ESAB Schematic_Mech_Elec/EPP-362 Plasma Power Source Instruction manual

Appendix A

SCHEM.EPP-362,380/400/460V

05580011805-B

SCHEM.EPP-362,380/400/460V

05580011805-B

0558011730-A

Appendix B

Isolated DC/DC

ISOLATIONISOLATION

CAN Bus #1 Driver

CAN Bus Port #1 Signals

ISOLATIONISOLATION

Isolated DC/DC

CAN Bus #2 Driver

ISOLATIONISOLATION

CAN Bus Second Power Supply Signals

ISOLATIONISOLATION

CAN Bus Port #2 Signals

Relay Drivers

LED Indicators

Note: Pin1-2: 24Vac

Pin4: +15Vac Pin5: 15Vac CT Pin6: -15Vac

Power Supply

++

Note: Originally, there were 2 3W resistors, and they were replaced with 8 1/4W SMT resistors. This may not be enough.

++

Note: The MC7915 should have a copper pour to help dissipate heat. There may not be a partitioned copper plane, but the opposite side of the board can be used for additional heat sink area.

Note: The LM2576 should have a copper pour to improve heat dissipation. That pour should be stiched to the ground plane.

++

Note: This is a switching 24V regulator for the isolated inputs. Clearances must be maintained with respect to the rest of the circuitry.

++

++++

++

Note: All current transducers are oriented in the positive direction to minimize the load on on the -15V supply.

Analog LDO voltage regulator. The local analog and digital power planes are seperated here.

Precision Analog LDO

Current Sensor Connector

Note: Pin 5 on the plug should have a jumper connecting to pin 3 The cable shields should be tied to pin 1.

Current Sensor Inputs:

Current Sensor 2000:1 360A/2000 = 180mA

Voltage Conversion 180mA * 6.6 Ohm = 1.188V

OpAmp Transfer Function Output Margins Nearly 15% at the bound- aries leaving a 70% oper- ating range.

Vout=

-5.6k/(2.7k+180)*Vin -

5.6k/(3.3k+1.2k)*Vref33+ (1+5.6k/(2.7k+180)+

5.6k/(3.3k+1.2k))*Vref165

TransferFunc(1.188V) = 0.4756V TransferFunc(0.000V) = 2.7898V

The OpAmp biasing will introduce some error into the signal

Chassis GND

Note: Remove the B ports when not feeding into servo micro

Terminating Resistor

Netbridge Here

Note: This is an analog supply preload. It also provides a 1.65V reference for the inverting configuration.

Gain = [[0.57143,0.28562][0.28562,0.57143]] Offset = [[0.468V][0.468V]]

Note: Remove the B ports when not feeding into servo micro

Gain = 2.1277

Terminating Resistor Gain = 0.5

LABEL PCB LAYOUT

0558954317

5

Appendix C

R118

R81

22.0

0.25W

R159

10.0

0.25W

R149

22.0

0.25W

R89

22.0

0.25W

R203

10.0

0.25W

R96

22.0

0.25W

R211

10.0

0.25W

C76

68.0nF

R144

22.0

0.25W

R190

10.0

0.25W

R88

22.0

0.25W

R168

10.0

0.25W

R150

22.0

0.25W

R174

10.0

0.25W

R155

22.0

0.25W

R182

10.0

0.25W

C61

68.0nF

R118

22.0

0.25W

R160

10.0

0.25W

R126

22.0

0.25W

R198

10.0

0.25W

R128

22.0

0.25W

R204

10.0

0.25W

R135

22.0

0.25W

R212

10.0

0.25W

C53

68.0nF

R117

22.0

0.25W

R125

22.0

0.25W

R127

22.0

0.25W

R136

22.0

0.25W

R99

22.0

0.25W

R106

22.0

0.25W

R107

22.0

0.25W

R114

22.0

0.25W

HVdd_24v0

HGND

1

3

6

U14

VCC

GND

IXDD630YI

OUT

EN

HVdd_9v00

HGND

TP19TP19

2

4

IN

5

C14

1.00uF

R13

33.0

0.1W

R82

R156

R186

22.0

0.25W

R157

10.0

0.25W

R87

22.0

0.25W

R166

10.0

0.25W

R200

22.0

0.25W

R172

10.0

0.25W

R213

22.0

0.25W

R180

10.0

0.25W

C63

1.00uF

22.0

0.25W

R158

10.0

0.25W

R169

22.0

0.25W

R196

10.0

0.25W

R90

22.0

0.25W

R202

10.0

0.25W

R95

22.0

0.25W

R210

10.0

0.25W

R156

22.0

0.25W

R189

10.0

0.25W

R105

22.0

0.25W

R167

10.0

0.25W

R170

22.0

0.25W

R173

10.0

0.25W

R183

22.0

0.25W

R181

10.0

0.25W

HVdd_24v0

C65

68.0nF

HGND

R197

10.0

0.25W

R100

22.0

D7

HVdd_9v00

D8

HVdd_9v00

D9

HVdd_9v00

D10

HVdd_9v00

R187

10.0

0.25W

R165

10.0

0.25W

R171

10.0

0.25W

R179

10.0

0.25W

22.0

0.25W

TVS_20VD7TVS_20V

R188

10.0

0.25W

R199

22.0

0.25W

TVS_20VD8TVS_20V

R195

10.0

0.25W

R108

22.0

0.25W

TVS_20VD9TVS_20V

R201

10.0

0.25W

R113

22.0

0.25W

TVS_20V

R209

10.0

0.25W

C73

C55

1.00uF

10uF

J8

1

A1

2

A2

PHOENIX TERMINAL 2

D D

J9

1

A1

2

A2

PHOENIX TERMINAL 2

J10

1

A1

2

A2

PHOENIX TERMINAL 2

C C

J11

1

A1

2

A2

PHOENIX TERMINAL 2

B B

Note: Capacitor biasing circuit, and supply preloading.

HGND

R74

10.0K

0.1W

MainPwmChannel

PwmEnable

U6

IN3OUTA ADJ/GND1OUTB

LM1086CS-ADJ

R12

330

0.1W

4

Note: A CMOS isolator was chosen to reduce

HGND

U15A

U15A MC74AC14D

MC74AC14D

12

nMainPwmChannel

TP5TP5

TP4TP4

nMainPwmChannel nRefPwmChannel nFaultReset nFault

HVdd_5v00

HGND

propagation delay, and output jitter.

U1

16

VCC2

14

OUTA

13

OUTB

12

OUTC

11

IND

10

EN2

15

GND2

9

GND2

ADUM2401CRWZ

ISOLATION

LVdd_3v30

1

VCC1

3

INA

4

INB

5

INC

6

OUTD

7

EN1

2

GND1

8

GND1

LGND ALGND

14 7

HVdd_5v00

HVdd_24v0

R57

10.0K

0.1W

MH1

TP6TP6

HGND

HVdd_5v00

2 4

+

R11

HGND

120

0.1W

C8

C8 100uF

100uF

HGND

C33

1.00uF

TP16TP16

MH1

1

HOLE_0v330-0v156_PLATED

HGND

3

U7

1

VCC

2

1Y

3

2Y

4

GND

SN65LVDS9637D

U8

1

VCC

2

R

3

D

4

GND

SN65LVDS179D

2

R21

R28

120

0.1W

8

1A

7

1B

6

2A

5

2B

8

A

7

B

5

Y

6

Z

0.1W

R29

120

0.1W

R23

120

0.1W

ALVdd_5v00

L2

47uHL247uH

Netbridge Here

+

C43

+

C43 100uF

100uF

R320R32

0

ALGND

FASTON 1/4" TERMINAL

LVdd_3v30

J2

1 2

nMainPwm1N nMainPwm1P

nRefPwm1P nRefPwm1N nFaultResetN

nFaultResetP PWM_FAULTP PWM_FAULTN

nPaIgbtP nPaIgbtN nMainPwm2N nMainPwm2P

nRefPwm2P

nRefPwm2N VarcP VarcN VbusP VbusN

LGND

VOUT(-)

J4

VWORK(+)

J6

VBUS(-)

J7

3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

LGND

ALGND

C11

1.00uF

R53

R61

2 1

G=[[4.3310E-4,-2.1648E-4][-2. 1648E-4,4.3310E-4]] [VworkOut-VbusOut][VworkOut-V ArcOut]] = G * [[VworkIn-VbusIn][VworkIn -VarcIn]]

100K

0.25W

R73

100K

0.25W

R98

100K

0.25W

100K

0.25W

R69

100K

0.25W

R79

100K

0.25W

ALVdd_5v00

TP9TP9

LVdd_3v30

TP10TP10

C56

C56 100nF

100nF

HVdd_5v00

HGND

R52

100K

0.25W

R68

100K

0.25W

R78

100K

0.25W

LGND

TP11TP11

TP12TP12

ALVdd_5v00

R39

2.70K

0.1W

R42

2.70K

C44

0.1W

100nF

R34

2.20K

0.1W

R15

2.20K

0.1W

R55

2.20K

0.1W

R43

2.20K

0.1W

8

2 7 1

8

2 7 1

ALVdd_5v00

3

+

VOCM PD

-

6

ALGND

ALVdd_5v00

3

+

VOCM PD

-

6

ALGND

U4

O-

VS+

O+

VS-

THS4521IDU4THS4521ID

U11

O-

VS+

O+

VS-

THS4521ID

R38

10.0K

0.1W

R14

10.0K

0.1W

R62

10.0K

0.1W

R41

10.0K

0.1W

5

4

5

4

C2 100nFC2100nF

R58

100K

0.25W

R71

100K

0.25W

R80

100K

0.25W

ALVdd_5v00

ALGND

R25

2.20K

0.1W

R19

2.20K

0.1W

R50

2.20K

0.1W

R47

2.20K

0.1W

ALGND

C39

10.0nF

C13

10.0nF

C54

10.0nF

C41

10.0nF

C22

C35

100nF

HVdd_5v00

R51

C52

221

10.0nF

0.1W

TP13TP13

HGND

C59

R67

10.0nF

221

0.1W

TP14TP14

HGND

C74

10.0nF

HGND

R77

R77 221

221

0.1W

TP15TP15

1

VDD1

2

VIN+

3

VINGND14GND2

ACPL-C784

1

VDD1

2

VIN+

3

VINGND14GND2

ACPL-C784

TP17TP17

HGND

ALGND

U10

U13

ISOLATION

VDD2

VOUT+

VOUT-

VDD2

VOUT+

VOUT-

LVdd_3v30

LGND

ALVdd_5v00

8 7 6 5

ALVdd_5v00

8 7 6 5

C4 100nFC4100nF

RIBBON_26-PIN_IDC_HT_REFLOWJ2RIBBON_26-PIN_IDC_HT_REFLOW

R60

100K

0.25W

R72

100K

0.25W

R97

100K

0.25W

1

R33

120

0.1W

R37

VarcP

120

0.1W

R24

VarcN

120

0.1W

R18

120

0.1W

R54

120

0.1W

R59

VbusP

120

0.1W

R49

VbusN

120

0.1W

R46

120

0.1W

HVdd_9v00

R56

1.00

0.25W

R63

1.00

0.25W

R65

1.00

0.25W

R70

1.00

0.25W

HVdd_9v00

TP7TP7

HVdd_9v00

C5

R45

+

220uF

1.00

0.25W

C6

R40

1.00

0.25W

R36

1.00

0.25W

R27

1.00

0.25W

C6

220uF

C25

220uF

C48

220uF

C62

220uF

+

HVdd_24v0

C64

C64 10uF

10uF

C28

C28 10uF

10uF

D3

C72

C69

1.00uF

C15

C15 100nF

100nF

C46

C46 100nF

100nF

C72

C75

C68

68.0nF

HGND

C49

C49 470nF

470nF

C27

C27 100nF

100nF

ALVdd_5v00

ALGND

C68

68.0nF

C23

C23 470nF

470nF

C32

C32 470nF

470nF

1.00uF

C38

C38 100nF

100nF

C45

C45 100nF

100nF

5

C71

C71 10uF

10uF

A A

C26

C26 100nF

100nF

LVdd_3v30

LGND

C70

68.0nF

C30

10.0uF

C1 470nFC1470nF

C67

68.0nF

C24

10.0uF

J5

A1 A2 A3

PHOENIX HEADER 3

1 2 3

D3

D_400V_3A_SMC

D2

D_400V_3A_SMC

D5

D_400V_3A_SMC

D6

D_400V_3A_SMC

4

C58

C58 100nF

100nF

C17

C17 100nF

100nF

U12

2

VIN

5

RT/SYNC

7

EN

4

GND

8

GND

LM22670TJ-ADJ

U2

2

VIN

5

RT/SYNC

7

EN

4

GND

8

GND

LM22670TJ-ADJ

BOOT

R66

C57

10.0nF

MBRS360T3GD4MBRS360T3G

C16

10.0nF

STPS5L60SD1STPS5L60S

R64

1.00K

0.1W

R16

1.00K

0.1W

R66

10.0K

0.1W

L3

33uHL333uH

R20

6.80K

0.1W

L1

56uHL156uH

3

C66

10.0uF

C34

10.0uF

+

C60

C60 100uF

100uF

C20

C20 100uF

100uF

HVdd_24v0

HVdd_9v00

HGND

TP8TP8

+

C50

+

C50 100uF

100uF

TP18TP18

+

C7

+

C7 100uF

100uF

C51

1.00uF

HVdd_24v0

C47

47.0nF

HGND

1

VIN

GND2-V

U5

+V

0V

ISOLATION

MEV1D2412SC

J3

A1

A2

PHOENIX HEADER 2

7

6 5

R1

4.70K

0.25W

R2

4.70K

0.25W

1

2

TP3TP3

2

R4

R4 100

100

0.25W

C12

47.0nF

C21

47.0nF

TP2TP2

R5

R5 100

100

0.25W

U3

8

VC

7

ANODE

VO1

6

C9

VO2

10.0uFC910.0uF

5

ISOLATION

VE

ACPL-J313-500E

C10

10.0uF

10.0uF TP1TP1

CATH

LVdd_3v30

U9

1

VCC

2

1Y

3

2Y

4

GND

SN65LVDS9637D

1A 1B

2A 2B

Q1

1

NC1

2

2N3904Q12N3904

3

4

NC2

LGND

R8

LGND

150

0.1W

R22

120

0.1W

8 7

6 5

nPaIgbtP nPaIgbtN

nMainPwm2P nMainPwm2N

R31

120

0.1W

Title

<Title>

Size Document Number Rev

0558038381 A

D

0558038381 A

D

0558038381 A

D

Date: Sheet of

1

LVdd_3v30

LGND

C31

C31 100nF

100nF

1 1Monday, November 26, 2012

6

FB

3

1

SW

D4

6

FB

3

1

SW

D1

Appendix D

C

A

P1 1 TB7-1 BLU 2 J1-J RED 3 4 TB4-2 ORN 5 TS2-1 WHT

1 TB3-13 BLU 2 TB3-14 YEL 3 TB3-15 BRN 4 TB3-4 ORN 5 TB3-5 VIO

6 K5-7 VIO

1 PCB1 P8-3 WHT 2 PCB1 P8-4 BLK 3 PCB1 P8-1 WHT 4 PCB1 P8-2 BLK

P2

1 TB3-9 WHT 2 3 TB3-10 GRY

1 HS1/HS2 SHIELD 2 HS1-1/HS2-1 BLK 3 HS1-3/HS2-3 RED PCB1 P9-5 RED 4 HS1-2 WHT 5 PCB1 P9-3 RED 6 7 8 HS2-2 ORN

PCB1

P3

P8

PCB1 P16-2

P9

BLK

P6

RIBBON CABLE

TO

RB1 (RELAY TERM BLK)

P12

RIBBON CABLE

TO

PCB2 J2 (DRIVER PCB)

P15

1 J2-1 WHT

2 J2-2 BRN

3 J2-3 GRN

B B

B B B

B

P16

BLK

B

B B

1 J3-1 RED 2 J3-2 BLK PCB1 P8-4 3 J3-3 BRN

K4 (FRONT) K5 (REAR)

B

J3 (FS1 CONNECTION)

RB1

PCB1

(CONTROL)

PCB2 (DRIVER)

RIBBON CABLE TO PCB1 P6

PL1

FL1

C

TB7

JUMPER (11-5 TO 11-6)

TB4

GND-3

D D

PL1-2 VIO

TB2-7 BLU K4-4 ORN

D

TB3-9 WHT

D

K2-B WHT

D

K1-B ORN

D

M1-2 BLU

D

FL1-2 RED

J1-D YEL

D

J1-C BLK

K4-8 BLK

J1-G GRY

RB1

1 2 3 4 5 6 7

B

C

8

C

TB7-2 ORN

J1-L ORN

TS1-1 (SP) ORN

PCB1 P1-4 ORN

K5-4 ORN

2

TB4

(11)

1

(14)

J1-K G/Y

GND-3 G/Y

TB3-12 WHT

(12)

GND-3

J1-H WHT

TB4-1 G/Y

D

RB1-2 (11) ORN

TB2-3 BRN

K5-A WHT J1-E BLU

TB4-2 ORN

PCB1 P1-6 VIO K4-A WHT

CB1-2 RED

K4

2

1 4

7 AB

3

5

6

8

9

TB3-10 GRY

K2-A VIO

D

K5-B YEL TB3-6 YEL

RB1-6 (11) BLK

D

K5

2

1 4

7 AB

3

5

6

8

9

K4-B YEL

B B

B

1

PCB1 P14-1 WHT

2

PCB1 P14-2 BRN

3

PCB1 P14-3 GRN

4

TRIM YEL

5

TRIM GRY

6

TRIM PNK

7

TRIM BLU

8

TRIM RED

PL1

1

2

ORN

TB3-17 VIO

RB1-4 (11) VIO

J2

PCB1 P1-1 BLU LS1-1 WHT*

12

B

J1

C

B

TB7

TB4-2 ORN LS1-2 WHT*

J1

TB3-16 ORN

B

J2

5

4

3

6

8

7

2

1

C

F

G

H

M

I

N

E

D

C

J

L

K

B

A

A B

RB1-6 (14) BLK

C

RB1-5 (14) YEL

D

K4-A BLU

E

TB3-8 BRN

F

RB1-5 (11) GRY

G

TB4-1 WHT

H I J

PCB1 P1-6 RED

K

TB4-1 G/Y TB4-2 ORN

L M

N

C



TB3-1 BLK TB3-2 RED

D

Q1-6 (SPLICE) RED

1 2 3

Q1-7 (SPLICE) WHT

RIBBON CABLE TO PCB1 J12





2

1



2

1





2

1



2

1



2 1



Q5-7 RED Q5-6 BLK

ELECTRODE BLU WORK WHT NEG(-) BUS BRN

A

Q2-7 (SPLICE) WHT

Q2-6 (SPLICE) RED

Q3-6 (SPLICE) RED

Q3-7 (SPLICE) WHT

Q4-6 (SPLICE) RED

WIRING DIA EPP-362, 400-460V

Q4-7 (SPLICE) WHT

1

FL1

RB1-4 (14) RED

2

0558011841

SHEET 1 OF 6

D

ESAB Schematic_Mech_Elec/EPP-362 Plasma Power Source Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual