Thermal Comfort 3000 manual System Theory, Coolant Level and Conductivity, Draining Coolant

hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before re-in- stalling in the Internal Filter Assembly.

E. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50mm) from the top of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity LED on the front panel must be ON for normal operation. If the LED is OFF then drain the old coolant from the Power Supply and torch leads and replace with new cool- ant. Check the condition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag.

F.Draining Coolant

Remove the old coolant from the Power Supply res- ervoir per the following procedure:

1.Remove the right side and top panels from the Power Supply.

2.Disconnect the coolant hose input to the rear panel filter assembly.

3.Carefully lower the hose out the right side of the Power Supply and drain the coolant into an ac- ceptable container.

CAUTION

Handle and dispose of the used coolant per recom- mended procedures.

A-01017

Coolant Hose

Coolant Hose

Connection

Figure 4-2 Draining Coolant From Reservoir

4.Reconnect the hose to the filter assembly.

5.Install new coolant and deionizer bag.

6.Reinstall the top and right side panels.

4.03 System Theory

A. Circuit Description

The Merlin 3000 system is designed for mechanized cutting only and consists of the Merlin 3000 plasma power supply, the Maximizer 300 Torch, Torch Leads Extension, and Arc Starter Box. An Optional Remote Control (RC6010), Standoff Control (SC10 or SC11, see notes) and Gas Control (GC3000) may be used in vari- ous combinations. Different interconnect and input/ output (I/O) cables may be used depending on which options are installed. An Optional Dual Meter, Arc Hours and Arc Starts Counter, may be included on the Power Supply front panel.

NOTES

The Standoff Control SC10 must be used with the Remote Control RC6010.

The Remote Control RC6010 is not used if the Standoff Control SC11 is used.

B. Input Voltage Selection

The main transformer (T1) has busbar connections to select one of three input voltage ranges. Each main transformer secondary has two taps. One secondary tap is automatically selected by the Voltage Selection PC board when primary power is applied. If input voltage is within the lower half of the selected volt- age range (for example, 380V or 415V in the 380/415/ 460V range), the higher voltage taps are selected. If input voltage is within the upper half of the selected voltage range (460V in the 380/415/460V range), the lower voltage taps are selected. This arrangement provides secondary voltages close to the optimum levels. When the lower voltage taps are selected a red indicator, D18, on the Voltage Selection PC Board will be ON.

The auxiliary voltage taps, 115 VAC and 28 VAC cir- cuits, are selected directly by relays on the Voltage Selection PC Board. The fan and pump motors are supplied by the Motor Control Contactors (MC1 and MC2). MC1 is for the high voltage tap and MC2 is for the low voltage tap. Three-phase primary power is controlled by one of the Main Contactors (W1 for the high voltage tap or W2 for the low voltage tap).

SERVICE TROUBLESHOOTING 16 Manual 0-2533