Panel far enough to disconnect the wiring connections.

4.Note where each connector is located on the Switch- ing Control PC Board.

5.Disconnect the connectors from the Switching Con- trol PC Board.

6.Reconnect the original wiring connectors to the replacement Switching Control PC Board before installing the replacement Switching Control PC Board.

7.Install the replacement Switching Control PC Board by reversing the above procedure.

L.Coolant Check Valve Replacement

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

2.Disconnect the Hose Assemblies from the fitting connection at the input end of the Check Valve.

3.Carefully remove the Check Valve and fittings from the TORCH COOLANT SUPPLY fitting.

4.Remove the Fittings from the old Check Valve.

NOTE

The input 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.

REPLACEMENT PROCEDURES

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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 LaborGeneral Service Philosophy Service ResponsibilitiesSection Introduction Scope Of ManualIntroduction Specifications & Design Features Section Introduction DescriptionGeneral Description Input and Output Power Theory Of OperationPlasma Arc Cutting and Gouging Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlSection Service Troubleshooting Diagnostics Periodic Inspection & ProceduresIntroduction 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 pilotTest Procedures Enable Circuit TestsVoltage Selection PC Board Check Blown Fuse F1 or F2 Motor Control Contactor Check MC1 or MC2Diode Check Thermal Sensing Circuit Check Pressure Sensing CircuitGas Solenoid Circuits Coolant Flow Sensor Circuit CheckPower Supply Start Circuit Remote Control Start CircuitRefer to Appendix IX for Start Circuit Diagram 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 CSDPilot Resistor Adjustment Refer to Appendix XII for OK-To-Move Circuit DiagramOK-To-Move Tests 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 ReplacementCoolant Tank Replacement Flow Switch Assembly ReplacementConductivity Sensor 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 installedRelay Replacement Amp REV Diode ReplacementAmp STR 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.
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