ESAB 100i Service Manual page 57

4
DPC3000 - PRESSURE CONTROL ASSEMBLY
Power Supply PCB (19X2384) LEDS
D5 = +VDC Fused (24VDC )
D6 = +12VDC
D7 = +24VDC SW (24VDC to Valves
D9 = +5VDC
D16 = -12VDC
( ) 1 120 VAC
P60 P60 J60 J60
120 VAC RET
1 1
E_STOP NO
(2a)
2 2
3 3
E_STOP COM
4 4
5 5
KEY PLUG
6 6
7 7
(8)
8 8
(9)
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
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.
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.
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
GROUNDING SCREW
H35 >
O2 >
AUX >
H2O >
AIR >
ARGON >
N2 >
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.
4
Manual 0560956456
19X2383
STATUS LED (RED) STATUS LED (RED)
& Solenoids through E-Stop Relay
FERRITE
19X2384 SMPS +24; +/-12; +5
CORE
P1 P1
F3 1.6A SB F3 1.6A SB
( ) 1 120 VAC
1
2
E-STOP E-STOP
E-STOP E-STOP
3
(2a) 120 VAC RET
4
(8)
+24 VDC
5
(9)
6
F4 3A SB F4 3A SB
7
E-STOP E-STOP
8
MANIFOLD (partial)
SOL3 SOL3 PLASMA_CUTTING
SOL2 SOL2 PLASMA_VENT
V5 V5
1
2
V1 V1
3
1
Plasma_Cut_Hi
2
3
V2 V2
SHIELD SHIELD
1
2
3
V3 V3
SHIELD_H2O SHIELD_H2O
1
2
3
Plasma_PILOT Plasma_PILOT
SOL1 SOL1 PLASMA_MARK
V4 V4
1
2
3
Plasma_Cut_Lo Plasma_Cut_Lo
DMC MANIFOLD
INLET PASSAGES
OUTLET PASSAGES
SOL#
HOSE
1
3
2 4
5 7 8 > GAS SHIELD
6
9 > H2O SHIELD
10
11 12
> PREFLOW
13 14 15
> MARKING
> PLASMA
APPENDIX
iSERIES 100 /200 /300 /400
5
PANEL INDICATORS
POWER LED (GRN) POWER LED (GRN)
DPC3000 CONTROL PCB
19X2382
OPTION SWITCHES
P4 P4
SW1-1 SW1-1
4
(WHT)
(BLK) 3
SW1-2 SW1-2
2
(WHT)
1
SW1-3 SW1-3
STATUS LEDS STATUS LEDS
SW1-4 SW1-4
SW2-1 SW2-1
FERRITE
CORE SW2-2 SW2-2
P2 P2 P9 P9
(PW1) -12VDC SW2-3 SW2-3
1 1
(PW2) GND SW2-4 SW2-4
2 2
(PW3) +5VDC
3 3
LEDs Listed Below
(PW4) +12VDC
4 4
(PW5) +24VDC SW
5 5
(PW6) +24 VDC_FUSED
6 6
(PW7) GND
7 7
(PW8) E-STOP
8 8
J5 J5
1
2
3
4
5
6
7
8
(S3-T)
9
(S3-B)
PROG via RS232 PROG via RS232
(S2-B)
J10 J10
(S2-B)
P6 P6 1
2
(V5-1)
3
16
4
15
(V5-2)
5
14
6
13
7
12
8
11
(V1-1)
9
10
10
9
(V1-2)
11
8
12
7
13
6
14
5
(V2-1) 4
JTAG JTAG
3
2
(V2-2)
1
J8 J8
Valves Valves
1
2
(V3-1)
TX/RX TX/RX
(V3-2)
DPC FiberOptic Port
U1/U2 U1/U2
Tx Gray;
(S1-T)
1
Rx Black
2 DPC CANBUS
(S1-B)
ACTIVE
FiberOptic FiberOptic
(V4-1)
GROUNDING SCREW
(V4-B)
SOL# = ON/OFF CONTROL VALVE
V# = PROPORTIONAL VALVE
PS# = PRESSURE SENSOR
FS# = FLOW SENSOR (LIQUID)
MARKING >
PLASMA >
PRE-FLOW >
H2O SHIELD >
GAS SHIELD >
Rev Rev Rev Revisions Revisions Revisions By By By Date Date Date
AA ECO-B1391 DAT
4-24-2009
AB ECO-B1507 - added text DAT
4-19-2010
Last Modified: Last Modified: Last Modified: Monday, April 19, 2010 Monday, April 19, 2010 Monday, April 19, 2010
14:00:59 14:00:59 14:00:59
5
6
MANIFOLD (partial)
P3 - HWID P3 - HWID J23 J23
3 1
2 2
1 3
MANAFOLD ID
PS3 PS3
BLK
1
PURPLE
2
ORANGE
3
Plas_Pilot_P-in Plas_Pilot_P-in
PS6 PS6
BLK
1
PURPLE
2
P1 P1
ORANGE
+12V
3
1
Plasma_P-out Plasma_P-out
2
3
4 PS1 PS1
5 BLK
6 1
7 PURPLE
8 2
9 ORANGE
10 3
11
Shield_Gas_P-in Shield_Gas_P-in
12
13
PS5 PS5
14
15
BLK
16 1
17
PURPLE
18 2
ORANGE
Press_sensors Press_sensors
3
Shield_Gas_P-out Shield_Gas_P-out
PS4 PS4
BLK
1
PURPLE
2
ORANGE
3
Plasma_Cut/Mark_P-in Plasma_Cut/Mark_P-in
PS2 PS2
BLK
1
PURPLE
2
ORANGE
3
Shield_Water_P-in Shield_Water_P-in
P2-WFS P2-WFS FS-1 FS-1
BLACK/SHIELD
1 1
WHITE
+5V 2 2
RED
3 3
H2O_Shield_FlowSensor H2O_Shield_FlowSensor
D12 D12
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
DPC MANIFOLD
SOL1
PS4 PS4
V4 PS6 PS6
PLASMA OUT
SOL3
V3
PS3 PS3
SOL2
VENT
V2
PS2 PS2
SHIELD OUT
V1
PS1 PS1
PS5 PS5
Art # A-13074
PCB No: PCB No: PCB No:
THERMAL DYNAMICS THERMAL DYNAMICS THERMAL DYNAMICS Assy No: Assy No: Assy No:
INDUSTRIAL PARK #2 INDUSTRIAL PARK #2 INDUSTRIAL PARK #2
References References References
WEST LEBANON, NH 03784 WEST LEBANON, NH 03784 WEST LEBANON, NH 03784
(603) 298-5711 (603) 298-5711 (603) 298-5711
Scale Scale Scale Supersedes Supersedes Supersedes
N/A
Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION.
Friday, December 08, 2006 Friday, December 08, 2006 Friday, December 08, 2006
Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: Drawn: Drawn: Date: Date: Date:
NOTE: UNLESS OTHERWISE SPECIFIED - NOTE: UNLESS OTHERWISE SPECIFIED - NOTE: UNLESS OTHERWISE SPECIFIED -
DAT 4/24/2009
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%. 1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%. 1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
Chk: Chk: Chk: App: App: App: Sheet Sheet Sheet
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). 2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). 2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).
1 1 1 of of of
SCHEMATIC, SCHEMATIC, SCHEMATIC,
TITLE: TITLE: TITLE:
Size Size Size DWG No: DWG No: DWG No:
DFC 3000 SYSTEM SCHEMATIC
42X1292 42X1292 42X1292
6
A
B
C
D
1 1 1
A-37