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Section E-1 Section E-1
PRO-CUT 25
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Line Voltage and Auxiliary Transformer .............................................................................E-2
Precharge and Protection ...........................................................................................................E-3
Main Transformer ........................................................................................................................E-4
Output Section and Torch...........................................................................................................E-5
Control Board .............................................................................................................................E-6
Protection Circuits ......................................................................................................................E-7
Overload Protection..............................................................................................................E-7
Thermal Protection ...............................................................................................................E-7
Accidental Operation Protection.................................................................................................E-7
Safety Parts-In-Place Protection ................................................................................................E-7
Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-8
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
115/230/1/50/60 VAC
INPUT
CN1
2
1
4
3
5
6
7
8
300uH
L1
RL3
10/10W
R1
V2
V1
B
A
1A/250V
F1
RL2
RL2
RL2
AC
CP
CP
AC
L1
RL1
RL2
115VAC
230V
T1
115V
RL1
L1
15VAC
15VAC
SAFETY
+28VDC
SEC GND
OVLOAD
115/230
+12VDC
AC
CP
CP
AC
CN2
6
9
10
2
20
1516
+15Vrms
EV1
NO
COM
NC
12VDC
PS2
PS1
861793
OVLOAD
SEC GND
SAFETY
CN1
121814 1 11 4 13 7 19 2421 23 8 1 2 3
3
22
17
V+
+12VDC
+12VDC_SW
+8V_SW
SEC GND
OVLOAD
TRANSFER SW
TRANSFER
SOL 1 DRIVER
SOL 2 DRIVER
TRIGGER
OUTPUT
V_OUT
121814 7 15 4 11 5 161012 13
5
4
POT_WIPER
23
POT_CW
22
POT_CCW
24
CP
15K/3W
R1
15K/3W
R2
1500uF/250V
C2a,b
1500uF/250V
C1a,b
C12
CP
C26
IRG4BC30W
Q1a,b,c
IRG4BC30W
Q2a,b,c
SEC
PRI
T2
C13
D10
D11
240uH
Lout
SHUNT
SH-
SH+
BS1
8A
+12VDC
TRANSFER
C14
6.8k/5W
R24
WRK
NZL (2)
EL (3)
CN3
2
1
3
4
12VDC
PT
WORK CLAMP
CN1
SW1
230VAC
FN1
+
+
RL1
Display LED's
Control Board
Output Control
Air
Solenoid
1
Purge
Switch
Input
Voltage Board
Main Inverter Board
Solenoid 2
FIGURE E.1 – PRO-CUT 25 BLOCK LOGIC DIAGRAM
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