Thermal Dynamics Ultra-Cut 400, Operation Manual

Page: 169 / 178

Manual 0-5164 A-21 APPENDIX
ULTRA-CUT 400
Art # A-09528
Art # A-09528
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
A A
B B
C C
D D
E E
F F
GNDP
Isense_W
/ 20
0
/ 40
0
/ 40
0
COM_
A
200_A 400_A
Ribbon Cabl
e
400 200
+15V
GNDW
CO
M
400_C
200_A
400_A
COM_A
400_B
200_B
COM_B
200_C
COM_C
Ribbon Cabl
e
Is
ense_W
PGND2
-15
Vw
-15V
INPUT_NG Isense_P
Ribbon Cabl
e
+5
V
GN
D
+15V
Ribbon Cable
+15V
GNDW
+15V
w
Ribbon Cabl
e
PGND1
+15V
MISSING_PHASE
-15Vp
COM_
B
GNDP
Ribbon Cabl
e
200_B
+15Vw
400_B
-15Vw
-15V
+15Vp
Isense_P
COM_
C
200_C 400_C
TORCH (-)
PILOT
WORK (+)
E
L1
L2
L3
+12VDC +12VDC
+15V
+12VDC
To PCB7 TB
3
To T1 PRI -
0
FAN + (24 VDC
)
NEG ARC VOLTS
FAN - (24 VDC)
RY2_C to INV # 2
RY2_B to INV #3
RY2_C to INV # 2
WORK
RY2_B to INV #3
To PCB7 CN2-2 To PCB7 CN2-1
PILOT (TIP) VOLTS
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
AA
42X1338
Tuesday, April 20, 2010
1 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CCC
08:11:44
Thermal Dynamics
D
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
AA
42X1338
Tuesday, April 20, 2010
1 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CCC
08:11:44
Thermal Dynamics
D
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
AA
42X1338
Tuesday, April 20, 2010
1 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CCC
08:11:44
Thermal Dynamics
D
RAS
CN6
100A INVERTER MODULE # 4 (right side)
(same as #1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1,3 Contactor, 3P ,Inv #1 input, Coil (B2, Sht 2)
" Contacts (A2, B3, Sht 1)
" Aux Contact (B3, Sht 2)
MC2 Contactor, pilot, Coil (B3, Sht 2)
" Contacts (B9, Sht 1)
MC4,5 Contactor, 3P ,Inv #2 input, Coil (B2, Sht 2)
" Contacts (B3,C3, Sht 1)
" Aux Contact (B3, Sht 2)
MC6 Contactor, 3P ,Inv #3 input, Coil (B2, Sht 2)
" Contacts (C8, Sht 1)
" Aux Contact (B3, Sht 2)
MOT1 Motor, Pump 230VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
R6 Resistor, 20K, 30W (A8, Sht 1)
R7 Resistor, 1K, 30W (D2, Sht 2)
R9 Resistor, 10, 40W (B9, Sht 1)
RY1 Relay 100 VAC NC contact (B2,B3 sht 2)
RY2 Relay 12 VDC 3PDF Volts sel. (E1, sht1)
T1 Aux Transformer (C-E1, Sht 2)
T2 Aux Transformer (F1, Sht 2)
TH1 Thermal Sensor, coolant return (B4, Sht 2)
(C7 & A9,Sht 2)
(C7, Sht 2)
CN104 16 CKT
400 VAC 3 Phas
e
CN1 CN5 CN6
CN4
BIAS SUPPLY PCB
DETECTOR PCB
INPUT POWER
INDICATOR
REAR PANEL
CN5
INPUT POWER
INDICATOR
INTERNAL
VAC_IN
(A1 Sht2) (A1 Sht2)
CN6
DAT
CN6
FILTER PCB
P_GND
CN102 16 CKT
(A1 Sht 2) (A1 Sht 2)
(C7 & A9,Sht 2)
HALL SENSOR
CN103 16 CKT
V_CHANGE PC
B
ON / OFF
LINE to LINE,
LINE TO GND
CAPS & VARISTORS
CN6
(B6)
PCB 1
WK-5630
(C3)
HALL SENSOR
COMPONENT LOCATOR
LED1 ON = INV OVER TEMP *
LED2 ON = OCR FAULT *
LED3 ON = INV NOT READY
* MAY BE ON DIM WHEN PLASMA
DISABLED OR IN E-STOP
(E2)
100A INVERTER MODULE # 1 (top)
PILOT CURRENT SIGNAL
<
WORK CURRENT SIGNAL
<
CN6
PCB 5 WK-6276A (partial)
INTERFACE PCB
MISSING PHAS
E
(pulses)
<
LED4 ON = INPUT NG FAULT
LED5 ON = COOLANT TEMP FAULT
LED6 ON = COOLANT LEVEL OK
LED7 ON = MISSING PHASE
LED8 ON = WRONG INPUT VOLTAGE FAULT
CN101 16 CKT
P_GND VAC_IN
Power Supply
Rear Panel
PCB3 WK-5694
PCB4 WK-5604
BIAS SUPPLY
FOR PCB5
Not used on
400A Supply
100A INVERTER MODULE # 2 (middle)
(same as #1)
100A INVERTER MODULE # 3 (bottom)
(same as #1)
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)
5- PS_START (Start)
6- REDUNDANT_START (Start2)
8- INV_READY
9- / PS_START disabled by Input_NG
12- / OCR
13- / PS_START disabled by OCR
14- /TEMP_ERR
15- / PS_START disabled by Temp _Err
--400--
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 1)
C2a,b Capacitor, 47uf, 400VAC (B9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1)
15A, 460V, 3P
C.P2 Circuit protector 2.5A 125V (C2, Sht 2)
C.P3 Circuit protector 3.15A 125V (D2, Sht 2)
C.P4 Circuit protector 10A 125V (D2, Sht 2)
C.P5 Circuit protector 2.5A 125V (D2, Sht 2)
C.P6 Circuit protector 2.5A 125V (E2, Sht 2)
C.P7 Circuit protector 8A 250V (F2, Sht 2)
C.P8 Circuit protector 3.15A 125V (E3, Sht 2)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)
FAN1,2 Fan, Coolant, 24 VDC (E4, Sht 2)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B9, Sht 1)
HCT2 Hall Current Sensor, Work (C9, Sht 1)
DC FAN
POWER
STATUS LEDS
PCB 8
WK-5687
RC &
RF CAPS
Wednesday, February 10, 2010
ECO-B1507 - Initial Release DAT 4-16-2010
(NOT USED)
(NOT USED)
(NOT USED)
(NOT USED)
(400V ONLY)
TB3 TB3
TB4 TB4
MC4-A MC4-A
MC6-A MC6-A
- + - +
3
1
2
4
++
CN4 - PCB12 CN4 - PCB12
1 2 3 4
N (-) N (-)
CN2-400V CN2-400V
1 2 3 4
SS
MC5-A MC5-A
1 2
3 4
+
RY2
+
RY2
TB2 TB2
CN4 - PCB12 CN4 - PCB12
1 2 3 4
CN32 CN32
1 2 3 4
P (+)1 P (+)1
CN3 CN3
1
4
++
CN4 - PCB1 CN4 - PCB1
1 2 3 4
INRUSH INRUSH
R1 R1
200V 200V
MC5-B MC5-B
TB1 TB1
T2 T2
CN4 - PCB12 CN4 - PCB12
1 2 3 4
P1 P1
TB1 TB1
CN1-200V CN1-200V
1
2
3
4
TT
CN1 CN1
1 5 8
CN4 CN4
1 2 3 4 5
MC3-A MC3-A
CN18 CN18
1 2 3
CN2-400V CN2-400V
1
2
3
4
SS
N2 N2
CN1-200V CN1-200V
1
2
3
4
R R
P (+) P (+)
N (-)1 N (-)1
HCT1 HCT1
1 2 3 4
CN1-200V
6
CN1-200V
6
1 2 3 4
MC4-C MC4-C
MC6-C MC6-C
+
RY2
RY2
+
RY2
RY2
1 2
3 4
R R
R R
SS
C2b
47 UF
C2b
47 UF
MC5-C MC5-C
P (+) P (+)
CN4 CN4
1 2 3 4
TB2 TB2
MC2-A MC2-A
P (+) P (+)
N (-) N (-)
CN32 CN32
1 2 3 4
CN1 CN1
1
2
3
4
CN2 CN2
1
2
3
+
-
+
-
1
2
3
4
5
6
MC2-B MC2-B
CN7 CN7
1 2 3 4 5
CN1 CN1
1
5
TB3 TB3
CN3 CN3
1 2 3 4
CN7 CN7
1 2 3 4 5
MC3-C MC3-C
CN3 CN3
1 2
R6
20K
30W
R6
20K
30W
TT
TT
CN4 CN4
1 4
MC4-B MC4-B
N (-) N (-)
MC6-B MC6-B
CN10 CN10
1 2
TB1 TB1
C.P1 C.P1
CN2 CN2
1 2
CN3 CN3
1
MC1-C MC1-C
MC1-A MC1-A
CN2 CN2
1 2 3
AC
AC
AC
+
-
D1
AC
AC
AC
+
-
D1
HCT2 HCT2
1 2 3 4
MC1-B MC1-B
CN2 CN2
1 2 3
WORK WORK
NE1 NE1
RY2 RY2
S1 S1
CN1-200V CN1-200V
1
2
3
4
CN2-400V CN2-400V
1
2
3
4
C1 C1
- + - +
3
1
2
4
C2a
47 UF
C2a
47 UF
R9
10
R9
10
NE2 NE2
CN2-400V CN2-400V
1
2
3
4
MC2-C MC2-C
MC3-B MC3-B