Thermal Dynamics ULTRA-CUT 200 XT, Operating Manual

Page: 166 / 228

ULTRA-CUT 200 XT
A-40 APPENDIX Manual 0-5304
APPENDIX 22: Schematic, DFC-3000 Auto Gas Box
System
Art # A-09197_AC
Art # A-09197_AC
1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
BLK
PURPLE
ORANGE
BLK
PURPLE
ORANGE
BLK
PURPLE
ORANGE
BLK
PURPLE
ORANGE
BLK
PURPLE
BLK
PURPLE
ORANGE
BLACK/SHIELD
WHITE
RED
ORANGE
(WHT)
(WHT)
(BLK)
(WHT)
(S15T)
(S14B)
(S14T)
(S13T)
(S12B)
(S12T)
(S11T)
(S10B)
(S10T)
(S9-B)
(S9-T)
(S8-B)
(S8-T)
(S7-B)
(S7-T)
(S6-B)
(S6-T)
(S5-B)
(S5-T)
(S4-T)
(S3-T)
(S2-T)
(S1-T)
(S1-B)
(S2-B)
(S3-B)
(S4-B)
(S11B)
(S13B)
(S14B)
(S2-B)
(2a) 120VAC DMC RET
GRN
BLK
(1) 120VAC DMC
(JMP)
(3)
(8)
(9)
(2b)
E_STOP NO
E_STOP COM
(8)
(9)
+5V
(PW3
)
120 VAC
) 1 ( ) 1 (
(2a)
120 VAC RET (2a)
(9)
E_STOP COM (9)
(2c)
(2c)
(8) E_STOP NO
(S2-B)
(V5-1)
(V5-2)
(V1-1)
(V1-2)
(V2-1)
(V2-2)
(V3-1)
(V3-2)
(S1-T)
(S1-B)
(V4-1)
(V4-B)
-12VDC (PW1)
GND (PW2)
+5VDC (PW3)
+24 VDC_FUSED (PW6)
-12V
(PW1
)
GND
+12V
(PW4
)
+24V SW
(PW5
)
+24V FUSED
(PW6
)
GND
SHIELD
Rx-
Rx+
Tx- (B)
SIG COM
SIG COM
Tx+ (A)
COM
PLASMA ENABLE
HMI PRESENT
24 VAC RET
24 VAC
RED
) 5 ( ) 5 (
) 6 ( ) 6 (
120VAC DMC
E_STOP CO
M
E_STOP NO
120VAC DMC RE
T
(2a)
WHT
(S3-B)
(5)
(5)
(6)
(6)
) 9 ( ) 9 (
(8)
Tx+ (A)
(12)
Tx- (B)
(12)
(1)
(2)
) 3 ( ) 3 (
(8)
) 0 1 ( ) 0 1 (
(1)
(2)
(20V)
(20V
)
(0V)
(0V)
+12VDC (PW4)
E-STOP (PW8)
+24VDC SW (PW5)
GND (PW7)
(S3-T)
(1)
(3)
(8)
(PW2
)
(PW8
)
(PW7
)
SHIELD
+24 VDC
+5 VDC
+24 VDC
+5V
+12V
+15 VDC
15 VDC RET
120 VAC ULTRACUT
120 VAC ULTRACUT RET
24 VAC RET
24 VAC
PLASMA
PLASMA ENABLE -
SHIELD
24 VAC
24 VAC RET
PLASMA ENABLE
KEY PLUG
Tx+ (A)
Tx- (B)
Rx+
Rx-
+5 VDC
Data +
Data -
COM
Shield
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,
THERMAL DYNAMICS
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
42X1292
Monday, April 19, 2010
1 1
Friday, December 08, 2006
14:00:59
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,
THERMAL DYNAMICS
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
42X1292
Monday, April 19, 2010
1 1
Friday, December 08, 2006
14:00:59
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,
THERMAL DYNAMICS
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
42X1292
Monday, April 19, 2010
1 1
Friday, December 08, 2006
14:00:59
DPC3000 CONTROL PCB
DFC 3000 SYSTEM SCHEMATIC
DPC3000 - PRESSURE CONTROL ASSEMBLY
PANEL INDICATORS
GROUNDING SCREW
19X2382
19X2383
CHASSIS GND
PLASMA_VENT
PLASMA_MARK
FUEL_PLASMA
H35_PLASMA
O2_PLASMA
O2_SHIELD
AIR_PREFLOW
AIR_PLASMA
AIR_SHIELD
AIR_MARKING
N2_PREFLOW
N2_PLASMA
N2_SHIELD
O2_PREFLOW
N2_MARKING
H20_SHIELD
ARGON_MARKING
DMC3000 - MANIFOLD CONTROLLER ASSEMBLY
19X2367
MANIFOLD (partial)
MANIFOLD (partial)
FERRITE
CORE
FERRITE
CORE
ULTRACUT POWER SUPPLY
MANIFOLD
PANEL INDICATORS
GROUNDING SCREW
GROUNDING SCREW
NOTE:
1: DO NOT DAISY CHAIN GROUNDS. USE A SEPARATE GROUND
CONDUCTOR FOR EACH ASSEMBLY TO STAR GND.
2: KEEP GROUNDS AS SHORT AS POSSIBLE.
3: USE #4 OR GREATER SIZE CABLE FOR GROUNDING
4: MAKE SURE ASSEMBLIES ARE SECURED PROPERLY BEFORE USE
5: ALL COVERS MUST BE FULLY INSTALLED BEFORE USE.
OPTION SWITCHES
LEDs Listed Below
CCM
DMC FiberOptic Ports
DPC FiberOptic Port
19X2385
DMC3000 CONTROL PCB
DMC3000 Control PCB LEDs
SOLENOID DRIVE ON INDICATOR (GREEN LEDs)
D1 - SOL_V1 (H35 PLASMA))
D2 - SOL_V2 (O2_PLASMA)
D3 - SOL_V3 (AIR_PLASMA)
D4 - SOL_V4 (N2 PLSMA)
D5 - SOL_V5 (AUX PLASMA)
D6 - SOL_V6 (O2 SHIELD)
D7 - SOL_V7 (AIR_SHIELD)
D8 - SOL_V8 (N2 SHIELD)
D9 - SOL_V9 (H2O SHIELD)
D10 - SOL_V10 (O2 PREFLOW)
D11 - SOL_V11 (AIR PREFLOW)
D12 - SOL_V12 (N2 PREFLOW)
D13 - SOL_V13 (ARGON MARKING)
D14 - SOL_V14 (AIR MARKING)
D15 - SOL_V15 (N2 MARKING)
D16 - (SPARE)
D17 - +5VDC
DPC3000 Control PCB LEDs
D1 - PLASMA_PWM
D2 - PLASMA_VENT_PWM
D3 - SHIELD_H20_PWM
D4 - SHIELD_GAS_PWM
D5 - MARKING_PWM
D6 - PLASMA_PILOT_PWM
D7 - +5VDC
D8 - DPC STATUS
D9 - SHIELD_H20_FLOW
D10 - PLASMA_CUT_PWM
D11 - PLASMA_LOW_PWM
D12 - CANBUS COMMUNICATION
SOLENOID FAULT INDICATOR (RED LEDs)
D_E1 - SOL_V1 FLAG (H35_PLASMA)
D_E2 - SOL_V2 FLAG (O2_PLASMA)
D_E3 - SOL_V3 FLAG (AIR_PLASMA)
D_E4 - SOL_V4 FLAG (N2_PLASMA)
D_E5 - SOL_V5 FLAG (AUX_PLASMA)
D_E6 - SOL_V6 FLAG (O2_SHIELD)
D_E7 - SOL_V7 FLAG (AIR_SHIELD)
D_E8 - SOL_V8 FLAG (N2_SHIELD)
D_E9 - SOL_V9 FLAG (H2O_SHIELD)
D_E10 - SOL_V10 FLAG (O2_PREFLOW)
D_E11 - SOL_V11 FLAG (AIR_PREFLOW)
D_E12 - SOL_V12 FLAG (N2_PREFLOW)
D_E13 - SOL_V13 FLAG (ARGON_MARKING)
D_E14 - SOL_V14 FLAG (AIR_MARKING)
D_E15 - SOL_V15 FLAG (N2_MARKING)
MANAFOLD ID
SOL1
SOL2
V1
V2
V3
V4
PRE-FLOW >
MARKING >
PLASMA >
GAS SHIELD >
H2O SHIELD >
SHIELD OUT
PLASMA OUT
VENT
19X2384 SMPS +24; +/-12; +5
755x000
CONTROL
CABLE
CHASSIS GND
UNIT E-STOP
SHIELD
120 VAC
120 VAC RET
FERRITE
CORE
OPTION SWITCHES
19X2384 SMPS +24; +/-12; +5
120 VAC
120 VAC RET
DPC MANIFOLD
PLASMA_CUTTING
SOL3
PLASMA ENABLE
BYPASS RELAY
I/O PCB
CPU PCB
I
CPU PCB
JUMPER
for 2 WIRE
(RS485 only)
wire to A & B
SERIAL
COMMUNICATION
(Isolated)
JUMPER
for 4 WIRE
uses
TX+, TX-
RX+, RX-
4W
2W
J14
J14
SW14 - LINE
TERMINATION
normally on
(refer to manual)
0
5
9
8
76
1
2
3
4
SW10-ADDRESS
normally 0
(refer to
manual)
POWER SUPPLY
24 VAC to 20 VDC
ISOLATED
HMI INTERFACE PCB
19X2407
KEY
RS232
Configured
for RS485
TPC- 660E TOUCH SCREEN PANEL
J63 HARNESS NOT INSTALLED
(for future use with Height Control)
GROUNDING SCREW
TSC 3000 19X2200
FERRITE
CORE
Plasma_Cut_Hi
HMI CONTROL &
COMMUNICATIONS
4W
2W
SW14
DAT
N/A
4/24/2009
SOL# = ON/OFF CONTROL VALVE
V# = PROPORTIONAL VALVE
PS# = PRESSURE SENSOR
FS# = FLOW SENSOR (LIQUID)
NOTE:
DMC solenoids are 18 VDC.
Coils are about 46 ohms.
24 VDC is applied for 1 second
then reduced by pulse width
modulation to an average of
approximately 7-8 VDC.
Proportional valves V1-V5
powered by up to 24 VDC
Actual average voltage is
proportional to the amount
valve opening.
Coil resistance (cold):
V1 = 23 ohms;
V2= 59 ohms;
V3 & 4 = 42 ohms
V5 = 55 ohms.
NOTE:
DPC SOL solenoids are 18 VDC.
Coils are about 46 ohms.
24 VDC is applied for about 0.1
second then reduced by pulse
width modulation to an average
of approximately 9-10 VDC.
KEY PLUG
KEY PLUG
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - FLOW (H2O Shield)
TP3 - +5V
TP4 - +VREF
TP5 - +24V Fused
TP6 - +3.3VA
TP7 - 3.3V
TP8 - +12V
TP9 - Processor CLKO
TP10 - Processor TEMP
TP11 - -12V
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - Processor TEMP
TP3 - +VREF
TP4 - Processor CLKO
TP5 - +3.3V
TP6 - AGND
TP7 - +5V
TEST POINTS - INTERFACE PCB
TP1 - GND
TP2 - UNREG VDC
TP3 - +5VDC
TP4 - +20 VDC
LEDS - INTERFACE PCB:
D1 = RX (RS 485)
D14 = RX (RS 232)
D15 = TX (RS 232)
SOL#
H35 >
O2 >
AUX >
H2O >
AIR >
ARGON >
N2 >
DMC MANIFOLD
1
> GAS SHIELD
2
3
4
5
6
7 8
9
10
11
> H2O SHIELD
> PREFLOW
12
13 14 15
> MARKING
> PLASMA
INLET PASSAGES
OUTLET PASSAGES
HOSE
AA ECO-B1391 DAT
4-24-2009
D5 = +VDC Fused (24VDC )
D6 = +12VDC
D7 = +24VDC SW (24VDC to Valves
& Solenoids through E-Stop Relay
D9 = +5VDC
D16 = -12VDC
Power Supply PCB (19X2384) LEDS
Power Supply PCB (19X2384) LEDS
See list by DPC 3000 Power Supply
CCM CANBUS
ACTIVE
DPC CANBUS
ACTIVE
Tx Gray;
Rx Black
Tx Gray;
Rx Black
DPC CANBUS
ACTIVE
D2 = SLAVE SUPPLY
CAN BUS ACTIVE
D3 = GCM CAN BUS ACTIVE
D11 = INITIALIZING /
PROGRAMMING
D12 = STATUS CODE
D13 = +5VDC
D17 = RS485 TXD
D18 = RS485 RXD
CPU LEDS
AB ECO-B1507 - added text DAT
4-19-2010
J65
USB
J65
USB
1
2
3
4
5
6
SW2-2 SW2-2
SW2-4 SW2-4
STATUS LED (RED) STATUS LED (RED)
SOL8 SOL8
PS3 PS3
J62
THC (future)
J62
THC (future)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J60 J60
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SOL4 SOL4
E-STOP E-STOP
PS3
Plas_Pilot_P-in
PS3
Plas_Pilot_P-in
1
2
3
SOL14 SOL14
P1 P1
1
2
3
4
5
6
7
8
PS5 PS5
J56 J56
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
27
28
29
30
31
32
33
34
35
36
37
U7/U9
FiberOptic
U7/U9
FiberOptic
1 2
F3 1.6A SB F3 1.6A SB
U4 / U7
SLAVE FiberOptic
U4 / U7
SLAVE FiberOptic
1
2
J21
MANIFOLD ID
J21
MANIFOLD ID
1
2
3
FS-1
H2O_Shield_FlowSensor
FS-1
H2O_Shield_FlowSensor
1
2
3
P8
SOL DRIVE A
P8
SOL DRIVE A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
PS6 PS6
PS2
Shield_Water_P-in
PS2
Shield_Water_P-in
1
2
3
SOL12 SOL12
SW2-1 SW2-1
V4
Plasma_Cut_Lo
V4
Plasma_Cut_Lo
1
2
3
SW2-3 SW2-3
J3
TX/RX
J3
TX/RX
1
2
J54 J54
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SOL3 SOL3
COM1 COM1
1 2 3 4 5 6 7 8 9
P5
HW ID
P5
HW ID
1
2
3
P1 P1 1 2 3 4 5 6 7 8
10
9
J5
PROG via RS232
J5
PROG via RS232
1
2
3
4
5
6
7
8
9
P5 P5
1 2 3 4 5 6 7 8
10
9
J6
JTAG
J6
JTAG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J57 J57
1
2
3
4
5
6
7
8
9
10
11
12
13
14
SOL10 SOL10
F2 3A SB F2 3A SB
P7
POWER
P7
POWER
1 2 3 4 5 6 7 8
D21 D21
SOL11 SOL11
SW1-3 SW1-3
P61 P61
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PS6
Plasma_P-out
PS6
Plasma_P-out
1
2
3
P1 P1
1
2
3
4
5
6
7
8
SW1-4 SW1-4
E-STOP E-STOP
SW2-2 SW2-2
SOL2 SOL2
SOL13 SOL13
P2-WFS P2-WFS
1
2
3
COM2 COM2
1 2 3 4 5 6 7 8 9
SW1-1 SW1-1
P2 P2
1
2
3
4
5
6
7
8
J10
JTAG
J10
JTAG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
E-STOP E-STOP
E-STOP E-STOP
D12 D12
P4
RS 485
P4
RS 485
1
2
3
4
5
6
SOL7 SOL7
J8
TX/RX
J8
TX/RX
1
2
STATUS LED (RED) STATUS LED (RED)
E-STOP E-STOP
SW1-3 SW1-3
SW1
PLASMA ENABLE
SW1
PLASMA ENABLE
SOL3 SOL3
P55 P55
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
27
28
29
30
31
32
33
34
35
36
37
SW2-1 SW2-1
U1/U2
FiberOptic
U1/U2
FiberOptic
1
2
SOL1 SOL1
U4/U5
FiberOptic
U4/U5
FiberOptic
1 2
P54
HMI Serial/Control
P54
HMI Serial/Control
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PS5
Shield_Gas_P-out
PS5
Shield_Gas_P-out
1
2
3
P9 P9
1
2
3
4
5
6
7
8
P2 P2
1
2
3
4
5
6
7
8
POWER LED (GREEN) POWER LED (GREEN)
F4 3A SB F4 3A SB
SOL9 SOL9
SW2-4 SW2-4
SOL6 SOL6
J55 J55
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
27
28
29
30
31
32
33
34
35
36
37
V5 V5
1
2
3
D22 D22
SW1-2 SW1-2
P4
STATUS LEDS
P4
STATUS LEDS
1
2
3
4
F1 1.6A SB F1 1.6A SB
SOL1 SOL1
SOL15 SOL15
P2
RS 485
P2
RS 485
1
2
3
4
5
6
V1
SHIELD
V1
SHIELD
1
2
3
P56 P56
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
27
28
29
30
31
32
33
34
35
36
37
J1 J1
1
2
3
4
U10 / U13
GAS FiberOptic
U10 / U13
GAS FiberOptic
1
2
P6
Valves
P6
Valves
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P1
Press_sensors
P1
Press_sensors
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
J63 J63
1
2
3
4
5
6
7
8
9
E-STOP E-STOP
PS4
Plasma_Cut/Mark_P-in
PS4
Plasma_Cut/Mark_P-in
1
2
3
SW1-4 SW1-4
SOL5 SOL5
SW2-3 SW2-3
V2
SHIELD_H2O
V2
SHIELD_H2O
1
2
3
J2
RS232 Prog
J2
RS232 Prog
1
2
3
4
5
6
7
8
9
J23 J23
1
2
3
P3
POWER
P3
POWER
1
2
3
4
5
6
E1 E1
P60 P60
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P10
HMI POWER
P10
HMI POWER
GN
D
- +
SW1-2 SW1-2
PS1
Shield_Gas_P-in
PS1
Shield_Gas_P-in
1
2
3
J61 J61
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PS4 PS4
SW1-1 SW1-1
V3
Plasma_PILOT
V3
Plasma_PILOT
1
2
3
SOL2 SOL2
PS1 PS1
POWER LED (GRN) POWER LED (GRN)
P3 - HWID P3 - HWID
1
2
3
P4
SOL DRIVE B
P4
SOL DRIVE B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P57 P57
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PS2 PS2