Appendix 7: System Schematic 200A, 380-415V - ESAB 100i Instruction Manual

100i / 200i / 300i / 400i
APPENDIX 7: System Schematic 200A, 380-415V PG 2
1
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
From Sys Bias J63
(Sht 1, F2)
A
(44A)
(43A) MC1A
R2
4.7 30W
(87)
J12
T1
460V
1 2 3 4
5 6 7 8
B
400V 120V_2 RET
120V_2
220V
120V-1 RET
0 V
J13
C
MC3A
(66)
MC3B
CHASSIS GND
(67)
J13 to CB5
(64B)
and to MC2
& MC3, also
J14, J16
all 18 AWG
MC2A
(65A) (69)
(70)
MC2B
(64A)
D
(69)
(70)
CHASSIS GND
Alternate fan.
100 & 200A units may use either this
single larger fan (same as 300 & 400A
units) or the 2 smaller fans shown above.
R BK
FAN1
J72 C4
BN
1
E 2
BL
3
R
F
Art # A-11975_AD
1
A-18
2 3
LS1
COOLANT LEVEL
FS1
J74 (84)
COOLANT
1 (83)
2
0.7 GPM
FL1
(80)
1 r
1
b (81)
2 2
g (82)
3
3
4
J49
(79)
24V RET
BLUE
6
(77) (78)
RED
5
CB2 5 A
24V
(76)
YELLOW
4
(74) (75)
BLUE
3
CB3 5 A
(73)
RED
2
(71) (72)
YELLOW
1
CB4 5 A
J14
To J100 of IM #1B
To J100 of IM #1A
120V_1
(Sht 1, C,D6)
To J100 of IM #2A
(Sht 1, B,C6)
J16 M1
1
2
3
Torch Coolant Pump Harness from Pilot PCB J45
(Sht 1, B8)
(69)
(53)
230 VAC _ SW _ RET
(A9)
J72
FAN1
1
2
3
(51)
J73
FAN2
(55)
1
2
3
(70)
230 VAC _ SW
(A9)
230 VAC_SW
goes to J70
for HE 400
Harness from System Bias PCB
(Sht 1 F2)
24 VDC (29)
24 VDC (30)
MISSING PHASE a (31)
MISSING PHASE b (32)
AC V HIGH a (33)
AC V HIGH b (34)
AC V LOW a (35)
24 VDC_RET (36)
24 VDC_RET (37)
AC V LOW b (38)
VAC_IDA a (39)
/ VAC_IDA b (40)
VAC_IDB a (41)
/ VAC_IDB b (42)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
2 3
APPENDIX
4
AMBIENT
1
(90)
2
(89)
3
4
J71
J5 J7 J1
COOLANT FLOW SW LEVEL SENSORS
WORK CURRENT SENSOR
1 +5VDC RELAY & INTERFACE PCB
2
SIGNAL (pulse)
3 D2, GREEN, 1TORCH GAS ON
4
D7, GREEN, PILOT ENABLED
TORCH FLOW SENSOR
J6 D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
12
D23, GREEN, RF ON
11
D24, GREEN, FANS ON
10
120VAC_2
D25, GREEN, PLASMA ENABLED
9
8
D26, GREEN, 1TORCH ON
7
D27, GREEN, COOLANT ON
24VAC
6
5
4
3
2
120VAC_1
1
J9
BIAS TRANSFORMER
019X501700
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON
N/C
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
N/C N/C
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
J28 30 CKT PIN HEADER
I / O PCB LEDS
----------------------------------------------
D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
1
D13 CSD (corner current reduction)
2
D18 MARK
3
D20 SPARE
4
5
D25 EXP METAL
6
D33 OK_CNC
7
8
D37 PSR
D41 SPARE OUT 2
J24
D43 SPARE OUT 1
I / O PCB TEST POINTS
-------------------------------------
TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
1 TP8 +16-18 VDC_ISO (ref to TP10)
2
TP9 ANALOG CURRENT SIGNAL
3 (remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
4
TP11 1 TORCH CONTACTOR ON
5
TP12 +5 VDC
6
TP13 -15 VDC
7
TP14 +15 VDC
8
TP15 +24 VDC
9
TP18 +5 VDC_ISO (ref to TP10)
10
11
I / O PCB DIP SW
12
---------------------------------------------
13
SW6 OK TO MOVE
14
(CONTACTS, VOLTS)
J27
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
19X501200
4
5
COOLANT
TS2
TS1
(92) (93)
(94)
(95)
J2
TEMP SENSORS
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84 J85
CPU PCB (CCM )
Manual PN: 0560956430