Ultra-cut 100 xt, Dpc3000 - pressure control assembly, Dmc3000 - manifold controller assembly – Tweco 100 Ultra-Cut Plasma Cutting System with Automated Gas Control User Manual

Page 162

ULTRA-CUT 100 XT

A-38

APPENDIX

Manual 0-5303

APPENDIX 21: Schematic, DFC-3000 Auto Gas Box System

Art # A-09197_AB

BLK

PURPLE

ORANGE

BLK

PURPLE

ORANGE

BLK

PURPLE
ORANGE

BLK

PURPLE

ORANGE

BLK

PURPLE

BLK
PURPLE
ORANGE

BLACK/SHIELD

WHITE
RED

ORANGE

(WHT)

(BLK)

(WHT

)

(S15T)

(S14B)

(S14T)

(S13T)

(S12B)

(S12T)

(S11T)

(S10B)

(S10T)

(S9-B)

(S9-T)

(S8-B)

(S8-T)

(S7-B)

(S7-T)

(S6-B)

(S6-T)

(S5-B)

(S5-T)

(S4-T)

(S3-T)

(S2-T)

(S1-T)

(S1-B)

(S2-B)

(S3-B)

(S4-B)

(S11B)

(S13B)

(S14B)

(S2-B)

(2a)

120VAC DMC RET

GRN

BLK

(1)

120VAC DMC

(JMP)

(3)

(8)

(9)

(2b)

E_STOP NO

E_STOP COM

(8)
(9)

+5V

(PW3

)

120 VAC

)

(

)

(

(2a)

120 VAC RET

(2a)

(9)

E_STOP COM

(9)

(2c)

(8)

E_STOP NO

(S2-B)

(V5-1)
(V5-2)

(V1-1)
(V1-2)

(V2-1)
(V2-2)

(V3-1)
(V3-2)

(S1-T)

(S1-B)

(V4-1)
(V4-B)

-12VDC

(PW1)

GND

(PW2)

+5VDC

(PW3)

+24 VDC_FUSED

(PW6)

-12V

(PW1

)

GND

+12V

(PW4

)

+24V SW

(PW5

)

+24V FUSED

(PW6

)

GND

SHIELD

Rx-

Rx+

Tx- (B)

SIG COM

Tx+ (A)

COM

PLASMA ENABLE

HMI PRESENT

24 VAC RET

24 VAC

RED

)

(

)

(

)

(

)

(

120VAC DM

E_STOP CO

E_STOP NO

120VAC DMC RE

(2a)

WHT

(S3-B)

(5)

(6)

)

(

)

(

(8)

Tx+ (A)

(12)

Tx- (B)

(12)

(1)

(2)

)

(

)

(

(8)

)

(

)

(

(1)

(2)

(20V)

(20V

)

(0V)

+12VDC

(PW4)

E-STOP

(PW8)

+24VDC SW

(PW5)

GND

(PW7)

(S3-T)

(1)

(3)

(8)

(PW2

)

(PW8

)

(PW7

)

SHIELD

+24 VDC

+5 VDC

+24 VDC

+5V

+12V

+15 VDC

15 VDC RET

120 VAC ULTRACUT

120 VAC ULTRACUT RET

24 VAC RET

24 VAC

PLASMA ENABLE +

PLASMA ENABLE -

SHIELD

24 VAC

24 VAC RET

PLASMA ENABLE

KEY PLUG

Tx+ (A)

Tx- (B)

Rx+

Rx-

+5 VDC

Data +

Data -

COM

Shield

DWG No:

Sheet

Supersedes

Scale

Date:

Drawn:

References

Date

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

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784

(603) 298-5711

42X1292

Monday, April 19, 2010

Friday, December 08, 2006

14:00:59

DWG No:

Sheet

Supersedes

Scale

Date:

Drawn:

References

Date

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

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784

(603) 298-5711

42X1292

Monday, April 19, 2010

Friday, December 08, 2006

14:00:59

DWG No:

Sheet

Supersedes

Scale

Date:

Drawn:

References

Date

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

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784

(603) 298-5711

42X1292

Monday, April 19, 2010

Friday, December 08, 2006

14:00:59

DPC3000 CONTROL PCB

DFC 3000 SYSTEM SCHEMATIC

DPC3000 - PRESSURE CONTROL ASSEMBLY

PANEL INDICATORS

GROUNDING SCREW

19X2382

19X2383

CHASSIS GND

PLASMA_VENT

PLASMA_MARK

FUEL_PLASMA

H35_PLASMA

O2_PLASMA

O2_SHIELD

AIR_PREFLOW

AIR_PLASMA

AIR_SHIELD

AIR_MARKING

N2_PREFLOW

N2_PLASMA

N2_SHIELD

O2_PREFLOW

N2_MARKING

H20_SHIELD

ARGON_MARKING

DMC3000 - MANIFOLD CONTROLLER ASSEMBLY

19X2367

MANIFOLD (partial)

MANIFOLD (partial)

FERRITE

CORE

FERRITE

CORE

ULTRACUT POWER SUPPLY

MANIFOLD

PANEL INDICATORS

GROUNDING SCREW

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.

OPTION SWITCHES

LEDs Listed Below

CCM

DMC FiberOptic Ports

DPC FiberOptic Port

19X2385

DMC3000 CONTROL PCB

DMC3000 Control PCB LEDs

SOLENOID DRIVE ON INDICATOR (GREEN LEDs)

D1 - SOL_V1 (H35 PLASMA))

D2 - SOL_V2 (O2_PLASMA)

D3 - SOL_V3 (AIR_PLASMA)

D4 - SOL_V4 (N2 PLSMA)

D5 - SOL_V5 (AUX PLASMA)

D6 - SOL_V6 (O2 SHIELD)

D7 - SOL_V7 (AIR_SHIELD)

D8 - SOL_V8 (N2 SHIELD)

D9 - SOL_V9 (H2O SHIELD)

D10 - SOL_V10 (O2 PREFLOW)

D11 - SOL_V11 (AIR PREFLOW)

D12 - SOL_V12 (N2 PREFLOW)

D13 - SOL_V13 (ARGON MARKING)

D14 - SOL_V14 (AIR MARKING)

D15 - SOL_V15 (N2 MARKING)

D16 - (SPARE)

D17 - +5VDC

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

SOLENOID FAULT INDICATOR (RED LEDs)

D_E1 - SOL_V1 FLAG (H35_PLASMA)

D_E2 - SOL_V2 FLAG (O2_PLASMA)

D_E3 - SOL_V3 FLAG (AIR_PLASMA)

D_E4 - SOL_V4 FLAG (N2_PLASMA)

D_E5 - SOL_V5 FLAG (AUX_PLASMA)

D_E6 - SOL_V6 FLAG (O2_SHIELD)

D_E7 - SOL_V7 FLAG (AIR_SHIELD)

D_E8 - SOL_V8 FLAG (N2_SHIELD)

D_E9 - SOL_V9 FLAG (H2O_SHIELD)

D_E10 - SOL_V10 FLAG (O2_PREFLOW)

D_E11 - SOL_V11 FLAG (AIR_PREFLOW)

D_E12 - SOL_V12 FLAG (N2_PREFLOW)

D_E13 - SOL_V13 FLAG (ARGON_MARKING)

D_E14 - SOL_V14 FLAG (AIR_MARKING)

D_E15 - SOL_V15 FLAG (N2_MARKING)

MANAFOLD ID

SOL1

SOL2

PRE-FLOW >

MARKING >

PLASMA >

GAS SHIELD >

H2O SHIELD >

SHIELD OUT

PLASMA OUT

VENT

FS-1 IN

FS-1OU

19X2384 SMPS +24; +/-12; +5

755x000

CONTROL

CABLE

CHASSIS GND

UNIT E-STOP

SHIELD

120 VAC

120 VAC RET

FERRITE

CORE

OPTION SWITCHES

19X2384 SMPS +24; +/-12; +5

120 VAC

120 VAC RET

DPC MANIFOLD

PLASMA_CUTTING

SOL3

PLASMA ENABLE

BYPASS RELAY

I/O PCB

CPU PCB

JUMPER

for 2 WIRE

(RS485 only)

wire to A & B

SERIAL

COMMUNICATION

(Isolated)

JUMPER

for 4 WIRE

uses

TX+, TX-

RX+, RX-

J14

SW14 - LINE

TERMINATION

normally on

(refer to manual)

SW10-ADDRESS

normally 0

(refer to

manual)

POWER SUPPLY

24 VAC to 20 VDC

ISOLATED

HMI INTERFACE PCB

19X2407

KEY

RS232

Configured

for RS485

TPC- 660E TOUCH SCREEN PANEL

J63 HARNESS NOT INSTALLED

(for future use with Height Control)

GROUNDING SCREW

TSC 3000 19X2200

FERRITE

CORE

Plasma_Cut_Hi

HMI CONTROL &

COMMUNICATIONS

SW14

DAT

N/A

4/24/2009

SOL# = ON/OFF CONTROL VALVE

V# = PROPORTIONAL VALVE

PS# = PRESSURE SENSOR

FS# = FLOW SENSOR (LIQUID)

NOTE:

DMC solenoids are 18 VDC.

Coils are about 46 ohms.

24 VDC is applied for 1 second

then reduced by pulse width

modulation to an average of

approximately 7-8 VDC.

Proportional valves V1-V5

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.

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.

KEY PLUG

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

TEST POINTS - CONTROL PCB

TP1 - GND

TP2 - Processor TEMP

TP3 - +VREF

TP4 - Processor CLKO

TP5 - +3.3V

TP6 - AGND

TP7 - +5V

TEST POINTS - INTERFACE PCB

TP1 - GND

TP2 - UNREG VDC

TP3 - +5VDC

TP4 - +20 VDC

LEDS - INTERFACE PCB:

D1 = RX (RS 485)

D14 = RX (RS 232)

D15 = TX (RS 232)

SOL#

H35 >

O2 >

AUX >

H2O >

AIR >

ARGON >

N2 >

DMC MANIFOLD

> GAS SHIELD

> H2O SHIELD

> PREFLOW

> MARKING

> PLASMA

INLET PASSAGES

OUTLET PASSAGES

HOSE

ECO-B1391

DAT

4-24-2009

D5 = +VDC Fused (24VDC )

D6 = +12VDC

D7 = +24VDC SW (24VDC to Valves

& Solenoids through E-Stop Relay

D9 = +5VDC

D16 = -12VDC

Power Supply PCB (19X2384) LEDS

See list by DPC 3000 Power Supply

CCM CANBUS

ACTIVE

DPC CANBUS

ACTIVE

Tx Gray;

Rx Black

Tx Gray;

Rx Black

DPC CANBUS

ACTIVE

D2 = SLAVE SUPPLY

CAN BUS ACTIVE
D3 = GCM CAN BUS ACTIVE
D11 = INITIALIZING /

PROGRAMMING
D12 = STATUS CODE

D13 = +5VDC
D17 = RS485 TXD

D18 = RS485 RXD

CPU LEDS

ECO-B1507 - added text

DAT

4-19-2010

J65

USB

J65

USB

SW2-2

SW2-4

STATUS LED (RED)

SOL8

PS3

J62

THC (future)

J62

THC (future)

J60

SOL4

E-STOP

PS3

Plas_Pilot_P-in

PS3

Plas_Pilot_P-in

SOL14

PS5

J56

U7/U9

FiberOptic

U7/U9

FiberOptic

1 2

F3 1.6A SB

U4 / U7

SLAVE FiberOptic

U4 / U7

SLAVE FiberOptic

J21

MANIFOLD ID

J21

MANIFOLD ID

FS-1

H2O_Shield_FlowSensor

FS-1

H2O_Shield_FlowSensor

SOL DRIVE A

PS6

PS2

Shield_Water_P-in

PS2

Shield_Water_P-in

SOL12

SW2-1

Plasma_Cut_Lo

SW2-3

TX/RX

J54

SOL3

COM1

1 2 3 4 5 6 7 8 9

HW ID

1 2 3 4 5 6 7 8

PROG via RS232

1 2 3 4 5 6 7 8

JTAG

J57

SOL10

F2 3A SB

POWER

D21

SOL11

SW1-3

P61

PS6

Plasma_P-out

PS6

Plasma_P-out

SW1-4

E-STOP

SW2-2

SOL2

SOL13

P2-WFS

COM2

1 2 3 4 5 6 7 8 9

SW1-1

J10

JTAG

J10

JTAG

E-STOP

D12

RS 485

SOL7

TX/RX

STATUS LED (RED)

E-STOP

SW1-3

SW1

PLASMA ENABLE

SW1

PLASMA ENABLE

SOL3

P55

SW2-1

U1/U2

FiberOptic

U1/U2

FiberOptic

SOL1

U4/U5

FiberOptic

U4/U5

FiberOptic

1 2

P54

HMI Serial/Control

P54

HMI Serial/Control

PS5

Shield_Gas_P-out

PS5

Shield_Gas_P-out

POWER LED (GREEN)

F4 3A SB

SOL9

SW2-4

SOL6

J55

D22

SW1-2

STATUS LEDS

F1 1.6A SB

SOL1

SOL15

RS 485

SHIELD

P56

U10 / U13

GAS FiberOptic

U10 / U13

GAS FiberOptic

Valves

Press_sensors

J63

E-STOP

PS4

Plasma_Cut/Mark_P-in

PS4

Plasma_Cut/Mark_P-in

SW1-4

SOL5

SW2-3

SHIELD_H2O

RS232 Prog

J23

POWER

P60

P10

HMI POWER

P10

HMI POWER

GND

SW1-2

PS1

Shield_Gas_P-in

PS1

Shield_Gas_P-in

J61

PS4

SW1-1

Plasma_PILOT

SOL2

PS1

POWER LED (GRN)

P3 - HWID

SOL DRIVE B

P57

PS2