Thermal Comfort
3000
manual
Parts Lists
Troubleshooting
Parts list
Appendix XIV System Schematic
Temp indicator on red
Warranty
Options And Accessories
Test Procedures
Pilot Resistor Adjustment
Remote Control
How to
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PARTS LISTS
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Manual
0-2533
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Contents
Merlin
October 6
Page
Table of Contents
Table of Contents
Important Safety Precautions
Section General Information
Publications
Fire and Explosion
Precautions De Securite Importantes
Avertissement
Choc Electrique
Documents De Reference
Bruit
General Information
National Standard and Technical Specifications
Declaration of Conformity
Statement of Warranty
Labor
Section Introduction
General Service Philosophy
Service Responsibilities
Scope Of Manual
Introduction
Section Introduction Description
Specifications & Design Features
General Description
Plasma Arc Cutting and Gouging
Input and Output Power
Theory Of Operation
Pilot Arc
Options And Accessories
Hour/Counter Meters
Plasma/Secondary Gas Control
Periodic Inspection & Procedures
Section Service Troubleshooting Diagnostics
Introduction
Draining Coolant
System Theory
Coolant Level and Conductivity
Circuit Description
Remote Control
Switch-Mode Power Supply Operation
Switching Control PC Board
Logic PC Board Functions
Advanced Troubleshooting
Troubleshooting Guide
Troubleshooting and Repair
Standoff Control
How to use this Guide
Fuse blown at disconnect when primary power is connected
Temp indicator on red
Coolant indicator off
Coolant conductivity indicator off
No pilot arc Pilot indicator on PCR energized
Weak or sputtering pilot
Enable Circuit Tests
Test Procedures
Voltage Selection PC Board Check
Motor Control Contactor Check MC1 or MC2
Blown Fuse F1 or F2
Diode Check
Gas Solenoid Circuits
Thermal Sensing Circuit Check
Pressure Sensing Circuit
Coolant Flow Sensor Circuit Check
Remote Control Start Circuit
Power Supply Start Circuit
Refer to Appendix IX for Start Circuit Diagram
Switching Control Check Q1
Q1 Location
Pilot Circuit Check
High Voltage is present
Front Panel Current Control
Current Control, Display and CSD checks
Tip Drag Circuit
Remote Current Control
Volt Bias Test
Corner Slowdown CSD
Refer to Appendix XII for OK-To-Move Circuit Diagram
Pilot Resistor Adjustment
OK-To-Move Tests
Service Troubleshooting
Parts Replacement General Information
Section Repairs & Replacement Procedures
Anti-Static Handling Procedures
Procedure
Left/Right Side Panel Replacement
External Parts Replacement
Handle Replacement
Top Panel Replacement
Access Panel Parts Replacement
Front Panel/Chassis Parts Replacement
Rear Panel Parts Replacement
Gas Solenoid Assembly Replacement
Three-Phase Contactor Replacement
Voltage 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 Replacement
Secondary Water Check Valve Replacement
29KVA Transformer T1 Assembly Replacement
Motor M1 Assembly Replacement
Upper Chassis Parts Replacement
Main Contactor W1 or W2 Replacement
Pump Assembly Replacement
Bxbx
Auxiliary Transformer T3 Assembly Replacement
Do not damage Heatsink
Pressure Switch Replacement
Pressure Gauge Replacement
Coolant Pressure Gauge Replacement
Plasma or Secondary Gas Input Fitting Replacement
Control Logic PC Board Assembly Replacement
Fuse F1 and F2 Replacement
Plasma or Secondary Regulator Assembly Replacement
Switching Control PC Board Assembly Replacement
Amp STR. Diode Replacement
Main Heatsink Assembly Parts Replacement
Secondary Gas Check Valve Replacement
Diodes can overheat if not properly installed
Amp REV Diode Replacement
Relay Replacement
Amp 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 Lists
Parts List Breakdown
Returns
External 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
Lts
Appendix II Sequence of Operation Block Diagram
Action
Appendix III Typical Mechanized System Cable Connections
System With Standoff Control SC11 And Gas Control GC3000
Remote 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 OUT
Xiii Hose
Block
Appendix XIV System Schematic
Appendix
Six Months or Every 720 Arc Hours
Daily Operational Checks or Every Six Arc Hours
Weekly or Every 30 Arc Hours
Twelve Months or Every 1500 Arc Hours
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