Thermal Arc Capstan Wire Feed & Control Circuit Installation guide

Brand
Thermal Arc
Model
Capstan Wire Feed & Control Circuit
Type
Installation guide

Thermal Arc Capstan Wire Feed & Control Circuit is an easy-to-install device that can greatly enhance the capabilities of your welding equipment. It allows for precise control of the wire feed rate, which can improve the quality of your welds and reduce the amount of rework required. The circuit also includes a number of safety features to protect you and your equipment from harm.

Here are some of the key benefits of using the Thermal Arc Capstan Wire Feed & Control Circuit:

  • Improved weld quality: By precisely controlling the wire feed rate, you can ensure that your welds are of the highest possible quality. This can result in less rework and fewer defects.

Thermal Arc Capstan Wire Feed & Control Circuit is an easy-to-install device that can greatly enhance the capabilities of your welding equipment. It allows for precise control of the wire feed rate, which can improve the quality of your welds and reduce the amount of rework required. The circuit also includes a number of safety features to protect you and your equipment from harm.

Here are some of the key benefits of using the Thermal Arc Capstan Wire Feed & Control Circuit:

  • Improved weld quality: By precisely controlling the wire feed rate, you can ensure that your welds are of the highest possible quality. This can result in less rework and fewer defects.
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
© 2009 Thermadyne Corp.
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
1
2
2
3
3
4
4
5
5
6
6
D D
C
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.
COPYRIGHT (c) 2001 COMPUTER WELD TECHNOLOGY, INC. ALL RIGHTS RESERVED
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
I/O COM
ESTOP+
+24 I/ O
+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
BRN
BRN
RED
RED
RED
ORG
ORG
ORG
ORG
WHT/ORG
WHT/ORG
ORG
ORG
*ORG
*ORG
BLK
BLK
BLK
BLK
WHT/YEL
YEL
YEL
YEL
YEL
YEL
YEL
GRN
GRN
WHT/ORG
BLU
BLU
VIO
VIO
OIV*OIV*
*GRY
GRY
GRY
D
E
RN
RB
WHT
WHT
WHT/BLK
WHT/BLK
WHT/BRN
WHT/BRN
WHT/YEL
*GRN/YEL
*GRN/YEL
**GRN/YEL
**BLU
**BRN
**BRN
**BLU
**BRN
*GRN/YEL
**BLU
**YEL
**BRN
**BLU
**YEL
*GRY
BRN
BRN
RED
RED
ORG ORG
YEL
YELGRN
BLU
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
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
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.
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Thermal Arc Capstan Wire Feed & Control Circuit Installation guide

Brand
Thermal Arc
Model
Capstan Wire Feed & Control Circuit
Type
Installation guide

Thermal Arc Capstan Wire Feed & Control Circuit is an easy-to-install device that can greatly enhance the capabilities of your welding equipment. It allows for precise control of the wire feed rate, which can improve the quality of your welds and reduce the amount of rework required. The circuit also includes a number of safety features to protect you and your equipment from harm.

Here are some of the key benefits of using the Thermal Arc Capstan Wire Feed & Control Circuit:

  • Improved weld quality: By precisely controlling the wire feed rate, you can ensure that your welds are of the highest possible quality. This can result in less rework and fewer defects.
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