Manual 0-5179
Capstan Wire Feed & Control Circuit
For use with the WC-1 Controller and
the WF-100 Motor Drive
Kit# C3A5005
Installation Instructions
Scope
This kit is for use only with Thermal Arc WC-1 Controller. Do not use this kit with any other equipment.
Supplied Parts
The kits include:
WC1 PWM Motor Drive Kit
• 1 - PWM Control Wire Harness
• 1 - PWM AC Power Harness
• 1 - PWM DC Power Wire Harness
• 1 - Motor Drive Cable
• 1 - Toroidal Transformer
• 1 - Motor Control Assembly:
Includes 1- PWM Driver PCB
1 - PWM CPU PCB
1 - PWM PS PCB
• 1 - Heatsink Assy
• 1 - 8 AMP Fuse
• 1 - Heyco Cable Clamp Fitting
• 1 - Installation Instructions
Instructions
WARNINGS
Disconnect primary power at the source before performing any inspection or repairs.
Only a qualifi ed technician should perform this procedure.
Follow the electrostatic discharge instructions included with the component to prevent damage to the
component.
Power Supply Preparation
NOTE:
Keep all hardware for remounting and attaching components. Some will be used and some will be discarded
when done.
© 2009 Thermadyne Corp.
September 15, 2010 1 Manual 0-5179 Rev. AA
1. Remove the Controller cover. 8 screws (not shown). Do not lose as you will need all of these for re-installation.
2. Facing the back of the unit, remove the 4 screws holding the plate in place.
Before
Art # A-09757
Art # A-09758
After
3. Remove “Wire Feed Motor” plug seen in previous illustration.
September 15, 2010 2 Manual 0-5179 Rev. AA
4. Locate the PCB assembly shown below and remove the top PCB by removing the 3 Phillips head screws holding
it in place. DO NOT disconnect any wires unless told to.
Top PCB
3 mounting
screws
Control Cable
Art # A-09759
5. Remove control cable with grey insulation connected to terminals 1 and 2 (black and white wires) as shown
in next illustration.
Art # A-09760
September 15, 2010 3 Manual 0-5179 Rev. AA
6. Attach the Control Cable to rear panel. Remove nut from through hole cable protector and feed cable through
the “Wire Feed Motor” hole in the rear panel as shown in next illustration.
Control Cable
Art # A-09761
7. Slide the nut over the cable as seen in previous illustration and lightly secure to rear panel. The Control Cable
needs to be loose enough to slide in and out until secured to PCB again in later step.
Art # A-09762
September 15, 2010 4 Manual 0-5179 Rev. AA
8. CAREFULLY install the Heat Sink Assembly. An extra set of hands can help as you insert the transformer coil
through the rear panel fi rst followed by the detached top PCB and fi nally the Heat Sink with remaining PCB’s
as shown below.
NOTE
Wires connected to the PCB’s should be to the left as you face the rear panel (closer to the center of the
unit).
Art # A-09763
Art # A-09764
September 15, 2010 5 Manual 0-5179 Rev. AA
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