Victor CUTMASTER 102, Service Manual

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CUTMASTER 102
Manual 0-4998 APPENDIX
A-9
A-09130_AD
A-09130_AD
5
5
4
4
3
3
2
2
1
1
D D
C C
B B
A A
+12VDC
+12VDC
+12VDC
+12VDC
+5VDC
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
24VAC
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, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1330
1 1
16052 Swingley Ridge Road
Suite 300
St Louis MO 63017 USA
CM102/152/35mm/40mm/A80/A120 380/400/415/600V 09:02:19
VICTOR TECHNOLOGIES VICTOR TECHNOLOGIES VICTOR TECHNOLOGIES
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, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1330 Friday, December 11, 2009
1 1
16052 Swingley Ridge Road
Suite 300
St Louis MO 63017 USA
CM102/152/35mm/40mm/A80/A120 380/400/415/600V 09:02:19 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, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App:
TITLE:
Last Modified:
Size
SCHEMATIC,
42X1330
1 1
16052 Swingley Ridge Road
Suite 300
St Louis MO 63017 USA
CM102/152/35mm/40mm/A80/A120 380/400/415/600V 09:02:19 D
_
OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE
ERROR IND
FAULT
PCB3
INRUSH
RESISTORS
LATCH
SET
RUN
RAR
MAX
90
85
80
75
70
65
MIN
TP1
TP2
TP3
TP4
TP5
TP6
TP7
LOGIC PCB
GND
+12 VDC
+5 VDC
3.3 VDC
0.v - 5.0 VDC / 0-100PSI
1.8 VDC
CURRENT DEMAND
TEST POINTS
TEMP
CIRCUIT
3.3VDC
TXD
RXD
Q2
D
SERIAL PORT
80
81
82
83
E64
E35
78
79
-
+
ATC CONNECTOR
GND1
GND2
+12V1
48V1
I_DMD_1
TIP_SEN
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE
TEST POINTS
J2
_
J1
CNC PINOUT
1 3
4 7
8 11
12 14
OK-TO-MOVE
/PIP
PCB1
+
+
+
+
Q1
/START
/SOLENOID
24VAC RETURN
24VAC SUPPLY
MAIN PCB ASSY
/OVERTEMP
TEMP
CIRCUIT
PRESSURE
TRANSDUCER
AIR
INLET
FILTER
REGULATOR
SOLENOID
VALVE ATC
GAS CONTROL
0-100PSI / 0-4.5VDC
/INRUSH
/OVERTEMP
D3
D1
(5A @ 250VAC / 30VDC)
C D
B
A
1TORCH
_
AUTOMATION
TORCH SOLENOID
Q2
_
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
-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
40 PIN RIBBON CABLE SIGNALS
B
A
PCB5
40/50 AMP PCB
PCB2
Q1
FAN
/FAN
FAN
D2
D1
C
D
INPUT CAPACITOR PCB
MARCH 30, 2009
1 /OVERTEMP
2 /FAN_ON
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID
6 COMMON
SYNC
}
OK-TO-MOVE
OK TO MOVE
}
}
PCB4
AUTOMATION
INTERFACE PCB
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
(+)
}
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
K1
To -V OUT 1
on PCB1
}
/START / STOP
*
*
}
DIVIDED ARC VOLTS
/START / STOP
(+)
(-)
(W/ 100K IN SERIES (2))
(-) *
ARC VOLTS
SYNC
FAN
9
8
7A
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND
L1
L2
L4
L3
T2
T1
T4
T3
24VAC RET
5
6
7
L2
L1
GND
L3
/FAN
AA
INTRO ECO B1357
BIAS
SUPPLY
+12VDC
BIAS
SUPPLY
FERRITE
FILTER
FERRITE
FILTER
RWH
RWH 03/31/09
CNC INTERFACE STANDARD ON A80 & A120 UNITS
CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS
*
EMI
CHOKE
EMI
FILTER
1
2
3
4
1
2
3
4
*
*
380/400/415V
OR 600V
3 PH AC INPUT
CE UNITS
ONLY
*CM102/35mm/A80
C7 & C10 may not be installed
AB
ECO B1399 RWH 05/05/09
MTH4 MTH4
TP3 TP3
WORK1 WORK1
AC3 AC3
J2 J2
1
2
-V OUT 1 -V OUT 1
NTC NTC
J9 J9
AC AC
AC2 AC2
J2 J2
2
3
4
5
6
7
8
9
10
11
12
13
14
1
MTH7 MTH7
90 90
MOT3 MOT3
+
-
+
C3,C4,C7,C8*
+
C3,C4,C7,C8*
CHOKE1 CHOKE1
SOL 1 SOL 1
J1 J1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
MTH6 MTH6
SEC1 SEC1
J14 J14
J3 J3
3
2
1
PRI 2 PRI 2
Q5
PILOT IGBT
Q5
PILOT IGBT
80A_AC2 80A_AC2
J13 J13
1 2 3 4 5 6
J10 J10
1
2
3
4
5
6
7
8
PRI 3 PRI 3
80A_AC3 80A_AC3
SEC1 SEC1
TS1 TS1
PMTH2 PMTH2
85 85
+
C16-17
+
C16-17
MTH8 MTH8
J4 J4
1
2
3
4
5
AC1 AC1
PRI 2 PRI 2
L2 L2
ERROR ERROR
NTC NTC
K1 K1
TIP1 TIP1
PRI 4 PRI 4
70 70
MIN MIN
D78 CSR D78 CSR
1 2 3
J7 J7
1
2
T1 T1
MTH2 MTH2
SW1 SW1
1 3
2 4
MOT1 MOT1
+ -
PMTH1 PMTH1
PRI 1 PRI 1
TORCH SWITCH TORCH SWITCH
PMTH3 PMTH3
ELECTRODE1 ELECTRODE1
J4 J4 1 2 3 4 5 6 7 8 9 10
W1 W1
SEC2 SEC2
J1 J1
1
2
AC2 AC2
P2 P2
1
2
3
4
5
6
7
8
40A_AC2 40A_AC2
MOT2 MOT2
+
-
SEC2 SEC2
AC1 AC1
W1 W1
PMTH1 PMTH1
Current Control Current Control
J5 J5
1
2
3
+
C12-13
+
C12-13
TP4 TP4
PRI 1 PRI 1
DC DC
CHOKE1 CHOKE1
MAX MAX
J11 J11 1 2
J6 J6
1
2
80A_AC1 80A_AC1
J1 J1
1
2
3
4
5
GAS GAS
65 65
PMTH4 PMTH4
AC3 AC3
PRI 4 PRI 4
TP2 TP2
PRI 3 PRI 3
J1 J1
1
2
3
4
5
6
7
8
40A_AC3 40A_AC3
P1 P1
1 2 3
L1 L1
OVERTEMP OVERTEMP
TP5 TP5
P10 P10
1
2
3
4
5
6
7
8
+OUT_1 +OUT_1
PRI 1 PRI 1
T2 T2
D1 D1
PMTH4 PMTH4
MTH1 MTH1
80 80
1
2
3
4
5
6
7
8
PRI 2 PRI 2
75 75
PIP SWITCH PIP SWITCH
TP1 TP1
+
C5,C6,C9,C10*
+
C5,C6,C9,C10*
TP8 TP8
K1 K1
40A_AC1 40A_AC1
D59 PCR D59 PCR
J3 J3 1 2
PMTH3 PMTH3
E1 E1
J9 J9
1
2
3
4
5
6
7
WORK WORK
PMTH2 PMTH2
J2 J2
1
2
P10 P10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
AB
ECO B1611 RWH 05/05/09