Thermal Dynamics Ultra-Cut 400, Operation Manual

Page: 175 / 178

Manual 0-5164 A-27 APPENDIX
ULTRA-CUT 400
Art # A-09531
Art # A-09531
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
400
AC120V @ 1A
AC13V @ 2A
/PUMP
+15V
+15V
400
/FAN
200 - not used
/RAS
COM
200
24VAC
400
24 VAC RE
T
+15V
/ AC
/ TEMP
/ STATUS
/ DC
/ GAS - COOLANT
COM
AC230V @ 5A
200
+15V
POT WIPER (GCM1000)
POT LOW (GCM 1000)
PLASMA ENABLE
PRESS OK (GCM 1000)
PLASMA ENABLE
POT HI (GCM1000)
- ARC V
- ARC V
0V-A (24V ret)
WORK
To PCB7 CN2-
1
AC120V-GCM
0V-B (120V ret)
To PCB7 CN2-
2
AC120V-RAS
0V-RAS (120V ret)
0V-A (24V ret)
NEG ARC VOLTS
To PCB7 TB
3
0V-RAS
AC120V-RAS
AC230V RET
NEG ARC VOLT
S
DC 15V
AC24V-GCM
DC 0V
AC230V @ 1.25A
PILOT (TIP) VOLT
S
0V-B (120V ret)
WORK
AC24V-GCM
AC120V-GCM
To T1 PRI -
0
DC 15V
DC 0V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
AC230V RET
AC230V @ 1.25A
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
42X1337
Monday, April 19, 2010
2 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CE
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
42X1337
Monday, April 19, 2010
2 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CE
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
42X1337
Monday, April 19, 2010
2 2
Industrial Park #2
West Lebanon NH 03784
603-298-5711
400-Amp Power Supply 400V CE
08:11:44
Thermal Dynamics
D
DAT
(F1 Sht 1) (F1 Sht 1)
MC2=PILOT
CONTACTOR
From
(Grid
D2)
INPUT
CONTACTORS
PILOT (TIP) VOLTAGE
COOLANT TEMP
(ON COOLANT
RETURN)
* Only in CCM w/19X2634 I/O PCB.
Remote Marking only for DFC 3000
(not isolated).
SW8-4 on CPU PCB must be on to
enable Remote Marking.
ISOLATED COMM
+16 to +18VDC
Rx-
Tx+
Rx+
Tx-
CCM MODULE
Signal & GND
Isolated from
Plasma Supply
INTERNAL TERMINAL
STRIP TB3
KEY PLUG
+15VDC_ISO
From
(Grid C9, sht 1)
-15VDC_ISO
RS 485 (2 wire)
uses Tx+ & Tx- only
(used for TSC 3000)
RIBBON CABLE
TEST SOCKET
(F1 Sht 1)
RS 422 (4 wire)
connect TX+ to RX+
of CNC, Tx- to Rx-
of CNC
(F1 Sht 1)
ISOLATED
VOLTAGES
JUMPER IN
REMOTE
HMI
** RS 485 / 422
on CPU board
19X2554 only.
NEG ARC VOLTS
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT
"B" DEFAULT, "A" REMOTE
KEY PLUG
Was 7 pin
changed to
14 pin in 2009
SW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB7 WK-5628
RELAY PCB
CIRCUIT COMM (GND)
CN11 34 CKT CN10 26 CKT
PILOT DEM to PS
ANALOG DEM to CPU
Iso
J36 34 CKT
PCB6 DISPLAY
WK-5603
JUMPER
for 2 WIRE
(RS485 only)
wire to A & B
4W
4W
2W
JUMPER
for 4 WIRE
uses
TX+, TX-
RX+, RX-
J35 26 CKT
J14
J14
2W
SW14
SW14 - LINE
TERMINATION
normally on
(refer to manual)
CUT DEM to PS
RIBBON CABLE
5
9
8
76
1
2
3
4
SW10-ADDRESS
normally 0
(refer to
manual)
0
TEST SOCKET
From
(Grid A9, sht 1)
UNDIVIDED ARC VOLTS
FOR HEIGHT CONTROLS
GND
GND
& CNC COMM
PLASMA ENABLE
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
POWER SUPPLY
REAR PANEL
TO AC INDICATOR (on PCB6)
29-41 VDC
RIBBON CABLE SIGNALS
/ = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2- Cut Demand
4- Pilot Demand
6- / Start
7- / Start2
9- / Pilot Enable
10- / HF Enable
12- / Pump Enable
13- / Fan Enable
15- / DC Indicator
16- / Over Temperature Indicator
18- / Gas-Coolant OK Indicator
19- / Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal
3- / Arc Transferred (CSR)
4- / Pilot On
6- Coolant Flow (freq)
7- Coolant Temp (analog)
9- / Temp OK (Inverter/Chopper)
10- / Coolant Level OK
12- Missing Phase
13- / Ready to Operate
15- / Input Volts OK
16- / Inverter OCR
18- / PS ID "00*"
19- / PS ID "0*0"
20- / PS ID "*00"
21- E-Stop
22- E-Stop
29,31,33- 24 VAC Supply
30,32,34- 24 VAC Return
Rx-
Tx+
Rx+
Tx- +15VDC
+5VDC
-15VDC
COOLANT FLOW (freq) *
I/O PCB
CPU PCB
Wednesday, February 10, 2010
START / STOP
DIVIDED ARC VOLTS
REMOTE ANALOG
CURRENT CONTROL
OK TO MOVE
OK to MOVE -
E-STOP -
E-STOP +
* REMOTE MARKING +
OK to MOVE +
MOMENTARY START / STOP
START / STOP
* REMOTE MARKING -
STOP
START
TB1
TB2
+
-
Signal - Basic ID
Used to identify
GCM 1000 present
DIVIDED ARC V +
DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -
REMOTE ANALOG CURRENT C
TB3
PILOT ON
OUTPUT
* OK2
* OK2
HOLD START -
HOLD START +
* +10VDC @ 10 ma.(for CC pot high)
PREFLOW ON -
PREFLOW ON +
DCS1
100VAC - 24 VDC
230 VAC @ 1.25A
for Ext Heat
Exchanger
PCB 5 WK-6276A (partial) INTERFACE PCB
ECO-B1507 - Initial Release DAT 4-16-2010
To J70 (at C9) for
Ext. Heat Exchanger
(HE400) Power
From T2
(Grid F3)
To J59
(Grid C9)
To J55
(Grid E9)
To J55 & TB3
(grids D9, A10)
To J55 & TB3
(grids D9, A10)
From T1
(Grid D2)
From T1 (Grid D2)
From CN12 (Grid E4)
From Sheet 1
Grids (A9, B9 & C9)
From CN7
(Grid E4)
1
2
3
RY4 RY4
RY5 RY5
55
TB1 TB1
TP16 TP16
C.P2 C.P2
K6 K6
FAN2 FAN2
+ -
+V
GN
D
SIG
FL1
FLOW_TURBINE_PULSE
+V
GN
D
SIG
FL1
FLOW_TURBINE_PULSE
R B G
J70 - HE J70 - HE
7
2
3
C.P5 C.P5
t
TH1
t
TH1
11 11
TP5 TP5
J59-RAS J59-RAS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TP14 TP14
C.P6 C.P6
D23 CNC_START D23 CNC_START
1
2
CN14 CN14
1 2
J15-CNC J15-CNC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TP13 TP13
11 11
GREEN
AC
GREEN
AC
TB4 TB4
66
MC3 MC3
77
D18 RS485 RXD
CN2 CN2
1
2
CN12 CN12
1 2 3
+
RY1
+
RY1
J7 J7
1
2
3
4
5
6
7
8
9
MC1 MC1
10 10
CN5 CN5
1
2
3
4
5
6
PUMP
MOT1
PUMP
MOT1
' .
TP15 TP15
1
2
3
T1 T1
460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
TP4 TP4
RY4 RY4
TP9 TP9
TP3 TP3
99
C.P4 C.P4
100K3 100K3
12 12
C.P8 C.P8
TB3 TB3
J5 J5
1
2
3
4
5
CN13 CN13
1 2 3
100K 100K
CN8 CN8
1
2
3
4
66
D2&3 CANBUS ACTIVE
D7 E-STOP_PS D7 E-STOP_PS
22
TP10 TP10
CN4 CN4
1
2
3
J4 J4
1
3
5
7
MC3 AU
X
MC3 AU
X
77
CN1 CN1
1
3
E-STOP E-STOP
88
33
1
2
R8
1K 30W
R8
1K 30W
GAS ON GAS ON
CN2 CN2
1 2 3 4 5
55
33
RY3 RY3
J55-GCM J55-GCM
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
D12 STATUS CODE
D26 HOLD_START D26 HOLD_START
TP12 TP12
10 10
MC6 MC6
1
2
CN3 CN3
4
5
TP18 TP18
11
D9 GAS_ON D9 GAS_ON
FAN1 FAN1
+ -
GREEN2
DC
GREEN2
DC
12 12
GREEN1
GAS
GREEN1
GAS
22
CN9 CN9
1
2
3
1K 1K
1 2 3
C.P7 C.P7
J9 J9
1 2 3 4 5 6
C.P3 C.P3
CN8 CN8
1 2 3 4
11
CN1 CN1
1 2
12 12
D11 INITIALIZING / PROGRAMMING
88
1 2
TP1 TP1
+
RY2
+
RY2
77
RED
STATUS
RED
STATUS
YELLOW TEMP YELLOW TEMP
D8 OK_CNC D8 OK_CNC
OK2 * OK2 *
44
MC4 AU
X
MC4 AU
X
TP8 TP8
D28 CNC_PREFLOW D28 CNC_PREFLOW
D13 +5V
T2 T2
600_
460_
0...
230
400__
220__
200__
0___
1
2
TP2 TP2
TP6 TP6
MC5 MC5
MC2 MC2
CN1 CN1
1
2
3
4
5
6
CN9 CN9
1
2
3
4
5
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
11 11
J1 J1
1
2
3
4
5
6
7
8
9
RY1 RY1
99
66
PSR PSR
CN5 CN5
1
2
3
4
5
6
11
CN12 CN12
1
2
99
RY1-1 RY1-1
MC5 AU
X
MC5 AU
X
J8 J8
1
2
3
4
CN6 CN6
1
2
3
4
22
1 2
MC1 AU
X
MC1 AU
X
D15 PSR D15 PSR
TP7 TP7
K6-2 K6-2
22
TB2 TB2
TP11 TP11
55
TP17 TP17
RY3 RY3
11
88
TB5 TB5
CN10 CN10
1
2
3
CN11 CN11
1
2
D17 RS485 TXD
J54-REMOTE HMI J54-REMOTE HMI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
33
CN3 CN3
1
2
3
MC4 MC4
J6 J6
1 5 8
D21 CNC_E-STOP D21 CNC_E-STOP
44
CN7 CN7
1
2
3
4
1 2 3
10 10
44
RY5 RY5
J6 ** J6 **
1
2
3
4
5
6