Thermal Comfort 3000 manual How to use this Guide

The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live mea- surements. It is helpful for solving many of the common problems that can arise with the Merlin 3000 Plasma Cut- ting System.

If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.

Follow all instructions as listed and complete each in the order presented.

Specific test procedures and LED status identification tables have been grouped together, and are referenced by the troubleshooting guide.

C. How to use this Guide

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. This guide is set up in the following manner:

1.Perform operational check(s) on the equipment to iso- late problem to possible circuit(s).

2.Determine symptom and isolate to defective assembly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1.Cause (Italic Type)

a. Check/Remedy (Text Type)

3.Locate your symptom in the appropriate Sub-Section.

4.Check the causes (easiest listed first) for the symptom.

5.Check the remedies listed for each cause.

6.Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTE

Many signals are transfered between Printed Circiut Board Assemblies on Ribbon Cables. If these cables become faulty they can then cause vari- ous problems. Do not forget about these cables when troubleshooting.

A.No front panel LED indicators ON; Fan and pump not operating

1.No primary power. Refer to symptoms C and D also.

a.Check for proper three-phase power at input terminal board

2.Faulty ON/OFF switch (SW1)

a.Disconnect primary power. Check each section for continuity. Replace switch if necessary

3.Faulty voltage selection board

a.Refer to Section 4.05-A, Voltage Selection PC Board Check. Replace Voltage Selection PC Board if necessary

B.AC indicator ON; Fan and pump not operating

1.ENABLE signal not ON

a.Remote ENABLE or ENABLE at TB2 must be on. Refer to Section 4.05-B, Enable Circuit Test.

2.Blown fuse (F1 or F2)

a.Check and replace fuse if necessary. Refer to Section 4.05-C, Blown Fuse (F1 or F2).

3.Faulty ON/OFF switch (SW1)

a.Disconnect primary power. Check each section for continuity. Replace switch if necessary

4.Faulty Voltage Selection PC Board

a.Refer to 4.05-A, Voltage Selection PC Board Check. Replace Voltage Selection PC Board if necessary

5.Faulty motor contactor (MC1 or MC2)

a.Refer to Section 4.05-D, Motor Control Contac- tor Check (MC1 or MC2). Replace contactor if necessary

6.Faulty ENABLE circuit

a.Refer to Section 4.05-B, Enable Circuit Test.

C.No indicators are on for the RC6010 or SC10 remotes.

1.No +48 VDC power to the remotes.

a.3 amp fuse blown on the Bias PCB, replace.

b.Defective Bias PCB, Refer to Section 4.05-P, 48 Volt Bias Test.

D.AMPS or VOLTS displays not on for RC6010 or SC10.

1.Normal if ENABLE not on.

a.Turn on ENABLE at RC6010 or TB2 (if RC6010 not used)

b.Defective ENABLE circuit, Refer to Section 4.05- B, Enable Circuit Test.

2.Faulty Remote Device

a.Replace as needed

Manual 0-2533 19 SERVICE TROUBLESHOOTING