TM 204

July 1996 Form: TM-204
Effective With Serial No. JK542460
TECHNICAL MANUAL
Service And Parts
Spectrum 500
Air Plasma Cutting System: Power Source, Torch, And Air Regulator
WARNING Use MILLER Testing Booklet (Part No.

150 853) when servicing this unit.
SERVICING can be hazardous. Use only genuine MILLER replacement
• Have all service procedures performed only by parts.
qualified persons following standard safety
practices.
For help, call Factory Or FAX inside the USA: Or write to:
Service Department: 800-637-2348 MILLER Electric Mfg. Co.
414-735-4505 Outside the USA: P.O. Box 1079
414-735-4136 Appleton, WI 54912 USA
cover_tm1 – ST-126 576-B  1996 MILLER Electric Mfg. Co. PRINTED IN USA
EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
NOTE Magnetic Fields
The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace, use the following
of the U.S. Congress, Office of Technology Assessment, Biological procedures:
Effects of Power Frequency Electric & Magnetic Fields – 1. Keep cables close together by twisting or taping them.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very 2. Arrange cables to one side and away from the operator.
large volume of scientific findings based on experiments at the 3. Do not coil or drape cables around the body.
cellular level and from studies with animals and people which clearly
4. Keep welding power source and cables as far away as
establish that low frequency magnetic fields can interact with, and practical.
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific 5. Connect work clamp to workpiece as close to the weld as
understanding does not yet allow us to interpret the evidence in a possible.
single coherent framework. Even more frustrating, it does not yet About Pacemakers:
allow us to draw definite conclusions about questions of possible The above procedures are among those also normally
risk or to offer clear science-based advice on strategies to minimize recommended for pacemaker wearers. Consult your doctor for
or avoid potential risks.” complete information. mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-1. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-1. Selecting A Location And Moving Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Installing And Connecting Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Connecting Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-4. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-2. Troubleshooting Circuit Diagram For Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-4. Troubleshooting Timer/Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6-5. Troubleshooting Relay Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-6. Troubleshooting Display Board PC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-7. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-3. Adjusting Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-4. Torch And Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 – HF IN PLASMA ARC CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

OM-204H – 7/94 / SPM-204-B – 5/94
PLASMA ARC CUTTING SAFETY PRECAUTIONS
WARNING PLASMA ARC CUTTING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In cutting, as in most jobs, exposure to certain hazards occurs. Cutting is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
CUTTING can cause fire or explosion. 7. Do not cut on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the cutting area as
Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and practical to prevent cutting current from traveling long, possibly
hot equipment can cause fires and burns. Check and unknown paths and causing electric shock and fire hazards.
be sure the area is safe before doing any cutting. 9. Never cut containers with potentially flammable materials
inside – they must be emptied and properly cleaned first.
1. Protect yourself and others from flying sparks and hot metal. 10. Do not cut in atmospheres containing explosive dust or vapors.
2. Do not cut where flying sparks can strike flammable material. 11. Do not cut pressurized cylinders, pipes, or vessels.
3. Remove all flammables within 35 ft (10.7 m) of the cutting arc. If 12. Do not cut containers that have held combustibles.
this is not possible, tightly cover them with approved covers.
4. Be alert that sparks and hot materials from cutting can easily go 13. Wear oil-free protective garments such as leather gloves,
through small cracks and openings to adjacent areas. heavy shirt, cuffless trousers, high shoes, and a cap.
5. Watch for fire, and keep a fire extinguisher nearby. 14. Do not locate unit on or over combustible surfaces.
6. Be aware that cutting on a ceiling, floor, bulkhead, or partition 15. Remove any combustibles, such as a butane lighter or
can cause fire on the hidden side. matches, from your person before doing any cutting.
ELECTRIC SHOCK can kill. 8. Check and be sure that input power cord ground wire is properly
Touching live electrical parts can cause fatal shocks connected to ground terminal in disconnect box or that cord
or severe burns. The torch and work circuit is plug is connected to a properly grounded receptacle outlet –
electrically live whenever the output is on. The input always verify the supply ground.
power circuit and machine internal circuits are also 9. When making input connections, attach proper grounding
live when power is on. Plasma arc cutting requires conductor first.
higher voltages than welding to start and maintain
the arc (200 to 400 volts dc are common), but also uses torches 10. Frequently inspect input power cord for damage or bare wiring –
designed with safety interlock systems which turn off the machine replace cord immediately if damaged – bare wiring can kill.
when the shield cup is loosened or if tip touches electrode inside the 11. Turn off all equipment when not in use.
nozzle. Incorrectly installed or improperly grounded equipment is a
hazard. 12. Inspect and replace any worn or damaged torch cable leads.
13. Do not wrap torch cable around your body.
1. Do not touch live electrical parts.
14. Ground the workpiece to a good electrical (earth) ground if
2. Wear dry, hole-free insulating gloves and body protection. required by codes.
3. Insulate yourself from work and ground using dry insulating
15. Use only well-maintained equipment. Repair or replace
mats or covers big enough to prevent any physical contact with
damaged parts at once.
the work or ground.
16. Wear a safety harness if working above floor level.
4. Do not touch torch parts if in contact with the work or ground.
17. Keep all panels and covers securely in place.
5. Turn off power before checking, cleaning, or changing torch
parts. 18. Do not bypass or try to defeat the safety interlock systems.
6. Disconnect input power before installing or servicing this 19. Use only torch(es) specified in Owner’s Manual.
equipment. Lockout/tagout input power according to OSHA 20. Keep away from torch tip and pilot arc when trigger is pressed.
CFR 1910.147 (see Safety Standards). 21. Clamp work cable with good metal-to-metal contact to
7. Properly install and ground this equipment according to its workpiece (not piece that will fall away) or worktable as near the
Owner’s Manual and national, state, and local codes. cut as practical.
ARC RAYS can burn eyes and skin. NOISE can damage hearing.
Arc rays from the cutting process produce intense Prolonged noise from some cutting applications can
visible and invisible (ultraviolet and infrared) rays that damage hearing if levels exceed limits specified by
can burn eyes and skin. OSHA (see Safety Standards).
1. Wear face protection (helmet or shield) with correct shade of 1. Use approved ear plugs or ear muffs if noise level is high.
filter to protect your face and eyes when cutting or watching. 2. Warn others nearby about noise hazard.
ANSI Z49.1 (see Safety Standards) suggests a No. 9 shade
(with No. 8 as minimum) for all cutting currents less than 300
amperes. Z49.1 adds that lighter filter shades may be used Table 1. Eye Protection For Plasma Arc Cutting
when the arc is hidden by the workpiece. As this is normally the
case with low current cutting, the shades suggested in Table 1 Current Level In Amperes Minimum Shade Number
are provided for the operator’s convenience. Below 20 #4
2. Wear approved safety glasses with side shields. 20 – 40 #5
3. Use protective screens or barriers to protect others from flash 40 – 60 #6
and glare; warn others not to watch the arc. 60 – 80 #8
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
sr2 11/92
FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
to your health. wearing an air-supplied respirator. Fumes from cutting and
oxygen depletion can alter air quality causing injury or death. Be
Cutting produces fumes and gases. Breathing these sure the breathing air is safe.
fumes and gases can be hazardous to your health.
6. Do not cut in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not cut on coated metals, such as galvanized, lead, or
1. Keep your head out of the fumes. Do not breathe the fumes.
cadmium plated steel, unless the coating is removed from the
2. If inside, ventilate the area and/or use exhaust at the arc to cutting area, the area is well ventilated, and if necessary, while
remove cutting fumes and gases. wearing an air-supplied respirator. The coatings and any metals
3. If ventilation is poor, use an approved air-supplied respirator. containing these elements can give off toxic fumes when cut.
4. Read the Material Safety Data Sheets (MSDSs) and the 8. Do not cut containers with toxic or reactive materials inside or
manufacturer’s instruction for metals to be cut, coatings, and containers that have held toxic or reactive materials – they must
cleaners. be emptied and properly cleaned first.
PLASMA ARC can cause injury. 3. The pilot arc can cause burns – keep away from torch tip when
trigger is pressed.
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn 4. Wear proper flame-retardant clothing covering all exposed
hazard. The intensely hot and powerful arc can body areas.
quickly cut through gloves and tissue. 5. Point torch away from your body and toward work when
pressing the torch trigger – pilot arc comes on immediately.
6. Turn off power source and disconnect input power before
1. Keep away from the torch tip. disassembling torch or changing torch parts.
2. Do not grip material near the cutting path. 7. Use only torch(es) specified in the Owner’s Manual.
FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles with side shields.
cause injury. 2. Wear proper body protection to protect skin.
Chipping and grinding cause flying metal. As welds 3. Wear flame-resistant ear plugs or ear muffs to prevent sparks
cool, they can throw off slag. from entering ears.
CYLINDERS can explode if damaged. 3. Keep cylinders away from any cutting or other electrical circuits.
4. Never allow electrical contact between a plasma arc torch and a
Gas cylinders contain gas under high pressure. If cylinder.
damaged, a cylinder can explode. Since gas 5. Never cut on a pressurized cylinder – explosion will result.
cylinders are normally part of metalworking 6. Use only correct gas cylinders, regulators, hoses, and fittings
processes, be sure to treat them carefully. designed for the specific application; maintain them and
associated parts in good condition.
7. Turn face away from valve outlet when opening cylinder valve.
1. Protect compressed gas cylinders from excessive heat, 8. Keep protective cap in place over valve except when cylinder is
mechanical shocks, slag, open flame, sparks, and arcs. in use or connected for use.
2. Install and secure cylinders in an upright position by chaining 9. Read and follow instructions on compressed gas cylinders,
them to a stationary support or equipment cylinder rack to associated equipment, and CGA publication P-1 listed in Safety
prevent falling or tipping. Standards.
PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American National Electrical Code, NFPA Standard 70, from National Fire
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
dent of Documents, U.S. Government Printing Office, Washington, way, Suite 501, Arlington, VA 22202.
D.C. 20402.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Recommended Practices for Plasma Arc Cutting, American Welding Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
Society Standard AWS C5.2, from American Welding Society, 550 levard, Rexdale, Ontario, Canada M9W 1R3.
N.W. LeJeune Rd, Miami, FL 33126
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Insti-
Recommended Safe Practices for the Preparation for Welding and tute, 1430 Broadway, New York, NY 10018.
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So- Cutting And Welding Processes, NFPA Standard 51B, from National
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126 Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
sr2 11/92
SECTION 1 – SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol

2 Signal Word
1 2 2
WARNING means possible death
or serious injury can happen.
WARNING 3 CAUTION CAUTION means possible minor
ELECTRIC SHOCK can kill. MOVING PARTS can injure. injury or equipment damage can
• Do not touch live electrical parts. • Keep away from moving parts. happen.
• Disconnect input power before 4 • Keep all panels and covers closed 3 Statement Of Hazard And
installing or servicing. when operating.
Result
4 Safety Instructions To Avoid
5 Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
WARNING READ SAFETY BLOCKS at start of
Section 3-1 before proceeding. Read safety blocks for each sym-
6 bol shown.
7 NOTE
7 NOTE Turn Off switch when using high frequency. Special instructions for best op-
eration – not related to safety.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Power Source
Specification Description
Type Of Output Direct Current, Straight Polarity (Electrode Negative)
Max. Open-Circuit Voltage 270 Volts DC
Plasma Gas Air Or Nitrogen Only
Plasma Gas Flow/Pressure 4.7 CFM (135 L/min) At 50 PSI (345 kPa)
Overall Dimensions With Handles Length: 17 in (432 mm); Width: 19 in (483 mm); Height: 20-1/2 in (521 mm)
Weight Net: 221 lb (100 kg); Ship: 261 lb (118 kg)
Low Range High Range

Rated Output 16 Amperes, 110 Volts DC At 100% Duty Cycle 50 Amperes, 110 Volts DC At 60% Duty Cycle
(See Section 2-2) (See Section 2-2)
Type Of Input Power Single-Phase; 200, 230, 460 Or 575 Volts AC; Single-Phase; 200, 230, 460 Or 575 Volts AC;
60 Hz 60 Hz
Input Amperes At Rated Output 31 A At 200 V, 27 A At 230 V, 13.5 A At 460 V, 80 A At 200 V, 70 A At 230 V, 35 A At 460 V,
10.8 A At 575 V 28 A At 575 V
Input Amperes While Idling 5 A At 200 V, 4.4 A At 230 V, 2.2 A At 460 V, 5 A At 200 V, 4.4 A At 230 V, 2.2 A At 460 V,
1.4 A At 575 V 1.4 A At 575 V
KVA/KW Used At Rated Output 6.2 kVA/3.9 kW 16 kVA/7.5 kW
KVA/KW Used While Idling 1 kVA/0.8 kW 1 kVA/0.8 kW
Spectrum 500 TM-204 Page 1

2-1. Cutting Speed
CAUTION
EXCEEDING RECOMMENDED CUTTING SPEEDS will cause rapid erosion of the tip and electrode.
• Do not exceed indicated cutting speeds.
The cutting speed curve shows the

maximum cutting speed capabili-
ties of the power source and torch
for mild steel of various thickness.
ST-130 085-B
Figure 2-1. Cutting Speed
2-2. Duty Cycle
CAUTION
CUTTING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
• Do not cut at rated load longer than shown below. warn7.1* 8/93
0
Definition
10
Duty Cycle is percentage of 10 minutes that unit and
torch can cut at rated load without overheating.
Minutes
60% Duty Cycle With Range Switch In High Position 100% Duty Cycle With Range Switch In Low Position
6 Minutes Cutting 4 Minutes Resting Continuous Cutting

sb1.4* 8/93
Figure 2-2. Duty Cycle

TM-204 Page 2 Spectrum 500
SECTION 3 – INSTALLATION
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers,
and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• Read and follow entire Section 8 for proper location and installation requirements for high-frequency equipment before
installing unit. swarn13.1* 4/93
Table 3-1. Items Included With Power Source

Item Quantity
Torch – See Torch Manual 1
Work Cable And Clamp 1
Air Filter/Regulator 1
Gouge Tips 5
Stand-Off Guides 2
Stop Guide Sleeve (APT-7000 Torches Only) 1
3-1. Selecting A Location And Moving Power Source
WARNING
ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF
• Do not touch live electrical parts. FRESH AIR AND PROPER
• Disconnect input power conductors from
VENTILATION can be harmful.
deenergized supply line BEFORE moving power • Do not breathe cutting fumes.
source. • Place unit only where there is a good fresh air
supply and proper ventilation.
FIRE OR EXPLOSION can result from
p l a c i n g u n i t o n , o v e r, o r n e a r FA L L I N G E Q U I P M E N T c a n c a u s e
combustible surfaces. serious personal injury and equipment
• Do not locate unit on, over, or near combustible damage.
surfaces.
• Use lift eye to lift unit only, NOT running gear, gas
• Do not install unit near flammables. cylinders, or any other accessories.
BLOCKED AIRFLOW causes • Use equipment of adequate capacity to lift the unit.
overheating and possible damage to
unit.
• Do not block or filter airflow.
Warranty is void if any type of filter is used. swarn11.1* 3/93

Movement 1 Handles
2 Running Gear Wheel
Use running gear with handles to
move unit.
1 3 Lifting Eye
4 Lifting Forks
Use lifting eye or lifting forks to
3 move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
5 Rating Label
OR OR
Use rating label to determine input
power needs.
4 6 Line Disconnect Device
Locate unit near correct input pow-
er supply.
2
Location And Airflow

6
Special installation may be required

where gasoline or volatile liquids are
present – see NEC Article 511 or CEC
Section 20.
18 in
(460 mm) 18 in
(460 mm)
18 in 18 in
(460 mm) (460 mm)
ssb9.1 5/94 – Ref. ST-126 576-B / ST-800 402
Figure 3-1. Movement And Location Of Power Source
3-2. Installing And Connecting Work Clamp
1 Insulator
1
2 Bolt
3 Smaller Hole
4 Work Clamp Tabs
6 Bend tabs around work cable.

5 5 Work Cable From Unit
2
6 Nut
3 Connect work clamp to a clean,
Tools Needed:
paint-free location on workpiece,
4 as close to cutting area as pos-
sible.
3/8, 7/16 in
Ref. ST-025 190-C
Figure 3-2. Installing And Connecting Work Clamp

3-3. Connecting Gas/Air Supply
CAUTION
INCORRECT PLASMA GAS can cause torch and power source damage.
• Use only air or nitrogen for the plasma gas.
• Do not use any other gas or combination of gases.
1 Air Filter/Regulator
2 Gas/Air Inlet Opening
3 Hose
4 Teflon Tape
Obtain hose with 5/8-18 right-hand
thread fitting. Wrap threads with
teflon tape, and install fitting in
opening. Route hose to gas/air
supply.
Adjust gas/air pressure according
to Figure 4-5.
1 2
Use only clean and dry gas/air with

3
80-150 psi (552-1034 kPa) pressure.
To Gas/Air Supply
Tools Needed:
5/8 in
ST-126 579-B / S-0818
Figure 3-3. Connecting Gas/Air Supply

3-4. Connecting Input Power
WARNING
HIGH-FREQUENCY RADIATION can in- ELECTRIC SHOCK can kill.
terfere with radio navigation, safety ser- • Do not touch live electrical parts.
vices, computers, and communications • Turn Off welding power source, and disconnect in-
equipment. put power before inspecting or installing.
• Have only qualified person familiar with electronic • Have only qualified persons install unit.
•
equipment perform this installation.
Read and follow entire Section 8 for proper location
• Installation must meet National Electrical Code and
all other codes.
and installation requirements for high-frequency
equipment before installing unit. swarn13.2 4/93
A. Positioning Jumper Links
Jumper links allow operation on

different input voltages and are
factory set for the highest input
voltage.
Check input voltage available at
site.
Remove right side panel to check
jumper links.
1 Input Voltage Label – Only
One Is On Unit
Look at jumper links and compare
link position with unit label.
2 Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts posi-
tion when 230 volts input power is
available.
Reinstall side panel and go on to
Figure 3-5.
200 VOLTS 230 VOLTS
S-046 472-B
230 VOLTS 460 VOLTS
S-133 010-A
2
460 VOLTS 575 VOLTS
Tools Needed:
S-105 419-B
3/8 in
ssb5.1 2/92 – Ref. ST-800 082
Figure 3-4. Input Voltage Jumper Links Location

B. Connecting Input Power
Have only qualified persons make

this installation.
1 Line Disconnect Device Of
Proper Rating
2 Grounding Conductor –
Green Or Green With Yellow
Stripe(s)
3 Input Conductors
Install grounding conductor and in-
put conductors from unit to deener-
gized line disconnect device.
Connect grounding conductor first,
then line input conductors.
1 Be sure grounding conductor goes
to an earth ground.
4
4 Overcurrent Protection
Select type and size using
Table 3-2. Install into deenergized
2 line disconnect device (fused dis-
connect switch shown).
Tools Needed:
ssb2.3 11/93 – ST-126 578-B
Figure 3-5. Input Power Connections
Table 3-2. Electrical Service Requirements*
Input Voltage 200 230 460 575
Input Amperes At Rated Output (High Range) 80 70 35 28
Recommended Standard Fuse Or Circuit Break-

125 100 50 40
er Rating In Amperes1
* These values are calculated from the 1993 edition of the National Electrical Code (NEC).
1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-12(a) of NEC
allows fuse or circuit breaker sizing up to 200% of rated input amperage. Ref. S-0092-G
SECTION 4 – OPERATION
WARNING
ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin;
• Always wear dry insulating gloves. NOISE can damage hearing.
• Insulate yourself from work and ground. • Wear face protection with correct shade of filter.
• Do not touch live electrical parts. • Wear correct eye, ear, and body protection.
• Keep all panels and covers securely in place. MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous • Keep away from moving parts.
to your health. • Keep all doors, panels, covers, and guards closed
• Keep your head out of the fumes. and securely in place.
• Ventilate area, or use breathing device. See Safety Precautions at beginning of manual for ba-
• Read Material Safety Data Sheets (MSDSs) and
sic cutting safety information.
manufacturer’s instructions for material cut.
CUTTING can cause fire or explosion.
• Do not cut near flammable material.
• Provide protection from flying sparks.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not cut on closed containers.
• Allow work and equipment to cool before handling. swarn6.1* 10/91
6 5 4 3 2 1 1 Pilot Light
2 Power Switch
3 Ready Light
4 Trouble Lights (See Section
7-2B)
5 Range Switch
6 Gas/Air Switch
ST-800 078
Figure 4-1. Controls
1 2 5 Wear the following while cutting:

1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 4 3 Welding Helmet
4 Face Shield
Wear either helmet or face shield
with correct shade of filter (See
ANSI Z49.1).
OR 5 Ear Muffs
Wear approved ear muffs or ear
plugs if noise exposure exceeds
OSHA limits. sb3.1* 1/94
Figure 4-2. Safety Equipment

CAUTION
INCORRECT STAND-OFF DISTANCE can damage ARCING can damage switch.
torch. • Do not change Range switch position while cutting.
• When Range switch is in High position, always use 1/8 in (3 mm) Arcing inside switch can damage contacts, causing switch to fail.
stand-off distance between torch tip and workpiece (see stand-off
guide installation instructions in torch Owner’s Manual).
1 Range Switch
Use switch to select cutting output.
Use Low position when cutting thin
material, and when making shal-
low gouges.
Use High position when cutting
thicker material, and when making
deeper gouges.
1
Ref. ST-143 671
Figure 4-3. Range Switch
1 Ready Light
Use light to tell if unit is ready for
operation.
Ready light comes on when Power
switch is placed in On position, in-
dicating that all safety shutdown
systems are okay.
If Ready light does not come on,
check Trouble Lights (see Section
1 7-2B).
Figure 4-4. Ready Light

CAUTION
CUTTING WHEN GAS/AIR SWITCH IS IN GOUGE POSITION will damage torch.
• Do not cut when in Gouge position.
• Use Gouge position for gouging only. The Gouge position provides an inadequate supply of airflow for cooling during cutting.
1 Gas/Air Switch
Use switch to safely adjust gas/air
pressure without activating cutting
output, and to set output for cutting
or gouging.
Place switch in Pressure Set posi-
tion to adjust gas/air pressure.
1 When the Power switch is turned
On, the air solenoids activate.
Place switch in Cut position to cut.
Place switch in Gouge position to
gouge.
2 Air Filter/Regulator
3 Pressure Adjustment Knob
Lift knob and turn to adjust pres-
sure. Push knob down to lock in
setting.
Setting Gas/Air Pressure
3
Requires 80-150 psi Set To
(552-1034 kPa) Supply 50 psi (345 kPa)
Set Switches Turn On Gas/Air Supply Adjust Pressure Set Switch To

Begin Cutting
Or Gouging
Ref. ST-143 671 / Ref. ST-129 418-B
Figure 4-5. Gas/Air Switch And Setting Gas/Air Pressure

1 Power Switch
1 2 Pilot Light
Use switch to turn unit, pilot light,
and fan On and Off.
2
Figure 4-6. Power Switch And Pilot Light
CAUTION
HITTING TORCH ON A HARD SURFACE to remove TIP AND ELECTRODE WEAR BEYOND
spatter can damage torch. R E C O M M E N D E D VA L U E S o r O P E R AT I O N
• Do not clean torch by hitting it against a hard surface. WITHOUT TIP OR ELECTRODE can damage torch.
• Hitting hard surfaces can damage torch parts and stop proper • Inspect shield cup, tip and electrode before cutting or whenever
operation. cutting speed has been significantly reduced (see torch manual).
• Do not operate torch without a tip or electrode in place.
• Use correct stand-off distance.
Install & Put On Personal Check Torch Check Gas/Air Set Turn On
Connect Safety (See Torch Pressure Controls Power Source
Equipment Equipment Manual) (See Figure 4-5)
Begin
Cutting
Example Of Operation
Place torch tip on edge Press trigger. After 2 seconds of preflow, After cutting arc starts, slowly
of metal, or allow correct pilot arc starts. Pilot arc stops after 2 start moving torch across metal.
stand-off distance. seconds if cutting arc does not start.
Adjust torch speed so Pause briefly at end of Postflow continues for 20 seconds
sparks go through metal cut before releasing trigger. after releasing trigger; cutting arc
and out bottom of cut. can be instantly restarted during postflow.
ST-161 698
Figure 4-7. Sequence Of Plasma Arc Cutting (PAC)

CAUTION
CUTTING WHEN GAS/AIR SWITCH IS IN GOUGE TIP AND ELECTRODE WEAR BEYOND
POSITION will damage torch. R E C O M M E N D E D VA L U E S o r O P E R AT I O N
• Do not cut when in Gouge position. WITHOUT TIP OR ELECTRODE can damage torch.
• Use Gouge position for gouging only. The Gouge position provides • Inspect shield cup, tip and electrode before cutting or whenever
an inadequate supply of airflow for cooling during cutting. cutting speed has been significantly reduced (see torch manual).
• Do not operate torch without a tip or electrode in place.
HITTING TORCH ON A HARD SURFACE to remove
spatter can damage torch.
• Use correct stand-off distance.
• Do not clean torch by hitting it against a hard surface.

• Hitting hard surfaces can damage torch parts and stop proper
operation.
Install & Install Gouging Put On Personal Check Torch Check Gas/Air Set
Connect Tip (See Torch Safety (See Torch Pressure Controls
Equipment Manual) Equipment Manual) (See Figure 4-5)
Turn On Begin
Power Source Gouging
Example Of Gouging Operation
Place torch tip on metal Press trigger. After 2 seconds of Establish arc length of 1 to 1-1/2 in
at about a 40° angle or less. preflow, pilot arc starts. Pilot arc (25 - 38 mm), and slowly
stops after 2 seconds if gouging start moving torch across metal.
arc does not start.
Adjust torch speed, arc length and angle Release trigger. Postflow continues
as needed. Direct sparks away from for 20 seconds. Gouging arc can be
torch. Do not gouge too deeply in one instantly restarted during postflow.
pass. Make repeated passes if needed.
Ref. ST-162 317
Figure 4-8. Sequence Of Plasma Arc Gouging (PAG)

SECTION 5 – THEORY OF OPERATION
ON OFF
Power Switch (S1)
Approx.
2 sec
Trouble Lights (PC3)
Ready Light (PL2)
Torch Switch
Postflow
Low Air Solenoid (AS1) 20
sec
High Air Solenoid (AS2)
2
Preflow Time sec
High Frequency Before HF
Pilot Arc
Reed Switch (RS1)
Output Current
Ref. S-0518
Figure 5-1. Operation Sequence

1 Power Switch S1
Provides on/off control of power to
main transformer T1, and fan mo-
tor FM.
2 Input Terminal Board TE1
Provides means for operation on 3
different input voltages.
3 Fan Motor FM Fan Motor FM
Provides cooling of internal com-
ponents, turns on when contactor 230 VAC
W is energized.
1 2 4 W
4 Main Transformer T1
Single-Phase Power Main
Supplies power to output circuit, Line Input Input Terminal
timer/control board PC1, and relay Switch Board TE1 Transformer
Power S1 T1
board PC2. Primary Secondary
5 Line Contactor W
Connects input power from main 18 VAC
transformer T1 to output circuit.
6 Relay Board PC2 6
If PC2 senses an electrode-to-

nozzle short, PC2 locks unit out
through cup interlock circuit. Built– Relay Board
in delays provide relay isolation of PC2
the sense circuits during high-fre-
quency operation.
7 Timer/Control Board PC1
Provides all timing and control
functions, and monitors safety in- Short/Cup High
terlocks. Figure 5-1 shows when Sensor Frequency
various machine functions are acti- Control
vated. 7
8 Ready Light PL2
Lights when PC1 has checked all
safety interlocks and unit is ready
for operation.
9 Indicator Board PC3 8
Has LED’s which light if PC1 Ready
senses air pressure, temperature, Light
or torch tip problems. PL2
10 Air Filter/Regulator Timer/Control Board PC1
9
Filters and regulates pressure of
input air. Indicator
Board
11 Pressure Switch S4 PC3
Provides signal to PC1 to shut
down unit if improper air pressure 5
is present.
Line
12 Air Solenoids AS1/AS2 Contactor
W
AS1 allows airflow for preflow, pilot
arc, cutting, and postflow. AS2 al-
lows airflow for cutting. Orifice pro-
vides path for low airflow when
AS2 is not activated.
13 Main Rectifier SR1 10 11 12
Changes the ac input from T1 to
Input 80-150 PSI Air Filter/ Pressure Low Air
full-wave rectified dc. Regulated by Air Switch Solenoid
PC1 to control output current. Regulator S4 AS1
Supply
14 Range Switch S2, Resistor
R2
S2 selects cutting output range. R2
limits pilot arc to approximately 18
amperes.
Figure 5-2. Functional Diagram

15 Pilot Arc Relay CR1
Energized by PC1 to allow pilot
current flow. Deenergizes when
reed switch RS1 senses cutting
current.
14 18
16 High Frequency Circuit
Range Switch Reed Consists of HF transformer T3,
S2, Switch
Resistor R2 RS1 spark gap G, capacitor C13, and
coupling coil T2.
Synchronized with CR1. HF circuit
provides high frequency energy for
13 + 15 the pilot arc (tip) to jump to the torch
(electrode). When resistance be-
Main Pilot Arc tween work and electrode is low
Rectifier Relay CR1 enough, current starts flowing
SR1 through work rather than pilot,
– starting cutting arc and stopping
high frequency.
17 Stabilizer Z1
17 16
Pilot (+) Smooths out output current.
High
Stabilizer Frequency 18 Reed Switch RS1
Z1 Circuit Senses when cutting current is
Electrode (–) present and provides control signal
to PC1 to stop pilot arc and HF,
start high airflow, and activate the
trigger hold circuit.
Work (+) 19 Gas/Air Switch S3

Test position allows AS1 and AS2
to activate without activating cut-
ting output so air pressure can be
safely set.
20 HF Noise Filters L1 Thru L14,
C14 Thru C17
Prevents high frequency noise
(HF) from entering the circuitry.
19
Gas/Air
Switch
S3
12
High Air
Solenoid
AS2
12 20 AC Or DC Control Circuits
HF Noise
Orifice Filters L1–L4, To Torch 1φ Power
C14–C17
Cutting And Pilot Current Circuits

SECTION 6 – TROUBLESHOOTING
6-1. Troubleshooting Table
WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Do not touch live electrical parts. • Keep away from moving parts.
• Turn Off power source, and disconnect input power
before inspecting, maintaining, or servicing.
• Disable high frequency by disconnecting lead 25
from coil of relay CR1 before testing unit. STATIC ELECTRICITY can damage parts
on circuit boards.
HOT PARTS can cause severe burns. • Put on grounded wrist strap BEFORE handling
• Allow cooling period before servicing unit. boards or parts.
• Use proper static-proof bags.
Have only qualified persons familiar with and following

standard safety practices perform troubleshooting
procedures.
smwarn1.1* 2/93
Table 6-1. Cutting Power Source Trouble
NOTE Use MILLER Testing Booklet (Part No. 150 853) when checking solid-state parts.
Trouble Remedy Section

No cutting output; Power light off; Place Power switch in On position. Figure 4-6
Ready light off; Trouble Lights off; fan
motor does not run.
Place line disconnect device in On position. 3-4B
Check line fuse(s) and replace if necessary or reset circuit break- 3-4B
ers.
Check continuity of Power switch S1, and replace if necessary. 6-2
No cutting output; Power light on; Be sure work clamp is connected. 3-2
Ready light on; Trouble Lights off; fan
motor running.
Check for proper torch switch PB1 lead connections. See torch ––
manual.
Check fuse F1 on timer/control board PC1, and replace if neces- 7-2A
sary.
Check coil voltage and connections of contactor W. Check conti- 6-2
nuity of coil and condition of contacts. Replace W if necessary.
Check bypass capacitors C1-C6, C8, C11, and C14-C17 for a 6-2
short or open, and check for proper connections. Replace capaci-
tor(s) if necessary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.
No cutting output; Power light on; Check fuses F1 thru F4 on timer/control board PC1, and replace 6-4, 7-2A
Ready light off; Trouble Lights off; fan if necessary.
motor running.

necessary.

No gas/air flow; Power light on; Ready Check fuses F1 thru F4 on timer/control board PC1, and replace 6-4, 7-2A
light on; Trouble Lights off; fan motor if necessary.
running.
No gas/air flow; Power light on; Ready Check fuse F4 on timer/control board PC1, and replace if neces- 7-2A
light off; Trouble Lights off; fan motor sary.
running.

necessary.
No pilot arc or high frequency; difficulty Check fuse F3 on timer/control board PC1, and replace if neces- 6-4, 7-2A
in establishing an arc. sary.
Check and adjust spark gap G if necessary. 7-3
Check for damaged torch or torch cable (see torch manual). ––
Check capacitor C13 for a short or open, and check for proper con- 6-2
nections. Replace C13 if necessary.
Check coil voltage and connections of control relay CR1. Check 6-2
continuity of coil and condition of contacts. Replace CR1 if neces-
sary.
Check relay board PC2 and connections, and replace if neces- 6-5
sary.
necessary.
Gas/Air Trouble Light on; Ready light Place Gas/Air switch in Cut or Gouge position. Figure 4-5
off.
Check for correct gas/air pressure adjustment. Figure 4-5
Check for sufficient gas/air supply pressure. Figure 4-5
Clean air filter/regulator filter. See instructions supplied with air fil- ––
ter/regulator.
Torch Tip Trouble Light on; Ready light Check torch shield cup and shield cup detector pins. See torch ––
off. manual.
Check to make sure torch electrode is not touching tip inside the ––
torch. See torch manual.
Check to make sure torch connections are tight on terminal strip 7-4
1T.
Check fuse F1 on relay board PC2, and replace if necessary. 6-5, 7-2A
necessary.
Temperature trouble light on; Ready Allow a cooling period of approximately fifteen minutes. If thermo- 7-2B
light off. stat TP1 remains open, check continuity and replace if necessary.
No low gas/air flow (preflow and post- Check coil voltage and connections of air solenoid AS1. Check 6-2
flow air). continuity of coils. Replace AS1 if necessary.
Check and clean orifice parallel with air solenoid AS2, if neces- ––
sary.
necessary.

No high gas/air flow (cutting air), or de- Check reed switch RS1, and replace if necessary. ––
creased cutting ability.
Check coil voltage and connections of air solenoids AS1 and AS2. 6-2
Check continuity if coils. Replace AS1 and AS2 if necessary.
Check connections of relays on timer/control board PC1. Check 6-4
continuity of coils and condition of contacts. Replace relay(s) if
necessary.
necessary.
Fan motor does not run; Power light and Check coil voltage and connections of fan motor FM. Check conti- 6-2
Ready light both on. nuity of coil. Replace FM if necessary.
Trouble Lights not working. Check display board PC3 and connections, and replace if neces- 6-6
sary.
necessary.
Electronic equipment in plasma arc cut- HF interference problem. Check for proper installation, and cor- 8
ting area not working properly. rect problem.
Table 6-2. Cutting Process Trouble

Sparks come out top of cut, or cut is not Torch travel speed too fast; reduce travel speed. Figure 4-7,
clean. Figure 4-8
Check torch tip and electrode and replace if necessary. See torch ––
manual.
Metal being cut is too thick. Figure 4-3
Low cutting output. Check position of input voltage jumper links, and check for proper 3-4
input voltage connections.
Arc goes out while cutting. Make sure torch tip is contacting metal while cutting in Low range, Figure 4-3,
or that correct stand-off distance is maintained while cutting in Figure 4-7,
High range. Figure 4-8
Be sure work clamp is securely attached. 3-2
Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed. Figure 4-7,
Figure 4-8
Check torch tip and electrode and replace if necessary. See torch ––
manual.
Tip wears at higher rate than normal. Check diode D5, and replace if necessary. 6-2

NOTES

6-2. Troubleshooting Circuit Diagram For Power Source
WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts
• Do not touch live electrical parts. on circuit boards.
• Turn Off power source before making or changing • Put on grounded wrist strap BEFORE handling
meter lead connections and before disconnecting boards or parts.
or connecting any leads. • Use proper static-proof bags.
from coil of relay CR1 before testing unit.
procedures. smwarn2.1* 2/93
With Range switch S2 in High position, touching

Contactor W energizes torch tip nozzle to work causes Torch Tip light to
while torch switch come on and prevent arc from starting.
PB1 is pressed
R1
V1 V2/R1
V3
See Section 6-5

for PC2 data R2
Ready
Light
PL2
Power Contactor W
Light
PL1
V7
V6
Temperature
Gas/Air
Torch Tip
See also
Section 6-6 for
PC3 data
Figure 6-1. Troubleshooting Circuit Diagram For Power Source

Resistance Values Voltage Readings
a) Tolerance – ±10% unless specified a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input b) Reference – to circuit common (lead 43)
power before checking resistance unless noted
R1 All values for T1 are less than 1 ohm c) Wiring Diagram – see Section 8
R2 Less than 1 ohm
V1 230 volts ac with Power switch S1 On
R3 5.3 ohms
V2 226 volts ac with torch switch pressed
R4 6.1 kilohms
V3 +270 volts dc
V4, V5 115 volts ac with torch switch pressed
V6 +24 volts dc
Reed switch RS1 detects current transfer
to work and switches on High Solenoid V7 24 volts ac with Power switch S1 On
AS2. RS1 also disables HF circuit.
V8 24 volts ac during low airflow
V9 24 volts ac during high airflow
See Section 6-3 V10 +270 volts dc with reed switch RS1 leads
for waveforms 36 and 37 jumpered together
A, B V11 +270 volts dc with HF disabled
+24 volts dc sent to electrode to nozzle
V10, A, B
interlock circuit during idle for indicating an
electrode-to-nozzle short
V11
V5, R3
V4 See Section 7-3
for spark gap
adjustment
R4
Pilot Arc Relay CR1
Pressure switch
S4 requires 35
PSI to close
See Section 6-4

for PC1 data
Test Equipment Needed:
V9
V8 Effective with Serial

No. KA8800669, a
Gouge position was
added to Gas/Air
switch S3. ST-800 092-A / SC-169 194

6-3. Waveforms For Section 6-2
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source before making or changing any test equipment leads or cable connections.
• Disable high frequency by disconnecting lead 25 from the coil of relay CR1 before testing unit.
Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
smwarn3.1* 12/93
5 ms 50 V 5 ms 50 V
gnd
A. DC Open-Circuit Voltage B. 110 Volts DC, 50 Amperes, Range Switch

S2 In High Position (Resistive Load)
Figure 6-2. Waveforms For Section 6-2

6-4. Troubleshooting Timer/Control Board PC1
WARNING
procedures.
smwarn2.1* 2/93
Be sure plugs are secure before

testing. Use Table 6-3 for specific
values during testing.
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Fuse F4
6 Fuse F2
7 Fuse F1
8 Fuse F3
See Section 7-2 for fuse informa-
tion.
8 4 7 6
ST-800 092-A / SB-131 064-D
Figure 6-3. Timer/Control Board PC1 Testing Information (Use With Table 6-3)
Table 6-3. Timer/Control Board PC1 Test Point Values (Use With Figure 6-1 And Figure 6-3)
Voltage Readings:
a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 43) unless noted
Receptacle Pin Value
RC1 A 18 volts ac input with respect to RC1 pin B
B 18 volts ac input with respect to RC1 pin A
C, D, E, F Not used
G, H, J, K +24 volts dc output when trouble lights are off; 0 volts dc (grounded) when trouble light is on
C Circuit common (lead 43)
D 24 volts ac input
E, F, G, H, J, +24 volts dc output

K, L, M
N, P Not used
RC3 A Circuit common
B 24 volts ac output to energize contactor W
C Circuit common
D 24 volts ac output to energize low air solenoid AS1
E Circuit common
F 24 volts ac output to energize high air solenoid AS2
G +24 volts dc input when gas/air pressure switch S4 senses sufficient air pressure (interlock)
H +24 volts dc input when shield cup is installed and no tip-to-electrode short exists
J +24 volts dc input when normally-closed thermostat TP1 is closed
K +24 volts dc input when torch switch is closed
L +24 volts dc input from reed switch RS1 when RS1 senses output current
M +24 volts dc input from Gas/Air switch S3 when S3 is in Pressure Set position
N Circuit common
P +24 volts dc output to activate HF contactor CR1
R 115 volts ac output when HF is activated
S 115 volts ac output to power HF circuit

6-5. Troubleshooting Relay Board PC2
WARNING
procedures.
smwarn2.1* 2/93

testing. Use Table 6-4 for specific
values during testing.
1 Relay Board PC2
2 Receptacle RC1
3 Terminal A
4 Terminal B
5 Fuse F1 For Torch Tip Sens-
ing Circuit
See Section 7-2 for fuse informa-
tion.
3 4
2 5
ST-800 092-A / SA-128 922-C
Figure 6-4. Relay Board PC2 Testing Information (Use With Table 6-4)
Table 6-4. Relay Board PC2 Test Point Values (Use With Figure 6-1 And Figure 6-4)
Voltage Readings:
a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 43) unless noted
Receptacle Pin Value
Terminal A -24 volts dc input with respect to terminal B if no tip-to-electrode short exists; 0 volts dc if short ex-
ists
Terminal B +24 volts dc input with respect to terminal A if no tip-to-electrode short exists; 0 volts dc if short
exists
C, D Not used
E +24 volts dc input when HF is on. If voltage is not present, check timer/control board PC1 (see Sec-
tion 6-4). This voltage energizes relays CR1 and CR2, thereby isolating the circuit which detects
electrode-to-nozzle shorts from HF. It also energizes CR3 turning on the HF circuit
F Not used
G Circuit Common
H +24 volts dc output if no tip-to-electrode short exists. If a short is detected, relay CR4 contacts
open, thereby activating the shield cup detector circuit
J Not used
K +24 volts dc output when cup is in installed correctly
L Not used
M 115 volts ac input when unit is ready for operation and Ready light is on; 0 volts ac when Ready
light is off
N Not used
P 115 volts ac output when HF and pilot arc are on

6-6. Troubleshooting Display Board PC3
WARNING
procedures.
smwarn2.1* 2/93

testing.
1 Display Board PC3
2 Connector CN1
+24 volts dc input is supplied to
CN1-1 from timer/control board
PC1.
3 Trouble Lights
LED’s turn on when appropriate
LED cathode is grounded through
a limit resistor. See also Section
7-2B.
1 2
ST-800 092-A / SA-165 553-A
Figure 6-5. Display Board PC3 Testing Information

6-7. Input Voltage Labels And Connection Diagrams
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and disconnect input power before inspecting or servicing.
Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
smwarn4.1* 12/93
1 Input Voltage Label And

Connection Diagram – Only
One Label Is On Unit
2 Terminal Strip TE1
Ref. ST-800 082 / SA-146 898-A / SA-146 899-B
Figure 6-6. Input Voltage Labels And Connection Diagrams

SECTION 7 – MAINTENANCE
WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Do not touch live electrical parts. • Keep away from moving parts.
• Turn Off power source, and disconnect input power
before inspecting, maintaining, or servicing.
STATIC ELECTRICITY can damage parts
HOT PARTS can cause severe burns. on circuit boards.
• Allow cooling period before maintaining or • Put on grounded wrist strap BEFORE handling
servicing. boards or parts.
Maintenance to be performed only by qualified

persons. swarn8.1* 2/93
7-1. Routine Maintenance
Turn Off all power before maintaining.
Each Use 3 Months 3 Months
Check Service
Replace
Gas/Air Air Filter/
Cracked
See Regulator
Pressure Regulator Parts
Figure Filter ––
4-5 Manual Torch Body
Check
Torch Tip, Replace
Electrode, Unreadable
And Shield Parts Labels
Torch
Manual Cup List Gas/Air Hose Torch Cable
Tape
Every Week Torn 6 Months
Outer
Covering
Check ––
Blow Out
Torch Tip OR Or
Shutdown Clean
Vacuum
Section System And
Inside
7-2B Tighten
Torch
Section During Heavy Service,
7-4 Connections
–– Clean Monthly
Adjust
Spark
Gap
Section
7-3
Figure 7-1. Maintenance Schedule

7-2. Overload Protection

Section 7 before proceeding.
A. Fuses
Turn Off power and disconnect in-

put power.
6 Remove both side panels.
2 PC1 Fuse F1
3 PC1 Fuse F2
4 PC1 Fuse F3
5 PC1 Fuse F4
Fuses on PC1 protect the circuit
board from overload. If fuse F1, F2,
or F4 opens, Ready light goes off,
and unit does not cut. If fuse F3
opens, high frequency output
stops.
6 Relay Board PC2
7
7 PC2 Fuse F1
Fuse F1 on PC2 protects torch tip
sensing circuitry on PC2 from
overload. If F1 opens, Ready light
goes off, and unit does not cut.
Check fuses and replace as need-
ed. See Parts List for fuse ratings.
Use proper tool when removing
fuses.
Reinstall side panels.
1 4 2 3
Tools Needed:
3/8 in
ST-800 092 / SA-128 922-B / SB-131 064-D
Figure 7-2. Fuses

B. Trouble Lights
If certain problems occur, the

Ready light goes off, a trouble light
comes on, and output stops.
1 Gas/Air Light
Lights if low gas/air pressure is
sensed by pressure switch S4.
Check for proper gas/air pressure
1 (see Figure 4-5).
2 2 Torch Tip Light
3 Lights if torch shield cup is loose, or
if a short exists between tip and
electrode. Check shield cup, tip,
and electrode (see torch manual).
Check torch tip shutdown system
once a week (see Figure 7-5).
3 Temperature Light
Lights if power source overheats
(see Figure 7-4).
Ref. ST-143 671
Figure 7-3. Trouble Lights
15
minutes
When overheated, thermostat Let fan run for When Ready light comes back
opens, output stops, and cooling 15 minutes. on, start cutting.
fan keeps running.
ssb10.1* 1/94 – Ref. ST-126 576-B
Figure 7-4. Overheating Protection
1 Torch Shield Cup

Turn Power On and loosen shield
1
cup. If shutdown system works
properly, Ready light goes off and
Torch Tip light comes on. If not, turn
power Off and check shield cup de-
tector pins (see torch manual). If
system works properly, retighten
shield cup.
Set Range switch to High position.
Without pressing torch trigger, mo-
mentarily touch torch tip to work-
piece. If shutdown system works
properly, Ready light goes off and
Torch Tip light comes on. If not, turn
power Off and contact Factory Ser-
vice Department.
Ref. ST-134 696-A
Figure 7-5. Checking Torch Tip Shutdown System

7-3. Adjusting Spark Gap

Turn Off power source and discon-

nect input power.
Remove left side panel.
1 Tungsten End Of Point
Do not clean or dress tungsten.
Replace point if tungsten end dis-
appears.
2 Spark Gap
Normal spark gap is 0.030 in
(0.762 mm).
If spark gap is okay, reinstall side
panel. If adjustment is needed,
continue as follows:
3 Adjustment Screw
Loosen screw. Place feeler gauge
of proper thickness in spark gap.
4 Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
adjustment screw.
Reinstall side panel.
3
2
4
Tools Needed:
3/8 in
0.030 in (0.762 mm) 5/32 in
Ref. ST-800 081 / S-0201
Figure 7-6. Adjusting Spark Gap

7-4. Torch And Work Cable Connections

If torch or work cable needs to be

replaced, proceed as follows:
Turn Off power source, and dis-
9 connect input power. Remove left
side panel.
1 Access Hole
1 2 3 4 Insert cables through access hole.
S-125 022-B 2 Work Cable
3 Work (+) Output Terminal
4 Torch Cable
5 Torch (–) And Gas/Air Output
Connector
8 6 Pilot Cable
7 7 Pilot (+) Output Terminal
6
Connect cables as shown.
4
8 Terminal Strip 1T
9 Connection Label
10 Shield Cup Detector Leads 1
And 2
5 11 Torch Switch Leads 3 and 4
Refer to label and connect leads as
1 shown.
10 Reinstall side panel.
2
11
Tools Needed: Side View
3/8 in
1/2, 11/16 in
Ref. ST-800 080
Figure 7-7. Torch And Work Cable Connections

SECTION 8 – HF IN PLASMA ARC CUTTING
mod6.2 5/94
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers,
and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the
installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and
shielding as shown in Figure 8-3 to minimize the possibility of interference.
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
1 1 Plasma Arc Torch
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
2 High-Frequency Voltage
ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
Used inside torch to ionize gap
between electrode and tip to help
ÉÉÉÉÉÉÉÉ
2 High start the pilot arc.
Frequency (HF)
ÉÉÉ ÉÉÉ
6 3 Electrode
3 4 Pilot Arc
5
5 Tip
Work 6 Shield Cup
Plasma Arc Cutting (PAC)
4
S-0753
Figure 8-1. High Frequency In Plasma Arc Cutting (PAC)
1 Sources Of Direct
Cutting Zone High-Frequency Radiation
3 High-frequency source (Plasma
Arc Cutting power source), cables,
torch, work clamp, workpiece, and
50 ft 3
(15 m) work table.
2 Sources Of Conduction Of
High Frequency
3
Input power cable, line disconnect
3 device, and input supply wiring.
2
3 Sources Of Reradiation Of
High Frequency
1
Ungrounded metal objects, light-
ing, wiring, water pipe and fixtures,
external phone and power lines.
2 1
S-0754
Figure 8-2. Sources Of High-Frequency Radiation From Incorrect Installation

7
Cutting Zone
3 50 ft
(15 m) 50 ft
(15 m)
1
6
2
9
9 Ground All
Metal Objects
And All Wiring
In Cutting Zone
Using #12 AWG Wire
Ground
Workpiece
If Required
By Codes
Nonmetal Building
9
9
11
Metal Building
10
S-0755
1 Plasma Arc Cutting Source 5 Conduit Joint Bonding And Grounding 9 Grounding Rod
Ground metal machine case, line discon- Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground Consult the National Electrical Code for
nect device, input supply, and workpiece (if specifications.
required). conduit every 50 ft (15 m).
6 Water Pipe And Fixtures
2 Center Point Of Cutting Zone 10 Windows And Doorways
Ground water pipe every 50 ft (15 m).
Midpoint between high-frequency source Cover all windows and doorways with
and cutting torch. 7 External Power Or Telephone Lines
grounded copper screen of not more than
Locate high-frequency source at least 50 ft 1/4 in (6.4 mm) mesh.
3 Cutting Zone (15 m) away from power and phone lines.
A circle 50 ft (15 m) from center point in all 8 Metal Building Panel Bonding 11 Overhead Door Track
directions. Methods
4 Torch And Work Cables Bolt or weld building panels together, install Ground the track.
copper straps or braided wire across
Keep cables close together. seams, and ground frame.
Figure 8-3. Correct Installation

NOTES

SECTION 9 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact factory for actual circuit, if needed.
The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
1 Know unit Model and Serial or Style Number.
2 Use this list to find diagram number.
3 Include your FAX number or mailing address with your request.
4 FAX Technical Publications Department at 414-735-4011 or call 414-735-4356.
Circuit Wiring Main Reason

Model Serial Or Style Number
Diagram Diagram For Change
Spectrum 500 JK542460 thru JK669758 SC-125 674-A D-125 926-B♦♦

200/230 V
JK669759 thru KA737050 C-130 636-A♦♦ D-131 368-B♦♦ Change coupling coil in HF
panel
KA737051 thru KA880068 C-130 636-A♦♦ D-131 931-A♦♦ Change coupling coil in HF
panel
KA880069 thru KE648702 C-136 393-A♦♦ D-136 586♦♦ Added gouge circuit
KE648703 and following SC-169 194 SD-169 195 New transformer and stabi-
lizer
230/460 V KD427345 thru KE648702 C-136 393-A♦♦ D-161 104♦♦
lizer
460/575 V KD427345 thru KE648702 C-136 393-A♦♦ D-136 587♦♦
lizer
Circuit Board PC1 JK542460 thru JK581592 D-124 532♦♦
JK581593 thru JK705565 D-128 917♦♦
JK705566 and following SD-131 065
Circuit Board PC2 JK542460 thru JK581592 B-124 519-A♦♦
JK581593 and following SB-128 923
Circuit Board PC3 JK542460 thru KA834915 A-129 640♦♦
KA834916 thru KB058479 A-135 750♦♦
KB058480 and following SA-143 674
♦♦ Not included in this manual

SC-125 674-A
Figure 9-1. Circuit Diagram For Spectrum 500 (200/230) Effective With Serial No. JK542460 Thru JK669758
SC-169 194
Figure 9-2. Circuit Diagram For Spectrum 500 Effective With Serial No. KE648703 And Following
Figure 9-3. Wiring Diagram For Spectrum 500 (200/230V) Effective With Serial No. KE648703 And Following
SD-169 195

Figure 9-4. Wiring Diagram For Spectrum 500 (230/460V) Effective With Serial No. KE648703 And Following
SD-169 197

Figure 9-5. Wiring Diagram For Spectrum 500 (460/575) Effective With Serial No. KE648703 And Following
SD-169 196

Figure 9-6. Circuit Diagram For Timer/Control Board PC1 Effective With
Serial No. JK705566 And Following
SD-131 065

SB-128 923
Figure 9-7. Circuit Diagram For Relay Board PC2 Effective With Serial No. JK581593 And Following
SA-143 674
Figure 9-8. Circuit Diagram For Display Board PC3 Effective With Serial No. KB058480 And Following
July 1996 Form: TM-204
Effective With Serial No. JK542460
SECTION 10 – PARTS LIST
Spectrum 500
Air Plasma Cutting System: Power Source, Torch, And Air Regulator

TM-204 Page 50
9
10 Figure 10-2
8
1
Figure 10-3
3 4
7
27 2
11 12
13 Figure 10-3
15
16
18 17
23 14
19
20
26 25
Spsectrum 500
24
Figure 10-4
22
21
ST-126 405-D
Figure 10-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . 125 690 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 128 097 . . STRIP, comb mrm .007 x 2.500 x 12.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . C7 . . 094 961 . . CAPACITOR, elctlt 2500uf 450VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 022 160 . . CLAMP, capacitor 3.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 124 737 . . HF PANEL, (Prior to JK669759) (Fig 10-3) (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 130 338 . . HF PANEL, (Eff w/JK669759 thru KA737050) (Fig 10-3) (consisting of) . . . . 1
. . . 5 . . . . . . . . . . 131 932 . . HF PANEL, (Eff w/KA737051 and on) (Fig 10-3) (consisting of) . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 124 707 . . . . BRACKET, mtg HF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . R3 . . 083 784 . . RESISTOR, WW fxd 100W 10 ohm (Eff w/KA737051) . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 134 220 . . FRAME, lifting (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 026 627 . . GASKET, lifting eye cover (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . Fig 10-2 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . Z . . . 124 692 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . C10 . ♦129 283 . . CAPACITOR, (Prior to JK669759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . C1 . ♦129 284 . . CAPACITOR, (200/230 or 460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . C2 . ♦129 285 . . CAPACITOR, (200/230 or 460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . C1,2 ♦129 285 . . CAPACITOR, (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . TE1 . ♦088 020 . . TERMINAL ASSEMBLY, pri 1ph dual voltage (200/230) (Fig 10-7) . . . . . . . . . 1
. . . 14 . . . . T1 . . 125 824 . . TRANSFORMER, pwr main (200/230) (Prior to KE648703) (consisting of) . . 1
. . . 15 . . . TP1 . . 166 063 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 158 614 . . . . COIL, pri (200/230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 131 698 . . . . COIL, pri (230/460) (Prior to KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 158 850 . . . . COIL, pri (230/460) (Eff w/KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 128 710 . . . . COIL, pri (460/575) (Prior to KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 158 851 . . . . COIL, pri (460/575) (Eff w/KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 124 554 . . . . COIL, sec (Prior to KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 158 613 . . . . COIL, sec (Eff w/KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 124 777 . . . . SHUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . T1 . . 169 310 . . TRANSFORMER, pwr main (200/230) (Eff w/KE648703) (consisting of) . . . . 1
. . . 15 . . . TP1 . . 166 063 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 169 314 . . . . COIL, pri 200/230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 169 315 . . . . COIL, pri 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 169 317 . . . . COIL, pri 460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 173 612 . . . . COIL, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 124 777 . . . . SHUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 127 686 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 095 094 . . WHEEL, poly-olefin 6 in dia x 1.500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . 602 247 . . WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . 095 319 . . AXLE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 081 960 . . . . RING, retaining ext. .500 shaft x .035 thk (Eff w/KA797307) . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 032 524 . . PIN, cotter .187 x 1.500 (Prior to KA797307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . 124 701 . . BASE, (Prior to KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 134 215 . . BASE, (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 124 704 . . PANEL, side RH (Prior to KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 134 218 . . PANEL, side RH (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . Fig 10-4 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 124 703 . . PANEL, side LH (Prior to KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 134 217 . . PANEL, side LH (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . +124 706 . . COVER, top (Prior to KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . +134 216 . . COVER, top (Eff w/KA783999) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 136 607 . . TIP, gouge GS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . 132 658 . . GUIDE, stand-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 010 368 . . CLAMP, grd 200A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 026 843 . . INSULATOR, vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Item Dia. Part
Figure 10-1. Main Assembly (Continued)
STANDARD OPTIONS
................ 042 306 . . MG AIR FILTER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

................ 125 929 . . . . FILTER, air 1/4NPT 100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 010 296 . . . . FITTING, hose-brs elb M 1/4NPT x 5/8-18R . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 125 688 . . . . HOSE, air 18 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 042 312 . . REPLACEMENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Prior to KE593886 these items were located on rear panel.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
5
6
2
1 7
29 10 9 8
11
12
28
13
14
15
27
21 20 19
26
25 24
23 18 17 16
22
ST-126 424-F
Figure 10-2. Panel, Rear w/Components

Item Dia. Part
Figure 10-2. Panel, Rear w/Components (Fig 10-1 Item 10)
. . . 1 . . . . R1 . . 094 964 . . RESISTOR, WW fxd 375W 161 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 124 713 . . BRACKET, mtg resistor (Prior to KA737051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . 131 933 . . BRACKET, mtg resistor (Eff w/KA737051 thru KA783998) . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . 124 713 . . BRACKET, mtg resistor (Eff w/KA783999 and on) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . 032 662 . . BLADE, fan 10 in 5wg .250 bore CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 124 702 . . PANEL, rear (Prior to KD346698) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 157 604 . . PANEL, rear (200/230V) (Eff w/KD346698) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 124 702 . . PANEL, rear (230/460V & 460/575V) (Eff w/KD346698) . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 125 044 . . BRACKET, mtg air filter/regulator (Prior to KC183768) . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 168 253 . . BRACKET, mtg air filter/regulator (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 168 252 . . NUT, .187-12 knrl (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 125 145 . . GAUGE, air 0-160psi 1/8NPT (Prior to KC183768) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 153 277 . . GAUGE, air 0-160psi 1/4NPT (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 125 688 . . HOSE, air 18 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 125 042 . . REGULATOR/FILTER, 150psig in 0-125psig out 1/4NPT
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 153 276 . . REGULATOR/FILTER, 150psig in 0-125psig out 1/4NPT
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 128 102 . . CABLE, pwr No. 6ga 3/c (Prior to KD346698) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 157 603 . . CABLE, pwr (200/230V) (Eff w/KD346698) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 128 102 . . CABLE, pwr (230/460V & 460/575V) (Eff w/KD346698) . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 044 426 . . CONNECTOR, clamp cable .690/1.070 (Prior to KD346698) . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 010 467 . . CONNECTOR, clamp cable 1.250 (200/230V) (Eff w/KD346698) . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 044 426 . . CONNECTOR, clamp cable .690/1.070 (230/460V & 460/575V)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/KD346698) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 110 498 . . HOSE, air 13 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 071 270 . . FITTING, pipe brs tee st 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 13 . . . . . . . . . . 124 714 . . FITTING, brs-barbed M 1/4tbg x 1/4NPT 1/16 ID orf (Prior to KD414913) . . . 1
. . . 13 . . . . . . . . . . 161 308 . . FITTING, brs barbed M 1/4tbg x 1/4NPT (Eff w/KD414913) . . . . . . . . . . . . . . . 1
. . . 14 . . AS1,2 . 035 630 . . VALVE, 24VAC/6VDC 2 way 1/4 IPS 1/8 orf (Prior to JK559100) . . . . . . . . . . . 2
. . . 14 . . AS1,2 . 109 930 . . VALVE, 24VAC 2 way 1/4 IPS 1/8 orf (Eff w/JK559100) . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . 082 589 . . FITTING, brs cprsn conn M 1/4tbg x 1/4NPT (Prior to JK559100) . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 010 830 . . FITTING, pipe brs nipple hex 1/4NPT (Eff w/JK559100) . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 010 296 . . FITTING, hose brs elb M 1/4NPT x .625-18R . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 010 869 . . FITTING, pipe brs bushing 1/4 x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . S4 . . 094 963 . . SWITCH, pressure air 40-100 lb (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . S4 . . 161 134 . . SWITCH, pressure air NO-NC cont adj 35 to 55psi (Eff w/KD414913) . . . . . . 1
. . . 19 . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT (Prior to KD414913) . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 602 958 . . FITTING, brs barbed M 1/4tbg x 1/4NPT (Eff w/KD414913) . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 010 323 . . CLAMP, hose .250-.625clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . 21 . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD (Eff w/KD414913) (order by ft) . . . . . . . . . . . . . 1ft
. . . 22 . . . . W . . . 035 519 . . CONTACTOR, def prp 40A 3P 24V (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 024 493 . . . . COIL, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . CR1 . 605 855 . . CONTACTOR, def prp 40A 3P 120V (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 095 317 . . LINK, connecting contactor term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . SR1 . . 124 700 . . RECTIFIER, si diode (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . C3-6 . 031 688 . . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . C8 . . 141 233 . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . D1,2 . 117 452 . . . . DIODE, rect 85A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . D3,4 . 117 451 . . . . DIODE, rect 85A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . D5 . . 095 141 . . . . DIODE, rect 40A 1000V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RV1 . . 095 492 . . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . R2 . . 097 495 . . RESISTOR, w/ mtg-hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . FM . . 032 678 . . MOTOR, 1/50 hp 230VAC 1500RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 10-2. Panel, Rear w/Components (Fig 10-1 Item 10) (Continued)
. . . 28 . . . . . . . . . . 124 683 .. WINDTUNNEL, 11 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . RS1 . . 124 712 .. REED SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 045 852 .. CLIP, component .687dia mtg adh back (Prior to KC270763) . . . . . . . . . . . . . . 1
................ 124 698 .. BRACKET, mtg pri board (Prior to KE593886) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9
4 8
5 12
1 3 6 7 11
10
2
21
12
20 11
10
19 13
18
14
18
17 16 15
ST-126 407-B
Figure 10-3. HF Panel

Item Dia. Part
Figure 10-3. HF Panel (Fig 10-1 Item 5)
... 1 . . . . . . . . . . 127 830 . . FILTER, HF (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . 1T . . 038 839 . . . . BLOCK, term 20A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . L1-4 . 127 831 . . . . COIL, choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 4 . . . . . . . . . . 127 832 . . . . MOUNTING BOARD, choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . 124 627 . . ADAPTER, 90 deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . 125 689 . . FITTING, pipe brs adapter bhd .562-18 x .750-16 . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . 124 708 . . PANEL, mtg components (Prior to KF926822) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . 175 607 . . PANEL, mtg components (Eff w/KF926822) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . 605 886 . . WASHER, lock stl int tooth .750NP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . 605 884 . . NUT, stl hex half .750-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . 038 888 . . STUD, pri bd brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . C11,12 124 735 . . CAPACITOR, (Prior to JK669759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 13 . . . C11 . . 131 880 . . CAPACITOR, (Eff w/JK669759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . T3 . . 074 398 . . TRANSFORMER, high voltage 115V pri 3600V sec . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . 096 614 . . STRIP, reinforcing HF panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . G . . *020 603 . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 . . . . . . . . . . 020 622 . . HOLDER, points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 18 . . C9,13 . 096 761 . . CAPACITOR, mica .002uf 10000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 19 . . . . T2 . . 126 274 . . COIL, HF coupling (Prior to JK669759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . T2 . . 129 271 . . COIL, HF coupling (Eff w/JK669759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . 038 502 . . CABLE TIE, 0-3.000 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 21 . . C14-17 ♦124 736 . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.

♦Item is not part of HF Panel.

Item Dia. Part
Figure 10-4. Panel, Front w/Components (Fig 10-1 Item 25)
. . . 1 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . 124 705 . . PANEL, front (Prior to KB058480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 143 511 . . PANEL, front (Eff w/KB058480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . S3 . . 089 085 . . SWITCH, tgl SPST 20A 125VAC (Prior to KA880069) . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . S3 . . 088 409 . . SWITCH, tgl DPDT 15A 125VAC (Eff w/KA880069) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . S2 . . 090 328 . . SWITCH, tgl DPST 40A 600VAC (Prior to KA751602) . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . S2 . . 128 755 . . SWITCH, tgl DPST 40A 600VAC (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 098 691 . . STAND-OFF, No. 6-32 x .500 lg (Prior to KB058480) . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . 115 443 . . STAND-OFF, No. 6-32 x .750 lg (Eff w/KB058480) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . PC3 . . 139 646 . . CIRCUIT CARD, display (Prior to KA834916) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . PC3 . . 135 748 . . CIRCUIT CARD, display (Eff w/KA834916 thru KB058479) . . . . . . . . . . . . . . . 1
. . . 6 . . . PC3 . . 165 552 . . CIRCUIT CARD, display (Eff w/KB058480 and on) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG5 . 134 859 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 125 748 . . . . TERMINAL, contact box shaped leaf 22-18 wire . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . S1 . . 045 834 . . SWITCH, tgl DPST 60A 600VAC (Prior to KA751602) . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . S1 . . 128 757 . . SWITCH, tgl DPST 60A 600VAC (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . PC1 . . 163 269 . . CIRCUIT BOARD, timer/control (Fig 10-5) (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . F1 . *012 658 . . . . FUSE, mintr gl slo-blo 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . F2,3 *085 875 . . . . FUSE, mintr gl slo-blo 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . F4 . *012 654 . . . . FUSE, mintr gl 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . 115 091 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . PC2 . . 163 270 . . CIRCUIT BOARD, relay (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . F1 . *012 633 . . . . FUSE, mintr gl 1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 11 . . . . . . . . . . 004 214 . . BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 136 156 . . LABEL, warning precautionary plasma cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . PL1 . . 048 573 . . LIGHT, ind red lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PL2 . . 125 521 . . LIGHT, ind green lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 059 712 . . CLIP, component .437dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 2 3 4 5 6
Figure 10-5
14 8
13
12
PC1
9
PC2
11 10
ST-126 406-B
Figure 10-4. Panel, Front w/Components
Dia. Part
Mkgs. No. Description Quantity
PC1 131 063 Figure 10-5. Circuit Card, Timer Control (Fig 10-4 Item 8)
. . . . . C1,4,15,39 . . . . . . . . 093 697 . . . CAPACITOR, mica 100 pf 300VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . C2,5,14,40 . . . . . . . . 053 992 . . . CAPACITOR, cer disc .001uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . C3,6,13,16-21,
. . . . . 29-32,41,47 . . . . . . . . 000 340 . . . CAPACITOR, cer disc .01uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . C7,12 . . . . . . . . . . . 083 973 . . . CAPACITOR, elctlt 1000uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . C8,9 . . . . . . . . . . . 000 348 . . . CAPACITOR, tantlm .47uf 35V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . C10,11 . . . . . . . . . . 059 122 . . . CAPACITOR, cer disc .01uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . C22,23,25,42 . . . . . . . 091 791 . . . CAPACITOR, tantlm 15uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . C24 . . . . . . . . . . . 073 713 . . . CAPACITOR, tantlm .15uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C26,33-38,43-46,48-51 . . . 119 197 . . . CAPACITOR, tantlm .1uf 100V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . C27 . . . . . . . . . . . 039 482 . . . CAPACITOR, elctlt 100uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . C28,52 . . . . . . . . . . 072 130 . . . CAPACITOR, tantlm 1uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . CR1 . . . . . . . . . . . 004 855 . . . RELAY, encl 24VDC 4PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CR2-5 . . . . . . . . . . 099 018 . . . RELAY, encl 24VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . D1-4 . . . . . . . . . . . 028 007 . . . DIODE, rect 1A 800V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . D6-17 . . . . . . . . . . 028 351 . . . DIODE, sig .020A 75V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . F1 . . . . . . . . . . . *012 658 . . . FUSE, mintr gl slo-blo 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . F2,3 . . . . . . . . . . *085 875 . . . FUSE, mintr gl slo-blo 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . F4 . . . . . . . . . . . *012 654 . . . FUSE, mintr gl slo-blo 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 089 835 . . . CLIP, fuse 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . L1,2,6 . . . . . . . . . . 150 644 . . . CHOKE, RF 180uh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . L3,4 . . . . . . . . . . . 126 630 . . . CHOKE, filter .50 ohm 1.6A 500uh . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . L5 . . . . . . . . . . . . 095 258 . . . CHOKE, 1000uh 28MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . O1-10 . . . . . . . . . . 000 041 . . . IC, interface 4N32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . Q1 . . . . . . . . . . . . 037 200 . . . TRANSISTOR, NPN 200MA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R1,24 . . . . . . . . . . . 093 041 . . . RESISTOR, MF .25W 150K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . R2,4,6,10,12,14 . . . . . . 030 843 . . . RESISTOR, C 1W 680 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . R3,5,7,11,13,15 . . . . . . 072 560 . . . RESISTOR, MF .25W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SB-131 064-D
Figure 10-5. Circuit Card, Timer/Control PC1

Dia. Part
Mkgs. No. Description Quantity
Figure 10-5. Circuit Card, Timer Control (Fig 10-4 Item 8)
PC1 131 063
(Continued)
. . . . . . . . . R8 . . . . . . . . . . . . 000 885 . . . RESISTOR, MF .25W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R9,29 . . . . . . . . . . . 108 437 . . . RESISTOR, MF .25W 4.75K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . R16,18,20,22 . . . . . . . 030 033 . . . RESISTOR, C .5W 470 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . R17,19,21 . . . . . . . . . 030 940 . . . RESISTOR, C .5W 2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . R23 . . . . . . . . . . . 108 435 . . . RESISTOR, MF .25W 3.92K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R25 . . . . . . . . . . . 052 145 . . . RESISTOR, MF .25W 475K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R27 . . . . . . . . . . . 093 030 . . . RESISTOR, MF .25W 15K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R30 . . . . . . . . . . . 039 326 . . . RESISTOR, MF .25W 68.1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . R31-33 . . . . . . . . . . 035 823 . . . RESISTOR, CF .25W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R34 . . . . . . . . . . . 093 037 . . . RESISTOR, MF .25W 47K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . RC1 . . . . . . . . . . . 113 747 . . . TERMINAL, hdr 10 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . SR1 . . . . . . . . . . . 021 939 . . . RECTIFIER, integ 1.5A 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . U1,2 . . . . . . . . . . . 113 461 . . . IC, digital 40106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . U3,5 . . . . . . . . . . . 093 069 . . . IC, digital 4081 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . U4 . . . . . . . . . . . . 090 597 . . . IC, digital 4093 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . U6 . . . . . . . . . . . . 093 068 . . . IC, digital 4071 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . U7 . . . . . . . . . . . . 094 594 . . . IC, digital 4098 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . U8,9,11 . . . . . . . . . . 097 767 . . . IC, interface 3634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . U10 . . . . . . . . . . . 113 482 . . . IC, linear 3632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . VR1 . . . . . . . . . . . 083 772 . . . IC, linear 7815 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.

Quantity
Item Dia. Part Model
No. Mkgs. No. Description 200/230V 230/460V 460/575V
Figure 10-6. Terminal Assembly, Pri 1ph
TE1 088 020 131 696 106 373
Dual Voltage (Fig 10-1 Item 13)
.. 1........ 601 835 ... NUT, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ........ 8 ....... 6
.. 2........ 026 631 ... INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ........ 4 ....... 6
.. 3........ 081 671 ... TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ........ 1 ....... 1
.. 4........ 038 887 ... STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . 3 ........ 4 ....... 3
.. 5........ 010 913 ... WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . 3 ........ 4 ....... 6
.. 6........ 038 618 ... LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ........ 2 ....... 1
1
2
3
4
5
ST-157 360
Figure 10-6. Terminal Assembly, Pri 1ph Dual Voltage (230/460 Model Illustrated)

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July 1996 Form: TM-204

Effective With Serial No. JK542460

WARNING Use MILLER Testing Booklet (Part No.

SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 8 – HF IN PLASMA ARC CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

PRINCIPAL SAFETY STANDARDS

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

Read all safety messages throughout this manual.

1 Safety Alert Symbol

Figure 1-1. Safety Information

Table 2-1. Power Source

Type Of Output Direct Current, Straight Polarity (Electrode Negative)

Max. Open-Circuit Voltage 270 Volts DC

Plasma Gas Air Or Nitrogen Only

Weight Net: 221 lb (100 kg); Ship: 261 lb (118 kg)

Low Range High Range

KVA/KW Used At Rated Output 6.2 kVA/3.9 kW 16 kVA/7.5 kW

KVA/KW Used While Idling 1 kVA/0.8 kW 1 kVA/0.8 kW

Spectrum 500 TM-204 Page 1

The cutting speed curve shows the

Figure 2-1. Cutting Speed

2-2. Duty Cycle

6 Minutes Cutting 4 Minutes Resting Continuous Cutting

Figure 2-2. Duty Cycle

Table 3-1. Items Included With Power Source

Work Cable And Clamp 1

Stop Guide Sleeve (APT-7000 Torches Only) 1

3-1. Selecting A Location And Moving Power Source

Spectrum 500 TM-204 Page 3

Location And Airflow

Special installation may be required

Figure 3-1. Movement And Location Of Power Source

3-2. Installing And Connecting Work Clamp

6 Bend tabs around work cable.

Figure 3-2. Installing And Connecting Work Clamp

Use only clean and dry gas/air with

Figure 3-3. Connecting Gas/Air Supply

A. Positioning Jumper Links

Jumper links allow operation on

200 VOLTS 230 VOLTS

230 VOLTS 460 VOLTS

Figure 3-4. Input Voltage Jumper Links Location

Have only qualified persons make

ssb2.3 11/93 – ST-126 578-B

Figure 3-5. Input Power Connections

Table 3-2. Electrical Service Requirements*

Input Voltage 200 230 460 575

Input Amperes At Rated Output (High Range) 80 70 35 28

Recommended Standard Fuse Or Circuit Break-

Figure 4-1. Controls

1 2 5 Wear the following while cutting:

Figure 4-2. Safety Equipment

Ref. ST-143 671

Figure 4-3. Range Switch

Figure 4-4. Ready Light

Spectrum 500 TM-204 Page 9

Setting Gas/Air Pressure

Set Switches Turn On Gas/Air Supply Adjust Pressure Set Switch To

Ref. ST-143 671 / Ref. ST-129 418-B

Figure 4-5. Gas/Air Switch And Setting Gas/Air Pressure