Thermal Comfort 3000 Relay Replacement, Amp REV Diode Replacement, Amp STR Diode Replacement

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d.Re-solder the wire lead to the replacement di- ode.

e.Apply a layer of RTV over the top of the Diode Assembly to encapsulate the lead and top of the diode.

Wire Lead

70 Amp

RTV

Diode

 

A-01166

f.Close up the Power Supply.

B.Relay Replacement

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

2.Move the Relay Hold-Down Spring to the side of the Relay Assembly.

3.Pull the Relay Assembly from the Relay Socket.

4.Install the replacement Relay Assembly by revers- ing the above procedure.

C.150 Amp REV Diode Replacement

The Diode Replacement Kit (Cat # 8-6152) is a direct parts replacement for the failed Diode Assembly in the Power Supply.

The following parts are supplied with each replace- ment assembly:

•150 Amp, 800V Rev Diode Assembly (1 each)

•1.06 inch diameter Thermal Interface Pad (1 each)

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.Open the Power Supply to gain access to the faulty Diode Assembly.

4.Locate the old Diode Assembly inside the Power Supply.

5.Remove the nut and washer securing the old diode assembly to the mounting surface.

6.Remove the nut securing the diode wire lead to the PC Board.

7.Make sure the replacement diode is a direct re- placement for the old one.

8.Install the replacement diode by reversing the above procedure and noting the following:

a.Wipe the surface clean where the replacement diode is to be installed.

NOTE

The thermal interface pads must be properly aligned when replacing the diode.

b.Position the thermal interface pad between the diode and contact surface where the diode will be installed.

CAUTION

Diodes can overheat if not properly installed.

c.Install the diode. Torque the nut securing the diode to 34 in-lbs (3.8 Nm).

d.Reinstall the nut and washer securing the re- placement diode wire lead to the PC Board.

D.150 Amp STR Diode Replacement

The Diode Replacement Kit (Cat # 8-6153) is a direct parts replacement for the failed Diode Assembly in the Power Supply.

The following parts are supplied with each replace- ment assembly:

•150 Amp, 800V Str. Diode Assembly (1 each)

•1.06 inch diameter Thermal Interface Pad (1 each)

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.Open the Power Supply to gain access to the faulty Diode Assembly.

4.Locate the old Diode Assembly inside the Power Supply.

5.Remove the nut and washer securing the old diode assembly to the mounting surface.

6.Remove the nut securing the diode wire lead to the PC Board.

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 General Description Specifications & Design FeaturesSection Introduction Description Plasma Arc Cutting and Gouging Input and Output PowerTheory Of Operation Pilot ArcOptions And Accessories Hour/Counter Meters Plasma/Secondary Gas ControlIntroduction Section Service Troubleshooting DiagnosticsPeriodic Inspection & Procedures 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 pilotVoltage Selection PC Board Check Test ProceduresEnable Circuit Tests Diode Check Blown Fuse F1 or F2Motor Control Contactor Check MC1 or MC2 Gas Solenoid Circuits Thermal Sensing Circuit CheckPressure Sensing Circuit 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 presentFront Panel Current Control Current Control, Display and CSD checksTip Drag Circuit 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 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 ReplacementConductivity Sensor Assembly Replacement Coolant Tank ReplacementFlow Switch 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 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 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

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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