Thermal Dynamics cutmaster A60, Service Manual

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CUTMASTER A60
APPENDIX A-8 Manual 0-4982
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
5
5
4
4
3
3
2
2
1
1
D D
C C
B B
A A
24VAC
+12VDC
+12VDC
+12VDC
+12VDC +12VDC
+12VDC
+12VDC
+5VDC
+12VDC
DWG No:
Sheet
of
Supersedes Scale
Date:
Drawn: References
Date By Revisions Rev PCB No:
Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1298 Monday, March 30, 2009
1 1
16052 Swingley Ridge Road
Suite 300
St Louis, MO 63017 USA
CUTMASTER 52/82/A40/A60 230/460V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
DWG No:
Sheet
of
Supersedes Scale
Date:
Drawn: References
Date By Revisions Rev PCB No:
Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1298 Monday, March 30, 2009
1 1
16052 Swingley Ridge Road
Suite 300
St Louis, MO 63017 USA
CUTMASTER 52/82/A40/A60 230/460V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
DWG No:
Sheet
of
Supersedes Scale
Date:
Drawn: References
Date By Revisions Rev PCB No:
Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1298 Monday, March 30, 2009
1 1
16052 Swingley Ridge Road
Suite 300
St Louis, MO 63017 USA
CUTMASTER 52/82/A40/A60 230/460V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
A B
24 VAC RETURN
J1
80
PCB4
AUTOMATION
INTERFACE PCB
OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE
81
ERROR IND FAULT
PCB3
8
9
82
7A
}
OK-TO-MOVE
OK-TO-MOVE
83
OK TO MOVE
1TORCH
Q2
PRIMARY POWER CONNECTIONS:
3PH USE L1,L2,L3 & GND
REMOVE JUMPER BETWEEN L2 TO L3
1PH USE L1, L2 & GND -
INSTALL JUMPER BETWEEN L2 TO L3
*
5
6
}
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
34
35
36
37
38
39
}
E64
E35
78
79
INPUT VOLTAGE SELECTOR
(Closed for 230VAC input)
-
+
-V_OUT_SIGNAL
/TIP_VOLTS
/TIP_SENSE
/460V_IN
/230V_IN
CUR_SET
/RAR (RAPID AUTO RESTART)
/INRUSH
/W1_ON
/SHDN
/TORCH_SOLENOID
/SOLENOID_ON
/OK_TO_MOVE
/FAN_ON
/LATCH_ACTIVE
/TORCH_SWITCH
/PIP
AC_ON
CSR
/TORCH_SOLENOID_DETECT
/OVERTEMP
V_IN
+12VDC
+12VDC
COMMON
COMMON
MAIN_PCB_ID
460_IN
+3.3VDC
TXD
RXD
COMMON
D
M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
CNC INTERFACE STANDARD ON A40 & A60 UNITS
CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS
(+)
*
L1
L2
L3
L4
T1
T2
T3
T4
* CM52 & A40
C3 & C5 not installed
/PIP
PCB2
/SOLENOID
Q1
PRIMARY
AC INPUT
/START
PCB1
N A F N A F
24VAC RETURN
ATC CONNECTOR
/FAN /FAN
24VAC SUPPLY
40 PIN RIBBON CABLE SIGNALS
460_IN
LATCH
SET
RUN
RAR
40 CIRCUIT
RIBBON CABLE
}
MAX
90
85
80
75
70
65
MIN
/460 /230
J2
7
JUMPER
D1
To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
L1
L2
L3
GND
K1
D C
To -V OUT 1
on PCB1
}
/START / STOP
* *
AIR
INLET
FILTER
}
REGULATOR
INTRO ECO B534
DIVIDED ARC VOLTS
(5A @250VAC / 30VDC)
SOLENOID
VALVE
/START / STOP
TP1
TP2
TP3
TP4
TP5
TP6
TP7
(+)
ATC
MAIN PCB ASSY
LOGIC PCB
(-)
(W/ 100K IN SERIES (2))
INPUT CAPACITOR PCB
(-)
GAS CONTROL
*
ARC VOLTS
GND
+12 VDC
+5 VDC
3.3 VDC
0.v - 5.0 VDC / 0-100PSI
1.8 VDC
POT. DEMAND
J2 PINOUT
1 3
4 7
8 11
12 14
TEST POINTS
GND1
GND2
GND3
+12V1
48V1
I_DMD_1
TIP_SEN
COMMON
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE
TEST POINTS
(Sink 50mA @12VDC)
AUTOMATION
TORCH SOLENOID
PRESSURE
TRANSDUCER
0-100PSI / 0-4.5VDC
INRUSH RESISTOR
S
/INRUSH
/OVERTEMP
TEMP
CIRCUIT
D3
CM82 / A60 ONLY
3.3VDC
TXD
RXD
D
SERIAL PORT
BIAS
SUPPLY
RWH
AA RWH 07/23/07
AB
MNC 04/23/08 ECO B890
AC MNC 05/09/08 ECO B855
AD MNC 10/03/08 ECO B1159
AE
RWH 03/31/09
ECO B1357
SEC1 SEC1
WORK1 WORK1
Q5
PILOT IGBT
Q5
PILOT IGBT
J1 J1
1
2
3
4
5
6
7
8
CHOKE1 CHOKE1 PRI 2 PRI 2
D1 D1
J3 J3
1
2
3
NTC NTC
J3 J3
1
2
3
W1 W1
K3 K3
+ C1-C4* + C1-C4*
J3 J3
1 2 3
MTH1 MTH1
J4 J4
1
2
3
4
5
W1 W1
MOT1 MOT1
+ -
70 70
AC3 AC3
90 90
1 2 3
P10 P10
1
2
3
4
5
6
7
8
J1 J1
1
2
3
4
5
6
7
8
MTH4 MTH4
TIP1 TIP1
J7 J7 1 2
K6 K6
65 65
PRI 1 PRI 1
J9 J9
1
2
3
4
5
6
7
DC DC
MOT2 MOT2
+ -
75 75
MTH7 MTH7
TS1 TS1
SW1 SW1
1 3
2 4
P10 P10
1
2
3
4
5
6
7
8
J1 J1
1
2
3
4
5
K1 K1
PRI 4 PRI 4
WORK WORK
80 80
SEC2 SEC2
OVERTEMP OVERTEMP
E1 E1
85 85
AC2 AC2
Current Control Current Control
L1 L1
MTH3 MTH3
MTH5 MTH5 J3 J3
1
2
K1 K1
D78 CSR D78 CSR
J8 J8
1 2
J6 J6
1
2
ERROR ERROR
D59 PCR D59 PCR
MTH6 MTH6
MAX MAX
SW2 SW2
J5 J5
1 2 3
J11 J11
1 2
T1 T1
J2 J2
2
3
4
5
6
7
8
9
10
11
12
13
14
1
-V OUT 1 -V OUT 1
AC1 AC1
TORCH SWITCH TORCH SWITCH
MTH2 MTH2
MTH8 MTH8
GAS GAS
ELECTRODE1 ELECTRODE1
K1-K4 K1-K4
J10 J10
3
5
6
7
8
1
2
4
PRI 3 PRI 3
AC AC
K4 K4
K5, K6 K5, K6
+ C5-C8* + C5-C8*
J12 J12
1 2 3
J2 J2
2
3
4
5
6
7
8
9
10
11
12
13
14
1
K2 K2
SOL1 SOL1
PIP SWITCH PIP SWITCH
1
2
3
4
5
6
7
8
K1 K1
MIN MIN
K5 K5
A-09131_AB
A-09131_AB