Tweco PAK 200i - Manual (Page 113)

PAK 200i
Manual 0-5335 APPENDIX A-33
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F F
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D D
C C
B B
A A
Rev Revision By Date
042X1363
C 1 2
02/14/2014 DAT
Victor Technologies Headquarters
16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
Drawn Date
Sheet
of
Size
Drawing Number SCHEMATIC
PAK 200i CE 380-415 VAC
The information contained herein is proprietary to Victor Technologies.
Title
Not for release, reproduction or distribution without written consent.
7/8/2014
Date Printed Date Revised
7/2/2014
Rev Revision By Date
Drawn Date
Sheet Size
Drawing Number Title
Date Printed Date Revised
00 Initial Design DAT 2/14/2014
Work
Tip
Electrode
(+)
(+)
(-)
1 2 3 4
Hall Effect Sensor HCT1
TORCH
WORK
W1A
W1B
W1C
1
2
J105A AC INPUT
1
2
J104A
1
2
J103A
1
2
J105B AC INPUT
1
2
J104A
1
2
J104B
1
2
J103B
1
2
J105A AC INPUT
J100 -- 30 CKT RIBBON
1
2
J103A
INVERTER MODULE (IM) #`1 (bottom)
J100 -- 30 CKT RIBBON
1
2
3
4
5
J102A
OUTPUT
1
2
3
4
5
J102B
OUTPUT
1
2
3
4
5
J102A
OUTPUT
ELECTRODE (-)
ELECTRODE (-)
WORK (+)
WORK (+)
+15 VDC
-15 VDC
COMMON
SIG (+)
TO J1 on RELAY PCB
TO CCM
CPU PCB J33
(Sht 2, C3)
TO CCM
CPU PCB
J31
(Sht 2, B3)
IM #1 Section B (upper)
IM #1 Section A (lower)
J100 -- 30 CKT RIBBON
1 2 3 4
J16
18 AWG wire
both in and out of
CB1 to J60
AC 24V- Ret -TB4-1 (Sht 2, B8)
AC 24V-TB4-2 (Sht 2, B8)
AC 120V- Ret- TB4-3 (Sht 2, B8)
AC 120V- TB4-4 (Sht 2, B8)
ARC VOLTS (TORCH)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
(52)
(49)
(51)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(51)
SYSTEM BIAS SUPPLY +24VDC
GND
+ V
To J27 on CCM I/O PCB
TO J12
T1 PRIMARY
(Sht 2, A1)
K1A
24 VDC
24 VDC
24 VDC_RET
24 VDC_RET
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V LOW a
AC V LOW b
AC V HIGH b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J62
480V-ID 400V-ID 208-230V-ID COM
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43A) (44A)
(48)
1 2 3 4 J61
VOLTAGE SELECTION
019X501900
K1B
1 2 3 4 5 6 7 8 9 10 11 12 J63
TO AUX TRANSFORMER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
J60
AC INPUT
J63 = Mini-Fit Jr goes to J12 on T1 primary
400 VAC -- Single 18 AWG in pins 1 & 12
480 VAC -- Single 18 AWG in pins 1 & 12
230 VAC -- 18 AWG wires in pins 1, 6, 7, 12
(7)
(8)
(9)
(7)
(8)
(9)
1 J43
ELECTRODE
1 2 3 4 5 6 7 8 9 10
J42
TO RELAY BOARD
10 ckt Ribbon TO J3 on RELAY PCB
TIP VOLTS
WORK
ARC VOLTS
To J24 on I-O PCB
1 2 3 4 5 6 7 8 J45 TO I/O BOARD
019X501600
1
2
3
4
5
J40
INVERTER
(51)
(53)
(51B)
(49)
(49)
L2
HF COIL_WC
C2
T2
120 / 6000 VAC
(98)
(99)
AC 120V (Sht 2, A8)
AC 120V_RET (Sht 2, A8)
SG1
0.062"
C1
6.5K 1W
6.5K 1W
C3
PLT
NEG
CGND
TO CCM
CPU PCB
J32
(Sht 2, B3)
INVERTER 1/2 MODULE (IM) #2 (top)
(50)
(49A)
(49B)
(49C)
(51C)
(51A)
(Sht 2, D3)
(Sht 2, A6)
(Sht 2, A5)
(Sht 2, E3)
C1-3 Capacitor, 1900 pf, 15Kv. (Sht 1, A10)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V (Sht 1, D1)
CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2 Fuse, 8A, 500V, S.B. (Sht 1, E1)
FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FS1 Flow SW, 0.25 GPM (3.8 lpm), N.O. (Sht 2, A2)
HCT1 Current Sensor, Hall Effect 200A, Work Lead (Sht 1, D9)
K1 Relay, 24VAC, Inrush Control (Sht 2, B9)
L2 Inductor, HF, 400A, Water Cooled (Sht 1, A10)
L3-6 Toriod Core Common Mode Ind (Sht1 B9, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present (Sht 1, C3)
M1 Motor, Pump, ¢ hp 230VAC, 50/60 Hz, 1Ph (Sht 2, C2)
MC1 Relay, 120 VAC, Inrush, Coil (Sht 2, B9), Contact (Sht2, A1)
MC3 Relay, 120 VAC, Pump Motor Control
(Coil at Sht 2, A7) (Contacts at Sht 2, C2)
PS1 Pressure Switch, Plasma Gas, N.O. , 51 PSI (Sht 2, C9)
R1 Current Control 10K (sht 2, D9)
R2 Inrush, 4.7 ohm 30W (Sht2, A1)
SA1, 2 Snubber, Contactor & Relay coil (Sht 2, A7)
SG1 Spark Gap (Sht 1, A9)
SOL1 Solenoid, Plasma Gas, 24 VAC (Sht 2, D9)
SOL2 Solenoid, Shield Gas, 24 VAC (Sht 2, D9)
SOL3 Solenoid, H2O Mist (water shield), 24 VAC (Sht 2, D10)
SW1 Switch, RUN / SET, DPDT (Sht 2, D10)
SW2 Switch, Shield Mode, SPDT (Sht 2, D10)
T1 Aux Transformer (Sht 2, B2)
T2 Transformer, HV, 120/6000V (Sht 1, A9)
TB4 Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return (Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil at Sht 2, A8) (Contacts at Sht 1, B2)
IM #2 Section A (lower)
ELECTRODE (-)
WORK (+)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
1 COMMON
2 1TORCH START *
3 NA
4 1TORCH GAS SOL ON *
5 MAIN TORCH IDLE *
6 1TORCH PRESS OK *
7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW
9 COOLANT LEVEL OK
10 COMMON
11 NA
12 PLASMA ENABLE-HMI
13 COOLANT PUMP ON
14 COMMON
15 PILOT ENABLE
16 RAS ON
17 CONTACTORS ON
18 COMMON
19 COOLANT FANS ON
20 1TORCH CONTACTOR ON *
* Used with 1 Torch Option
21 PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 40 ckt CCM (J23 (Sht 2, C7)) - RELAY PCB (J4 (Sht 2, B7))
1,3,5,724 VDC
2,4,6,8 COMMON
9,10 NC
11-16 SERIAL DATA
RIBBON CABLE 30 ckt.
CCM (J31-33) - INVERTER (J100)
(Sht 2, C4) (Sht 1, A6, B6)
1,2 24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE
8 PILOT CURRENT SIG
9 PILOT CURRENT SIG +
RIBBON CABLE 10 ckt
RELAY PCB (J3 (Sht 2, A6)) -
PILOT PCB (J42 (Sht 1, C8))
RIBBON CABLE 16 ckt
CCM ( J37 (Sht 2, C8)) -
DISPLAY PCB (J17 (Sht 2, C9))
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
AC
SUPPRESSION
PCB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J50
AC LINE
GND
1
2
3
4
J52
INTERNAL AC INDICATOR
1
2
3
4
J51
PANEL AC INDICATOR
LT1
LT2
019X504000
(3)
(2)
(1)
(10)
(11)
(12)
(13)
CHASSIS GND
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
1
2
3
4
5
6
7
TB4
WORK (+)
019x502000
019x502700
019x502000
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
CONTROL PCB LEDS
CAP BIAS PCB LEDS
MAIN PCB LEDS
Component Locations (not including PCB components)
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
CB1
ON / OFF
(27A&B)
(26) (28)
(27B)
8A, 500V, SB
F2
8A, 500V, SB
F1
(27A)
(86A)
(86B)
(85A)
(85B)
1
2
IN1
1
2
IN2
1
2
IN3
1
2
OUT1
1
2
OUT2
1
2
OUT3
GND2B
EMI
FIL-
TER
PCB
1
2
IN1
1
2
IN2
1
2
IN3
1
2
OUT1
1
2
OUT2
1
2
OUT3
GND2B
EMI
FIL-
TER
PCB
L6
Toriod Core
L5
Toriod Core
L4
Toriod Core
CHASSIS GND
CHASSIS GND
(20)
(21)
(22)
(1-20) (2-21) (3-22)
(1-20) (2-21) (3-22)
L3
Toriod Core
(7)
(8)
(9)
1
2
J41
TIP
1
J44
PILOT PCB
PILOT
(52)
CHASSIS GND
(49)
1 L1
1 L2
1 L3
1 Earth
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
(3)
(2)
(1)
CHASSIS GND
(3)
(2)
(1)
(55)
(55)
(53)
(51A)
(49)
o
b
g
w
J58A
J58C
J58B
PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
01 Fan, Flow SW, Text DAT 7/2/2014
Art # A-12405
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