Thermal Comfort 3000 Bedienungsanleitung

Manual No. 0-2533October 6, 1999MERLIN 3000Plasma Cutting Power SupplyService ManualA-00907

GENERAL INFORMATION 6 Date 6/22/9914. Norme AWSF4.1 de l’Association Américaine deSoudage, RECOMMANDATIONS DE PRA-TIQUES SURES POUR LA PRÉPARATION À

Date: 6/22/99 7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: Industrial Park #2West Lebanon, N

GENERAL INFORMATION 8 Date 6/22/991.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that it

Manual 0-2533 9 INTRODUCTIONSECTION 2:INTRODUCTION2.01 Scope Of ManualThis Manual provides Service Instructions for ThermalDynamics Merlin 3000 Power

INTRODUCTION 10 Manual 0-2533

Manual 0-2533 11 INTRODUCTION & DESCRIPTIONSECTION 3:INTRODUCTION &DESCRIPTION3.01 Scope of ManualThe information in this Section is the same

INTRODUCTION & DESCRIPTION 12 Manual 0-25335. Duty Cycle100%6. Pilot ModesAuto-Restart, Pre-Flow Delay, Recycle7. CNC SignalsEnable Start/Stop,

Manual 0-2533 13 INTRODUCTION & DESCRIPTIONE. RF ShieldingAll machine torch systems are shielded to minimize ra-dio frequency (RF) interference w

INTRODUCTION & DESCRIPTION 14 Manual 0-2533G. Hour/Counter MetersMeter assembly containing two meters. One meterindicates the total number of ho

Manual 0-2533 15 SERVICE TROUBLESHOOTINGSECTION 4:SERVICETROUBLESHOOTINGDIAGNOSTICS4.01 IntroductionThis Section provides service diagnostics for the

WARNINGWARNINGRead and understand this entire Service Manual and youremployer’s safety practices before installing, operating, orservicing the equipme

SERVICE TROUBLESHOOTING 16 Manual 0-2533hot soapy water. Remove soap residue by rinsing withclean hot water. Be sure that all the soap has beenremov

Manual 0-2533 17 SERVICE TROUBLESHOOTINGC. Switch-Mode Power Supply OperationPrimary three-phase power is rectified by the three-phase bridge diodes

SERVICE TROUBLESHOOTING 18 Manual 0-2533nector and an internal terminal strip are provided forCNC connections. The remote includes internal con-necti

Manual 0-2533 19 SERVICE TROUBLESHOOTINGThe advanced troubleshooting covered in this ServiceManual requires Power Supply disassembly and live mea-sure

SERVICE TROUBLESHOOTING 20 Manual 0-2533E. Fuse blown at disconnect when primary power isconnected1. Voltage selection busbars connected incorrectly

Manual 0-2533 21 SERVICE TROUBLESHOOTING3. Gas Control (GC3000) on wrong settinga. Select input that has gas connected.4. Gas supply turned off (or

SERVICE TROUBLESHOOTING 22 Manual 0-2533M. DC indicator off (after pre-flow); Main contactorcomes on momentarily; No pilot arc; No main arctransfe

Manual 0-2533 23 SERVICE TROUBLESHOOTINGU. Main arc transfers and pierces through the plate,but cutting machine doesn’t move1. Incorrect or missing

SERVICE TROUBLESHOOTING 24 Manual 0-2533work check continuity from TB2, wires 102 & 103, toJ50-10 & 11. If correct, replace the Switching Con

Manual 0-2533 25 SERVICE TROUBLESHOOTING2. High frequency protection for the input rectifierdiodes (D1-6) is provided by capacitors C1 - C6and MOV 1-

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 11.0

SERVICE TROUBLESHOOTING 26 Manual 0-25332. If the coolant conductivity indicator is not lit withthe probe disconnected, measure between theLogic PC B

Manual 0-2533 27 SERVICE TROUBLESHOOTINGlem is in the Standoff Control (SC10) or the ribboncable. Refer to Section 5, Customer/Operator Service,in t

SERVICE TROUBLESHOOTING 28 Manual 0-2533The PWM compares shunt amp output on J9-5 withthe current control signal (3.3 - 10 VDC) from the re-mote (J7-

Manual 0-2533 29 SERVICE TROUBLESHOOTINGIf 24 VAC is not present, remove J14 control connec-tor at the torch bulkhead and measure for 24 VAC be-tween

SERVICE TROUBLESHOOTING 30 Manual 0-2533The display signal at J7-2 should be equal to thecontrol pot wiper voltage at J7-18 measured in Step3 above.If

Manual 0-2533 31 SERVICE TROUBLESHOOTINGQ. OK-To-Move Tests1. The Shunt Amp sends a voltage level to the Switch-ing Control PC Board that correspond

SERVICE TROUBLESHOOTING 32 Manual 0-2533CAUTIONMove the clamps only what is necessary for a steadypilot. Too much adjustment can cause increasedparts

Manual 0-2533 33 REPLACEMENT PROCEDURESSECTION 5:REPAIRS & REPLACEMENTPROCEDURES5.01 IntroductionThis Section describes parts replacement procedu

REPLACEMENT PROCEDURES 34 Manual 0-2533WARNINGDisconnect primary power from the source beforeopening or disassembling the power supply. Makesure AC i

Manual 0-2533 35 REPLACEMENT PROCEDURES2. Loosen the two screws of the Work Cable strainrelief securing the Work Cable at the Front Panel.3. Remove

TABLE OF CONTENTS (continued)SECTION 6:PARTS LISTS...

REPLACEMENT PROCEDURES 36 Manual 0-25333. Remove the Coolant Hose from the Internal Cool-ant Filter Assembly.4. Remove the Internal Coolant Filter f

Manual 0-2533 37 REPLACEMENT PROCEDURES7. Locate and remove the four bolts and lock nutssecuring the Fan Assembly to the Rear Panel As-sembly.8. Car

REPLACEMENT PROCEDURES 38 Manual 0-2533G. Coolant Tank Replacement1. Remove the Left, Right, and Top Side Panels perSection 5.04-B.2. Drain the coo

Manual 0-2533 39 REPLACEMENT PROCEDURESCAUTIONHandle and dispose of the used coolant per recom-mended procedures.3. Remove the two wires from the Con

REPLACEMENT PROCEDURES 40 Manual 0-25336. Install the replacement Transformer Assembly byreversing the above procedure.C. Main Contactor (W1 or W2)

Manual 0-2533 41 REPLACEMENT PROCEDURESDriver PC BoardRear of Front PanelA-010835. Note and label the two wiring connectors that con-nect to the Driv

REPLACEMENT PROCEDURES 42 Manual 0-2533PTC Resistor AssemblyQ1Main HeatsinkA-0108917. Remove the four screws securing the SwitchingTransistor module

Manual 0-2533 43 REPLACEMENT PROCEDURESC. Pressure Gauge ReplacementNOTEBoth the Plasma and Secondary gauges are replacedin the same manner1. Remove

REPLACEMENT PROCEDURES 44 Manual 0-25333. Disconnect the gas Hose Assembly from the fittingat the end of the Gas Input Fitting.4. Remove the fitting

Manual 0-2533 45 REPLACEMENT PROCEDURESSymbolDirection Of FlowCheck ValveA-003705. Install the replacement Check Valve by reversingthe above procedur

Date: 6/22/99 1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and warning

REPLACEMENT PROCEDURES 46 Manual 0-2533d. Re-solder the wire lead to the replacement di-ode.e. Apply a layer of RTV over the top of the DiodeAssembl

Manual 0-2533 47 REPLACEMENT PROCEDURES7. Make sure the replacement diode is a direct re-placement for the old one.8. Install the replacement diode

REPLACEMENT PROCEDURES 48 Manual 0-2533NOTERefer to Subsection 6.08, Upper Chassis Replace-ment Parts for part numbers and detail drawing.1. Remove t

Manual 0-2533 49 REPLACEMENT PROCEDURES3. Remove the Hose Assembly from the unit.4. Install the replacement Hose Assembly by revers-ing the above pr

REPLACEMENT PROCEDURES 50 Manual 0-2533

Manual 0-2533 51 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all basic replace-ab

PARTS LISTS 52 Manual 0-2533A-012201234566.03 External Power Supply Replacement Parts ListItem # Qty. Description Catalog #Complete Merlin 3000 Power

Manual 0-2533 53 PARTS LISTS6.04 Access Panel Replacement PartsItem # Qty. Description Catalog #1 Access Panel Assembly Includes: 8-32571 1 Access Pa

PARTS LISTS 54 Manual 0-25336.05 Front Panel/Chassis Replacement PartsItem # Qty. Description Catalog #1 1 Front Panel With Overlay 8-63042 1 Front P

Manual 0-2533 55 PARTS LISTS124356789101112131415161918172021A-012172223

GENERAL INFORMATION 2 Date 6/22/99• Install and maintain equipment according to NECcode, refer to item 9 in Subsection 1.03, Publica-tions.• Disconnec

PARTS LISTS 56 Manual 0-25336.06 Rear Panel Replacement PartsItem # Qty. Description Catalog #1 1 Rear Panel 8-45052 1 Fan, 16" Axial 8-63123 2

Manual 0-2533 57 PARTS LISTS123456789101112131415161718192121222324252627282930311818203220203A-0121611

PARTS LISTS 58 Manual 0-25336.07 Base Assembly Replacement PartsItem # Qty. Description Catalog #1 1 Base 8-51452 2 Caster, 5" Diameter 8-55783

Manual 0-2533 59 PARTS LISTS9101211123413145615167817181920212223242120A-0089426259

PARTS LISTS 60 Manual 0-25336.08 Upper Chassis Replacement PartsItem # Qty. Description Catalog #1 1 Panel, Upper Chassis/Gauge 9-13022 1 Power Drive

Manual 0-2533 61 PARTS LISTSItem # Qty. Description Catalog #43 1 Check Valve, Male, 1/4 NPT, 5 PSI 8-451244 1 Hose Assembly, Secondary Water, Gauge T

PARTS LISTS 62 Manual 0-25336.09 Main Heatsink Assembly Replacement PartsItem # Qty. Description Catalog #1 1 Main Heatsink 9-14042 4 Capacitor, 550

Manual 0-2533 63 PARTS LISTS123456789101112131415161718192021222324252627293031323334111992221717111128A-00971323232323232

PARTS LISTS 64 Manual 0-25336.10 Power Supply Options And AccessoriesItem # Qty. Description Catalog #1 1 Remote Control (RC6010) 3-61062 1 Standoff

Manual 0-2533 65 PARTS LISTSA-01218OUTPUT AMPSPLASMAENABLEONSTARTREMOTE POWER SUPPLY CONTROLSD(%)25 7510050TRAVELSPEED125+ IPM0-125 IPMRUNPURGESETPLA

Date: 6/22/99 3 GENERAL INFORMATION8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the Nation

PARTS LISTS 66 Manual 0-2533

Manual 0-2533 67 APPENDIXAPPENDIX I: INPUT WIRING REQUIREMENTSInput Power Input Current Suggested Sizes (See Notes)Voltage Freq. 3-Ph 3-Ph Fuse (Amps

APPENDIX 68 Manual 0-2533APPENDIX II: SEQUENCE OF OPERATIONBLOCK DIAGRAMA-01016ACTIONClose externaldisconnect switchRESULT• Power to systemACTIONEna

Manual 0-2533 69 APPENDIXAPPENDIX III: TYPICAL MECHANIZED SYSTEM CABLECONNECTIONSCable Description Letter DesignationPower Supply to Remote Control A

APPENDIX 70 Manual 0-2533APPENDIX IV: INTERFACE CABLES FOR REMOTECONTROL (RC6010) AND STANDOFF CONTROL (SC11)A-00983MERLIN 3000 REMOTE CABLESFOR RC 6

Manual 0-2533 71 APPENDIXAPPENDIX V: CNC INTERFACEA-00982

APPENDIX 72 Manual 0-2533APPENDIX VI: 120 VAC CIRCUIT DIAGRAMK1J28 TO OPTIONAL STANDOFF CONTROLPCR(881)(89)SW3-A(5)K5LOGIC PCB(75)K3(110)SOL3SOL2SOL1

Manual 0-2533 73 APPENDIXAPPENDIX VII: LADDER DIAGRAM - 15 VDC3LOGIC CONTROL BOARD1311191559724111218144862212K4K3K2K5K1PLASMASECONDARYGASCONTROLCIRC

APPENDIX 74 Manual 0-2533APPENDIX VIII: SIGNAL FLOW BLOCK DIAGRAMA-01139

Manual 0-2533 75 APPENDIXAPPENDIX IX: START CIRCUIT DIARGRAMA-01080Standoff Control SC11Merlin 3000orMerlin 6000orMerlin 6000GSTJ15-24J15-25J42-3J42-

GENERAL INFORMATION 4 Date 6/22/99• Les sortes de gaz et de fumée provenant de l’arc deplasma dépendent du genre de métal utilisé, desrevêtements se t

APPENDIX 76 Manual 0-2533APPENDIX X: CURRENT CONTROL / DISPLAY CIRCUITDIAGRAMA-01138

Manual 0-2533 77 APPENDIXAPPENDIX XI: CSD (CORNER SLOWDOWN) CIRCUITDIAGRAMA-01140

APPENDIX 78 Manual 0-2533APPENDIX XII: OK-TO-MOVE CIRCUIT DIAGRAMA-01081PIERCEDELAY0 - 3 secondsOFF = OK-To-Move24 VAC SourceMerlin 3000 or Merlin 60

Manual 0-2533 79 APPENDIXAPPENDIX XIII: HOSE BLOCK DIAGRAMCoolant Filter Assembly(Rear Panel)Internal FilterAssemblyGas Connections(Rear Panel)Plasma

APPENDIX 80 Manual 0-2533APPENDIX XIV: SYSTEM SCHEMATICA-00981

Manual 0-2533 81 APPENDIXA-00981

APPENDIX 82 Manual 0-2533APPENDIX XV: RECOMMENDED ROUTINE MAINTENANCESCHEDULE FOR LIQUID COOLED PLASMA CUTTINGSYSTEMSThis schedule applies to all typ

Date: 6/22/99 5 GENERAL INFORMATION• Utilisez la nuance de lentille qui est suggèrée dansle recommendation qui suivent ANSI/ASC Z49.1:Nuance Minimum