If 24 VAC is not present, remove J14 control connec- tor at the torch bulkhead and measure for 24 VAC be- tween pins 5 and 8 of the receptacle. The 24 VAC comes from T3, is fused by F3, 1A 250v, and passes through the filter FL1 to J14. If voltage is not present at J14 the most likely fault is the fuse. T3 and the FL1 are other possibilities. If F3 is blown replace it and leave J14 disconnected. If it doesn’t blow, then recon- nect J14. If fuse blows again then the Arc Starter PC Board is defective or there is a short in the torch leads between J14 and the Arc Starter PC Board.

O. Current Control, Display and CSD checks

1. Tip Drag Circuit

The Merlin 3000 has a circuit that monitors the torch tip voltage to reduce cutting current to 40- 50 amps reducing consumable parts wear if the tip voltage is less than -20 volts indicating double arcing or the tip contacting the work. Wire #7 from the torch bulkhead (+) connection connects to the Logic PC Board at terminal W7. If the voltage there is less than -20 VDC the Logic PC Board puts a low on J3-25 (can measure at TP5 on the Logic PC Board) causing the Switching Control PC Board (J10-25) to reduce the current. When piloting or cutting the tip voltage at W7 should be greater than -20 volts, if so and Logic TP5 is low the Logic PC Board is defective.

2. Front Panel Current Control

If the Remote Control (RC6010) is being used the front panel control is inactive, go to next step.

The front panel current control receives it’s high level (10 VDC) on J10-17 and it’s low level (3.3 VDC) on J10-13. Verify those voltages (with re- spect to TP1 on the Switching Control PC Board) then measure the pot’s wiper between J10-15 and TP1. It should vary from 3.3 to 10 VDC as the control is moved from minimum to maximum. If it does not vary or is less than 3.3 VDC, then the control pot in the LED PC Board is faulty or the ribbon cable is faulty. If the high and low (3.3 VDC and 10 VDC) are incorrect, the Switching Control PC Board is faulty or the ribbon cable is shorted.

3.Remote Current Control

NOTE

Refer to Appendix X for Current Control Display Circuit Diagram.

The Remote Control (RC 6010) has front panel controls for OUTPUT AMPS and CSD. The up- per and lower limits of the current control range are set by the POT HI (+10 VDC) and POT LOW

(+3.3 VDC) signals from J50-8 and J50-6 on the Switching Control PC Board sent to the remote via the remote cable.

The CSD control upper limit is set by the wiper of the OUTPUT AMPS control thus the CSD range is a percentage (%) of the main output. The wiper of the main pot is sent through the normally closed CSD relay contact out the remote cable to J7-18 on the Switching Control PC Board. If CSD is en- abled, indicated by illuminating the 3 decimals in the display, then the CSD wiper provides the cur- rent control signal to J7-18.

NOTE

Refer to Appendix XI for Corner Slowdown (CSD) Circuit Diagram.

If the OUTPUT AMPS control or the CSD control have no effect on current level see if the panel con- trol does, if so, there may be a poor connection in the REMOTE INSTALLED circuit between the re- mote and Switching Control PC Board. Check TP1 to J7-20, if it does not measure less than 2v there is a faulty connection, otherwise the Switching Con- trol PC Board is faulty.

If the front panel control had no effect (which it shouldn’t) measure from TP1 to J7-18 while mov- ing the OUTPUT AMPS control from min to maxi- mum.

The voltage at J7-18 should vary from 3.3v to 10 v. If it does the Switching Control PC Board is faulty.

If voltage is incorrect at J7-18, check J50-8 for 10 v and J50-6 for 3.3 v. If OK then the remote is defec- tive or the connections (remote cable or Merlin) harness are open.

4. Remote AMPS Display

The AMPS display shows control pot setting (pre- view) and actual cutting amps. The decimal points indicate when CSD (standoff inhibit) is on by light- ing all 3 decimals and when OK-To-Move is not on by lighting the left hand decimal.

The AMPS display is driven by a signal from the Merlin Switching Control PC Board J7-2.

NOTE

Refer to Appendix X for Display Circuit Diagram.

Positive 3.3 to 10 volts at J37-1 gives a display from 50 to 150 AMPS. Prior to cutting arc transfer the display signal is in the “preview” mode as indi- cated by the left hand decimal being on. The dis- play is indicating the current control pot setting.

Manual 0-2533

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SERVICE TROUBLESHOOTING

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Thermal Comfort 3000 manual Current Control, Display and CSD checks, Tip Drag Circuit, Front Panel Current Control
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3000 specifications

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