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
9. Secure the Heat Sink Assembly to the rear panel with 4 socket head cap screws provided.
Art # A-09765
CAUTION
In the following steps you will be asked to re-attach or attach wires to terminal strips on the PCB’s. In every
case you will need to make sure that the terminal is open before attempting to insert the bare wires. If you
do not then you risk the likelihood of the wire not being properly connected when tightened and falling out
at a later time and making electrical contact with some other component within the controller resulting
in failure or worse. To loosen or open the terminal turn the screw counter clock wise (to the left) and to
tighten it turn the screw clock wise (to the right).See Illustration.
CORRECT
Loosen / open
terminal before
inserting wire
Art # A-09766
WRONG
NOTE
When attaching wires to the terminal block do not clamp to the insulation on the wire as shown in previous
illustration. Only attach to the bare wires. If needed, strip more insulation off the wire fi rst.
September 15, 2010 6 Manual 0-5179 Rev. AA
10. Re-attach the Control Cable wires (black and white) to terminals 1 and 2 on the Heat Sink Assembly. It may be
helpful to turn the controller on its side as shown in the following illustration.
Art # A-09767
White #1
Black #2
11. Adjust length of Control Cable inside unit and fi nish tightening inner and outer cable protector. Do not pull it
so short that it puts a strain on the terminal connections or kinks the cable.
Art # A-09768
September 15, 2010 7 Manual 0-5179 Rev. AA
12. Mount the coil portion of the assembly as follows. First place one of the provided pads over the threaded insert
in the bottom of the controller as shown in the following illustrion.
Art # A-09769
NOTE
It is advised that you visually check and test the insert threads before mounting the coil by turning the
provided screw in several threads and then out.
13. Place the coil on the bottom pad and place the second pad on top of the coil. See the following illustration.
Art # A-09770
September 15, 2010 8 Manual 0-5179 Rev. AA
14. Place the large washer (provided) with the cone facing down on the top pad and using the socket head cap
screw and star washer provided, secure the coil to the base of the controller. See following illustration.
Art # A-09771
15. Reinstall the top PCB to the Heat Sink Assembly using the 3 screws you removed earlier. See the following
illustration.
Art # A-09772
September 15, 2010 9 Manual 0-5179 Rev. AA
16. Attach all new wires as follows. Remember to open/loosen all terminals before attempting to insert wires and
do not clamp onto the insulation of the wire. Some wires will be combined with an existing wire on the same
terminal.
Art # A-09773
9
White / Red
10
Yellow
Orange
2
1
4
3
5
6
TB4
Green
7
Violet
8
Blue with existing blue
2
1
Yellow with existing yellow
4
3
TB6
5
6
Art # A-09774
September 15, 2010 10 Manual 0-5179 Rev. AA
Grey
White and
Existing
Orange
8
7
6
Art # A-09775
2
1
4
3
5
TB7
17. Remove the nut on the grounding stud in the corner and place the ring terminal ground wire (part of twisted
blue and yellow wires connected to TB6 from previous step) on the stud with the other two wires. Secure the
nut on the three ring terminals making sure they are all fanned out and all fl at.
Art # A-09776
September 15, 2010 11 Manual 0-5179 Rev. AA
18. Locate the large PCB in the bottom of the controller. If the revision looks like the one in the following illustration with two fuse holders then you can discard the fuse provided and move to the next and fi nal step. If
your revision has a larger single fuse holder then you will need to replace the 1 amp fuse with the 8 amp fuse
provided.
Art # A-09777
New fuse for single
fuse holder only!
Two fuse holders, OK
do not need new fuse
19. Replace the cover onto the controller using the 8 screws removed in the fi rst step, being careful not to pinch
any wires between cover and base.
September 15, 2010 12 Manual 0-5179 Rev. AA
**BLK
**WHT
A A
1
MOTOR DRIVE CABLE
P4
9
8
7
6
5
4
3
2
1
2
D D
1. ALL WIRES 24 AW G UNLESS OTHERWISE INDICATED.
NOTES:
2.( *) DENOTES 22 AW G WIRE
1
3.(**) DENOTES 18 AWG WIRE
SELECT
S4
GRN
VIO
PGM RUN
S5
SEL
GRY
BLU
C
ORG
RB
D5
D6
D7
S3
INC
S2
DEC
YEL
RN
E
D
SW1
PWR+
1
2
BRN
RED
PWR+
345
ORG
"SW INPUTS"
SW2
SW4
SW3
PWR+
PWR+
678
YEL
GRN
BLU
GRY
VIO
PENDANT PCB ASS'Y
P/N C5A5004
X0
TB7
1
B B
A0
R/W
CED0D1D2D3D4D5D6D7
X1X2X3
23456
Y0
VADJ
VADJA0R/WCED0D1D2D3D4
COM
VDS
VDS
Y1Y2Y3
7
BLK
RED
1
PEND PWR
1
2
JP7
BLK PWR
DATA+
PEND COM
DATA -
"PENDANT"
TB1
4
2
3
YEL
RED
ORG
BRN
COM
"KEYBOARD"
TB2
8
2
**YEL
**BLK
**ORG
**RED
**WHT
**BLK
1
2
PWM CONTROL PCB
P/N C5A5006
HIGH/VARM
+12 OUT
CCW INP
DRV ON
READY
+ESTOP
3
+12/+5
ENC
COM
101112
WHT/RED
DWG
LTR ECO BY DATE
CW INP
LOW
WIPER
9
7
8
GRY
VIO
WHT
CONTROL
1 0
TB1
JP8
1
2
5
6
3
4
ORG
YEL
GRN
ARM-
ARM+
+12
1
+5
2
IMOT
3
VMOT
4
CL
5
CL'
6
PWM
7
CW
8
CCW
9
COM
123
4
TB2
"MOTOR"
P/N C5A5005
"POWER"
TB1
+5 VDC
+36 VDC
COM
+12 VDC
PWM DRIVER PCB
4
**BRN
**BLU
ORG
YEL
GRN
WHT/RED
APPROVED
ELECT CHK
P/N:
REV:
DRAWN
PROPRIETY PROPERTY OF COMPUTER WELD TECHNOLOGY, INC.. THIS DRAWING IS NOT TO BE USED FOR MANUFACTURING PURPOSE
OR THE INFORMATION CONTAINED THERIN DISCLOSED TO ANY UNAUTHORIZED PERSON WITHOUT WRITTEN PERMISION OF CWT, INC.
SHEET OF
FMT 06/07/02
BY DATE
WC-1 PLASMA PROGRAM CONTROLLER ENCLOUSER SCHEMATIC
WITH CAPSTAN PWM MOTOR DRIVE CONTROL
COPYRIGHT (c) 2001 COMPUTER WELD TECHNOLOGY, INC. ALL RIGHTS RESERVED
COMPUTER WELD TECHNOLOGY, INC.
5
PARENTHETICAL INFO FOR REFERANCE ONLY
YEL
PEND COM
RTS OUT
123
BRN
BRN
RED
ORG
1
234
"PENDANT"
PEND PWR
DATA+
DTR IN
TXD OUTDATA -
RXD IN
COM
5
4
RED
ORG ORG
YEL
VIO
5
1
2
6
3
4
8910
7
TB1
CCW OUT
CW OUT
+5 VDC
PWM OUT
ENCODER IN
VARM IN
IARM IN
COM
DRV ENABLE
READY IN
WELD CONTROL PCB ASS'Y
P/N C5A5003
+24 I/O
+24 I/O
DSR OUT
"RS-232"
TB2
6
123
WHR/ORG
WHT/ORG
BLU
READY
I/O COM
I/O COM
ESTOP+
"I/O POWER"
TB3
4
5
12345
BLK
WHT/YEL
*GRN/YEL
**BLU
**YEL
**BRN
**BLU
**BRN
2
3
456
SCHED 0
678
SW LIGHT
EARTH
SCHED 2
SCHED 1
1
SW OUT
NEU
HOT
SW HOT
WC-B
WC-A
WCOM
W_READY
W_ARC ACTIVE
ANL COM
DAC 2
DAC 1
START
IN COM
SCHED 4
SCHED 3
12
10
11
9
WHT/BLK
WHT/BRN
BLK
WHT
TB6
"POWER"
"WELD REMOTE"
TB7
*GRY
8
7
BLK
6
WHT/ORG
5
WHT/ORG
4
*ORG
3
GRY
2
*BRN
1
TB5
"I/O"
"MOTOR I/O"
TB4
ACTIVE
OUT COM
COMPLETE
ARC ON
YEL
BLK
ORG
BRN
**YEL
3
1
2
S1
POWER
**RED
**ORG
**YEL
**BLK
3
2
1
4
TB3
PWR OUT
COM
+5 VDC
HOT
EARTH
NEU
TB1
"POWER"
2
3
1
*GRN/YEL
**YEL
**BLU
**GRN/YEL
**BLU
**BRN
*GRY
OIV*OIV*
*BRN
*GRN/YEL
*ORG
110VAC WIRING
220VAC WIRING
PWM POWER PCB
+36 VDC
P/N C5A5007
SEC-1
PRI-2
PRI-1
SEC-2+12 VDC
"XFMR"
TB2
1
234
ORG
BLK
WHT
RED
"XFMR"
TB2
2
3
1
4
WHT
BLK
ORG
RED
115 VAC POWER
HOTNEUGND
P1
POWER SUPPLY CONTROL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3
YEL
C3W5010
T1
RED
4
YEL
C3W5010
T1
RED
5
P3
1
2
3
4
5
6
7
8
9
REMOTE PENDANT
Art # A-09780
6
6
RED
YELGRN
BLU
BRN
1
6
RS-232
27384
GRN
9
5
P2
WHT/ORG
WHT/YEL
WHT/BRN
WHT/BLK
WHT
YEL
ORG
*GRN/YEL
BRN
C
September 15, 2010 13 Manual 0-5179 Rev. AA
This completes the installation of this Capstan Wire Feed & Control Circuit for use with the WC-1 Controller and the
WF-100 Motor Drive.
NOTE
Every effort has been made to provide complete and accurate information in this manual. However, the
publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused
by errors or omissions in this Manual, whether such errors result from negligence, accident, or any other
cause.
September 15, 2010 14 Manual 0-5179 Rev. AA
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