Thermal Comfort 3000 Daily Operational Checks or Every Six Arc Hours, Do not energize the Torch

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APPENDIX XV: RECOMMENDED ROUTINE MAINTENANCE

SCHEDULE FOR LIQUID COOLED PLASMA CUTTING

SYSTEMS

This schedule applies to all types of liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Arc Hours:

1.Check torch parts, replace if damaged.

2.Check plasma and secondary supply and pressure/flow.

3.Purge plasma gas line to remove any moisture build-up.

4.Check deionizer bag/cartridge, replace if color is predominantly yellow.

5.Check coolant pressure (100 - 120 psi).

Weekly or Every 30 Arc Hours:

1. Blow or vacuum dust and dirt out of the entire machine.

Six Months or Every 720 Arc Hours:

1.Remove and clean in-line filter screens.

2.Check cables and hoses for leaks or cracks, replace if necessary.

3.Check all contactor points for severe arcing or pits, replace if necessary.

4.Check all pillow blocks and bearings, clean and lubricate if necessary.

5.Check fan, pump and pulley belts for wear or cracking, replace if necessary.

Twelve Months or Every 1500 Arc Hours:

1.Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30 minutes.

WARNING

DO NOT energize the Torch.

Drain distilled water and replace with Thermal Arc Coolant. Use Standard Mix Coolant (Catalog # 7-2850) or Super Mix Coolant (Catalog # 7-2959) for environments below +10° F (-12° C).

2.Check radiator fins, clean and comb out if necessary.

3.Repeat six month maintenance.

APPENDIX

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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

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