ESAB Capstan Wire Feed & Control Circuit Installation guide

September 15, 2010 1 Manual 0-5179 Rev. AA

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.

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

September 15, 2010 2 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-installa-

tion.

2. Facing the back of the unit, remove the 4 screws holding the plate in place.

Art # A-09757

Before

Art # A-09758

After

3. Remove “Wire Feed Motor” plug seen in previous illustration.

September 15, 2010 3 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.

Control Cable

Top PCB

3 mounting

screws

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 4 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 5 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 6 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.

Loosen / open

terminal before

inserting wire

WRONG

CORRECT

Art # A-09766

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 7 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.

White #1

Black #2

Art # A-09767

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 8 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 9 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 10 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.

1

2

3

4

5

6

7

8

9

10

TB4

Orange

Yellow

Green

Violet

White / Red

Art # A-09773

1

2

3

4

5

6

TB6

Blue with existing blue

Yellow with existing yellow

Art # A-09774

September 15, 2010 11 Manual 0-5179 Rev. AA

1

2

3

4

5

6

7

8

TB7

Grey

White and

Existing

Orange

Art # A-09775

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 12 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 illus-

tration 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.

Two fuse holders, OK

do not need new fuse

New fuse for single

fuse holder only!

Art # A-09777

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 13 Manual 0-5179 Rev. AA

1

2

3

4

5

6

D D

C

B B

A A

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.

COMPUTER WELD TECHNOLOGY, INC.

PARENTHETICAL INFO FOR REFERANCE ONLY

SHEET OF

P/N:

REV:

DWG

DRAWN

ELECT CHK

APPROVED

BY DATE

LTR ECO BY DATE

WC-1 PLASMA PROGRAM CONTROLLER ENCLOUSER SCHEMATIC

1

2

3

4

TB1

"PENDANT"

1

2

3

4

5

6

7

8

9

10

TB4

"MOTOR I/O"

1

2

3

4

5

6

TB6

"POWER"

1

2

3

4

5

6

7

8

TB7

"WELD REMOTE"

1

2

3

4

5

6

7

8

9

10

11

12

TB5

"I/O"

1

2

3

4

5

6

TB2

"RS-232"

1

2

3

4

5

TB3

"I/O POWER"

NEU

HOT

SW HOT

SW OUT

SW LIGHT

EARTH

CW OUT

+5 VDC

CCW OUT

DRV ENABLE

PWM OUT

ENCODER IN

VARM IN

READY IN

IARM IN

COM

PEND PWR

DATA+

W_ARC ACTIVE

ANL COM

W_READY

WCOM

WC-A

WC-B

DTR IN

RXD IN

COM

DSR OUT

DAC 1

DAC 2

OUT COM

SCHED 0

ACTIVE

COMPLETE

ARC ON

READY

START

IN COM

SCHED 4

SCHED 3

SCHED 2

SCHED 1

I/O COM

ESTOP+

+24 I/ O

RTS OUT

TXD OUTDATA -

PEND COM

WELD CONTROL PCB ASS'Y

P/N C5A5003

1

2

3

4

5

6

7

8

9

P3

REMOTE PENDANT

1

6

2

7

3

8

4

9

5

P2

RS-232

HOTNEUGND

3

1

2

S1

POWER

1

2

3

4

TB1

"PENDANT"

PEND PWR

DATA+

DATA -

PEND COM

1

2

3

4

5

6

7

8

TB7

"SW INPUTS"

1

2

3

4

5

6

7

8

TB2

"KEYBOARD"

SW2

PWR+

SW1

PWR+

SW4

PWR+

SW3

PWR+

Y0

Y1

Y2

Y3

X0

X1

X2

X3

PENDANT PCB ASS'Y

P/N C5A5004

S3

INC

S2

DEC

S5

SEL

S4

SELECT

PGM RUN

1

2

JP7

BLK PWR

RED

BLK

COM

VDS

VADJ

A0

R/W

CE

D0

D1

D2

D3

D4

D5

D6

D7

COM

VDS

VADJ

A0

R/W

CE

D0

D1

D2

D3

D4

D5

D6

D7

WHR/ORG

BRN

*BRN

BRN

*BRN

BRN

RED

ORG

WHT/ORG

ORG

*ORG

BLK

WHT/YEL

YEL

GRN

WHT/ORG

BLU

VIO

OIV*OIV*

*GRY

GRY

D

E

RN

RB

WHT

WHT/BLK

WHT/BRN

WHT/YEL

*GRN/YEL

**GRN/YEL

**BLU

**BRN

**BLU

**BRN

*GRN/YEL

**BLU

**YEL

**BRN

**BLU

**YEL

*GRY

BRN

RED

ORG ORG

YEL

YELGRN

BLU

GRN

115 VAC POWER

WHT/ORG

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

P1

POWER SUPPLY CONTROL

FMT 06/07/02

WITH CAPSTAN PWM MOTOR DRIVE CONTROL

NOTES:

1. ALL WIRES 24 AWG UNLESS OTHERWISE INDICATED.

2.( *) DENOTES 22 AWG WIRE

3.(**) DENOTES 18 AWG WIRE

1

2

3

4

5

6

7

8

9

10

11

12

TB1

CONTROL

1

2

3

4

TB1

"POWER"

1

2

TB2

"MOTOR"

1

2

3

TB1

"POWER"

1

2

3

4

TB3

PWR OUT

1

2

3

4

TB2

"XFMR"

NEU

HOT

EARTH

PRI-2

PRI-1

SEC-1

SEC-2+12 VDC

+36 VDC

+5 VDC

COM

YEL

BLK

WHT

ORG

RED

**YEL

**BLU

*GRN/YEL

2

1

3

4

5

6

7

8

9

1 0

JP8

+12 VDC

+36 VDC

+5 VDC

COM

ARM-

ARM+

CCW

COM

CL'

CL

PWM

CW

+12

IMOT

+5

VMOT

+ESTOP

+12 OUT

CW INP

CCW INP

DRV ON

READY

HIGH/VARM

WIPER

+12/+5

LOW

ENC

COM

PWM CONTROL PCB

P/N C5A5006

PWM DRIVER PCB

P/N C5A5005

PWM POWER PCB

P/N C5A5007

1

2

3

4

5

6

7

8

9

P4

MOTOR DRIVE CABLE

**ORG

**YEL

**RED

**BLK

**ORG

**YEL

**RED

**BLK

**WHT

**BLK

**WHT

**BLK

ORG

YEL

GRN

VIO

GRY

WHT

WHT/RED

ORG

YEL

GRN

VIO

WHT/RED

GRY

T1

C3W5010

110VAC WIRING

1

2

3

4

TB2

"XFMR"

YEL

BLK

WHT

ORG

RED

T1

C3W5010

220VAC WIRING

Art # A-09780

September 15, 2010 14 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.

ESAB Capstan Wire Feed & Control Circuit Installation guide

ESAB Capstan Wire Feed & Control Circuit Installation guide

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