Thermal Dynamics A60 CUTMASTER Service Manual

CUTMASTER A60
Manual 0-4982 A-11 APPENDIX
A-09133_AC
A-09133_AC
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
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev
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,
42X1329
Wednesday, May 06, 2009
11
16052 Swingley Ridre Road,
Suite 300
St Louis, MO 63017 USA
CM52/82/12mm/20mm/25mm/A40/A60 380/400/415/600V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
DWG No:
Sheet
of
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev
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,
42X1329
Wednesday, May 06, 2009
11
16052 Swingley Ridre Road,
Suite 300
St Louis, MO 63017 USA
CM52/82/12mm/20mm/25mm/A40/A60 380/400/415/600V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
DWG No:
Sheet
of
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev
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,
42X1329
Wednesday, May 06, 2009
11
16052 Swingley Ridre Road,
Suite 300
St Louis, MO 63017 USA
CM52/82/12mm/20mm/25mm/A40/A60 380/400/415/600V
Thursday, March 27, 2008
13:16:29
THERMADYNE
C
AB
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 INDFAULT
PCB3
8
9
82
7A
}
OK-TO-MOVE
OK-TO-MOVE
83
OK TO MOVE
1TORCH
Q2
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND
*
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
-
+
-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
/PIP
PCB2
/SOLENOID
Q1
380/400/415V
OR 600V
3 PH AC INPUT
/START
PCB1
NAFNAF
24VAC RETURN
ATC CONNECTOR
/FAN/FAN
24VAC SUPPLY
40 PIN RIBBON CABLE SIGNALS
LATCH
SET
RUN
RAR
40 CIRCUIT
RIBBON CABLE
}
MAX
90
85
80
75
70
65
MIN
J2
7
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
DC
To -V OUT 1
on PCB1
}
/START / STOP
**
AIR
INLET
FILTER
}
REGULATOR
INTRO ECO B1357
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
13
47
811
1214
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 RESISTORS
/INRUSH
/OVERTEMP
TEMP
CIRCUIT
D3
3.3VDC
TXD
RXD
D
SERIAL PORT
BIAS
SUPPLY
RWH
AA
RWH 03/31/09
*
EMI
CHOKE
EMI
FILTER
1
2
3
4
1
2
3
4
*
CE UNITS
ONLY
RWH 90/50/509931B OCE
AB
*CM52/12mm/20mm/A40
C3 & C5 may not be installed
WORK1WORK1
SEC1SEC1
D1D1
PRI 2 PRI 2
CHOKE1CHOKE1
J1J1
1
2
3
4
5
6
7
8
Q5
PILOT IGBT
Q5
PILOT IGBT
NTCNTC
J3J3
1
2
3
J3J3
1 2 3
+
C1-C4*
+
C1-C4*
W1W1
AC3AC3
7070
MOT1MOT1
+ -
W1W1
J4J4
1
2
3
4
5
MTH1MTH1
J7J7
1 2
TIP1TIP1
MTH4MTH4
J1J1
1
2
3
4
5
6
7
8
P10P10
1
2
3
4
5
6
7
8
1 2 3
9090
7575
MOT2MOT2
+
-
DCDC
J9J9
1
2
3
4
5
6
7
PRI 1 PRI 1
6565
J1J1
1
2
3
4
5
P10P10
1
2
3
4
5
6
7
8
SW1SW1
1 3
2 4
TS1TS1
MTH7MTH7
SEC2SEC2
8080
WORKWORK
PRI 4 PRI 4
AC2AC2
8585
E1E1
OVERTEMPOVERTEMP
MTH3MTH3
L1L1
Current ControlCurrent Control
MTH6MTH6
D59 PCRD59 PCR
ERRORERROR
J6J6
1
2
J8J8
1 2
D78 CSRD78 CSR
K1K1
MTH5MTH5
-V OUT 1-V OUT 1
J2J2
2
3
4
5
6
7
8
9
10
11
12
13
14
1
T1T1
J5J5
1 2 3
J11J11
1 2
MAXMAX
PRI 3PRI 3
J10J10
3
5
6
7
8
1
2
4
ELECTRODE1ELECTRODE1
GASGAS
MTH8MTH8
MTH2MTH2
TORCH SWITCHTORCH SWITCH
AC1AC1
+
C5-C8*
+
C5-C8*
ACAC
J2J2
2
3
4
5
6
7
8
9
10
11
12
13
14
1
MINMIN
K1K1
PIP SWITCHPIP SWITCH
1
2
3
4
5
6
7
8
SOL1SOL1

Thermal Dynamics A60 CUTMASTER Specifications

General

Brand	Thermal Dynamics
Model	A60 CUTMASTER
Category	Welding System
Language	English