July 1996 Form: TM-205A

Effective With Serial No. KC286939

TECHNICAL MANUAL
Service And Parts

Spectrum 1500
For Plasma Arc Cutting (PAC) And Plasma Arc Gouging (PAG)

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-129 409-B  1996 MILLER Electric Mfg. Co. PRINTED IN USA
 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
 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3-1. Selecting A Location And Moving Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Installing And Connecting Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Coolant Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-4. Connecting Air/Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-5. Optional Remote Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-6. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-2. Troubleshooting Circuit Diagram For Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. Troubleshooting Timer/Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-5. Troubleshooting Firing Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-6. Troubleshooting Indicator Board PC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-7. Troubleshooting Filter Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-8. Troubleshooting Isolator/Filter Board PC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-9. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OM-205F 6/94 / SPM-205C 6/94
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-3. Changing Coolant And Servicing Coolant Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-4. Adjusting Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-5. Torch And Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 8 – HF IN PLASMA ARC CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

 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 Read safety blocks for each sym-
6 Section 3-1 before proceeding.
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)

Rated Output 80 Amperes, 120 Volts DC At 100% Duty Cycle (See Section 2-2)

Type Of Input Power Three-Phase; 200, 230, 460, Or 575 Volts AC; 60 Hz

Input Amperes At Rated Output 72 A At 200 V, 62 A At 230 V, 31 A At 460 V, 25 A At 575 V

Input Amperes While Idling 3.59 A At 200 V, 3.21 A At 230 V, 1.56 A At 460 V, 1.25 A At 575 V

KVA/KW Used At Rated Output 25 kVA/12.5 kW

KVA/KW Used At While Idling 1.24 kVA/0.43 kW

Max. Open-Circuit Voltage 270 Volts DC

Plasma Gas Air Or Nitrogen Only

Plasma Gas Flow/Pressure 1.8 CFM (50 L/min) At 60 PSI (414 kPa)

Coolant Tank Capacity 3.2 qt (3 L)

Overall Dimensions See Figure 3-2

Weight Net: 470 lb (213 kg); Ship 478 lb (217 kg)

Spectrum 1500 TM-205 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

recommended cutting travel speed
capabilities of the power source
and torch for mild steel of various
thickness.
The maximum cutting thickness is
1-3/16 in (30 mm) at 10 ipm (0.3
mpm) travel speed.

ST-130 081-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

Definition 100% Duty Cycle At 80 Amperes

0

10
Duty Cycle is percentage of 10
minutes that unit and torch can cut
at rated load without overheating.
Minutes Continuous Cutting sb1.1* 8/93

Figure 2-2. Duty Cycle

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.

Table 3-1. Items Included With Power Source

Item Quantity Item Quantity
Torch – See Torch Owner’s Manual 1 Gouge Tips 5
Work Cable And Clamp 1 Stand-Off Guides 2
Lift Hooks 2 Stop Guide Sleeve 1
Air Filter/Regulator 1

TM-205 Page 2 Spectrum 1500

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 hooks 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 Lift Hook

Install lift hooks using supplied
3 bolts. Tighten to 25 ft/lb (34 N·m).
2 2 Spreader Bar (Not Supplied)
3 Lifting Cable (Not Supplied)
If lifting unit, use spreader bar and
1 cable.
4 Lifting Forks
OR If using lifting forks, extend forks
beyond opposite side of unit.
5 Rating Label
Use rating label to determine input
power needs.
4
6 Line Disconnect Device
Locate unit near correct input pow-
er supply.

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)

Tools Needed:

3/8 in

18 in
(460 mm)
ssb9.1* 5/94 – S-0439-A / Ref. ST-800 402 / Ref. ST-129 409-B

Figure 3-1. Movement And Location Of Power Source

Spectrum 1500 TM-205 Page 3
 NOTE Overall dimensions (A, B, and C) include regulator and coolant tank cap.

Inches Millimeters
A 37-1/4 946

B 22-3/4 578
A
C 20 508

C D 22-1/16 560
B
E 21-1/32 210
F 1-1/32 26

G 18-13/16 478
D
H 17-11/16 449
E J 5-5/8 143
F
K 1-1/8 29
L 7/16 Dia. 11 Dia.
6 Holes 6 Holes

Bottom Front
L K

ST-159 464-B

Figure 3-2. Overall Dimensions And Base Mounting Hole Layout

3-2. Installing And Connecting Work Clamp

1 Insulator
1 2 Bolt
3 Smaller Hole
4 Work Clamp Tabs
Bend tabs around work cable.
6 5 Work Cable From Unit
5 6 Nut
2
Connect work clamp to a clean,
3 paint-free location on workpiece,
as close to cutting area as pos-
4 sible.
Tools Needed:

3/8, 7/16 in
Ref. ST-025 190-C

Figure 3-3. Installing And Connecting Work Clamp

TM-205 Page 4 Spectrum 1500
3-3. Coolant Guidelines

WARNING
ELECTRIC SHOCK can kill. INCORRECT COOLANT will damage
• Do not touch live electrical parts. unit.
• Turn Off power source, and disconnect input power • Use plain distilled or deionized water.
before inspecting, maintaining, or servicing. • In freezing temperatures use only a mix of pure
ethylene glycol and distilled or deionized water
INCORRECT COOLANT LEVEL will such as MILLER coolant Part No. 128 705 or
equivalent. DO NOT USE AUTOMOTIVE
damage coolant system and torch. ANTIFREEZE.
• Maintain correct coolant level at all times.
• Do not overfill coolant tank.

1 Coolant Level Indicator

Use to check coolant level before
each use. Check with Power
switch Off; coolant level should be
between the two arrows.
With Power switch On, coolant lev-
1 el normally drops below bottom ar-
row. Do not fill or tank may overflow
when turned Off.
2 Coolant
Tank is prefilled with coolant mix-
ture for temperatures down to 0° F
(-18°C).
When changing coolant, see table
for coolant mixture needed for vari-
ous temperatures (see Section
7-3).

Above 32° F 0° F (–18° C) Below 0° F

(0° C) And Above (–18° C)
TEMP.

2 See Ethylene
Distilled Or 35% Ethylene
Deionized Glycol
Glycol And Manufacturer’s
Coolant Water 65% Water
Suggestion

Ref. ST-800 259 / Ref. ST-138 447

Figure 3-4. Coolant Guidelines

Spectrum 1500 TM-205 Page 5
3-4. Connecting Air/Gas 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 Teflon Tape
2 Air Filter/Regulator
3 Air/Gas Inlet Opening
4 Hose
Obtain hose with 5/8-18 right-hand
1 thread fitting. Wrap threads with
teflon tape, and install fitting in
opening. Route hose to air/gas
supply.
Adjust air/gas pressure according
to Figure 4-5.

2
4

To Air/Gas Supply

Use only clean and dry air/gas with

80-150 psi (552-1034 kPa) pressure.

Tools Needed:

1-1/8, 5/8 in
Ref. ST-129 418-B / S-0818

Figure 3-5. Connecting Air/Gas Supply

TM-205 Page 6 Spectrum 1500
3-5. Optional Remote Control Connections

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and disconnect input power before making remote connections or installing torch.

swarn3.1* 10/91

Turn Off power source and discon-

nect input power. Remove left side
panel.
1 Terminal Strip 1T
2 Connection Label
Route leads through torch/work
cables opening in front panel. Re-
fer to connection label and use 1T
to make remote control connec-
tions to power source as follows:
Torch Shield Cup Connections:
3 Shield Cup Detector Leads
Torch On/Off Connections:
4 Remote On/Off Switch
Connect switch leads to terminals
3 and 4 as shown. Close switch to
start cutting arc.
2 Thickness Control Connec-
tions:
1
5 Jumper Link
1T For remote thickness control, re-
3 move jumper link between termi-
nals 9 and 10, and reinstall be-
Machine Torch tween terminals 8 and 9. This dis-
ables front panel Thickness control
1 and enables remote thickness
Detector
control.
Lead
2 6 Remote Thickness Control
Potentiometer
Optional Pendant Control Connect potentiometer leads to
3 terminals 7, 9, and 11 as shown.
Torch
Switch Output Sensor Connections:
4
7 Output Sensor Terminals
Terminals 5 and 6 connect to inter-
N.O. 5 nal normally-open contacts which
Output 7 close when cutting output is pres-
Sensor ent. For example, use signal to
6 start automatic fixture.
Command 6
Reinstall side panel.
Ref. 7
+10 Volts DC

Remote 8 4
5
Jumper
Common 9 Wiper

Panel 10
Tools Needed:
Signal
Ground 11 GND
3/8 in

Ref. S-126 622-B

Ref. ST-800 255 / Ref. ST-127 900 / Ref. ST-150 802-A

Figure 3-6. Optional Remote Control Connections

Spectrum 1500 TM-205 Page 7
3-6. 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 power source, and disconnect input power
equipment. 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

200 VOLTS 230 VOLTS 460 VOLTS

L1 L2 L3 L1 L2 L3 L1 L2 L3

S-031 770-A

230 VOLTS 460 VOLTS 575 VOLTS

L1 L2 L3 L1 L2 L3 L1 L2 L3

S-012 242-A

1 Jumper links allow operation on

different input voltages and are
factory set for the highest input
2 voltage.
Check input voltage available at
site.
Remove top cover and 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 cover and side panel or
go on to Figure 3-8.

Tools Needed:

3/8, 7/16, 1/2 in

ssb5.1 2/92 – Ref. ST-129 410-A

Figure 3-7. Input Voltage Jumper Links Location

TM-205 Page 8 Spectrum 1500
B. Connecting Input Power

Have only qualified persons make

this installation.
6 5 Remove top cover and right side
panel.
1 Line Disconnect Device Of
Proper Rating
2 Input Conductors
2
3 Grounding Conductor
Select size and length using
7 Table 3-2. Conductor rating must
comply with national, state, and lo-
3 cal electrical codes. Use lugs of
proper amperage capacity and
correct hole size.
4 Strain Relief Connector
Insert conductors through strain
8 relief.
5 Input Terminal Board
6 Line Terminals
7 Power Source Ground Termi-
nal
1 Connect grounding conductor to
ground terminal first. Then connect
input conductors to line terminals.
8 Disconnect Device Ground
Terminal
9 Install and connect grounding con-
ductor and input conductors in con-
duit or equivalent to deenergized
line disconnect device.
4 Connect grounding conductor first,
and then input conductors.
Be sure grounding conductor goes
to an earth ground.
Reinstall cover and side panel.
9 Overcurrent Protection
Tools Needed:
Select type and size using
Table 3-2. Install into deenergized
line disconnect device (fused dis-
3/8, 7/16, 1/2 in connect switch shown).
ssb2.4* 1/94 – ST-129 410-A

Figure 3-8. Input Power Connections

Table 3-2. Electrical Service Requirements*

Input Voltage 200 230 460 575

Input Amperes At Rated Output 72 62 31 25

Recommended Standard Fuse Or Circuit Break-

110 90 45 40
er Rating In Amperes1
Input Conductor Size In AWG/Kcmil2 4 6 8 10

Max Input Conductor Length In Feet (Meters)3 201 (61) 183 (56) 493 (150) 525 (160)

Grounding Conductor Size In AWG/Kcmil4 6 8 10 10

* 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.
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway
(Table 310-16 of NEC).
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles
210-19(a) and 215-2(b) of NEC).
4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be
larger than input conductor (Article 250-95 of NEC). S-0092-G
Spectrum 1500 TM-205 Page 9
 SECTION 4 – OPERATION

WARNING
ELECTRIC SHOCK can kill. CUTTING can cause fire or explosion.
• Always wear dry insulating gloves. • Do not cut near flammable material.
• Insulate yourself from work and ground. • Provide protection from flying sparks.
• Do not touch live electrical parts. • Watch for fire; keep extinguisher nearby.
• Keep all panels and covers securely in place. • Do not locate unit over combustible surfaces.
• Do not cut on closed containers.
FUMES AND GASES can be hazardous • Allow work and equipment to cool before handling.
to your health.
• Keep your head out of the fumes. MOVING PARTS can cause injury.
• Ventilate area, or use breathing device. • Keep away from moving parts.
• Read Material Safety Data Sheets (MSDSs) and • Keep all doors, panels, covers, and guards closed
manufacturer’s instructions for material cut. and securely in place.

ARC RAYS can burn eyes and skin; See Safety Precautions at beginning of manual for ba-
NOISE can damage hearing. sic cutting safety information.
• Wear face protection with correct shade of filter.
• Wear correct eye, ear, and body protection.
swarn6.1* 10/91

1 Trouble Lights (See Section

7-2B)
1 2 3 4 5
2 Ready Light
3 Test/Gouge/Run Switch
4 Thickness Control
5 Power Switch
6 Pilot Light

Ref. ST-800 259

Figure 4-1. Controls

Wear the following while cutting:

1 2 5 1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
3 4 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

TM-205 Page 10 Spectrum 1500
 CAUTION
INCORRECT STANDOFF DISTANCE can damage torch.
• When Thickness control is set above 3/8 in (9.5 mm), always use 1/8 in (3 mm) standoff distance between torch tip and workpiece (see
stand-off guide installation instructions in torch Owner’s Manual).

1 Thickness Control
Use control to select cutting output.
The scale is in inches. Set control
to the thickness of the metal being
cut.
2 Conversion Table
Use table to convert from millime-
ters to inches.
2

Ref. ST-138 447

Figure 4-3. Thickness Control

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-
1 dicating that all safety shutdown
systems are okay.
If Ready light does not come on,
check Trouble Lights (see Section
7-2B).

Figure 4-4. Ready Light

Spectrum 1500 TM-205 Page 11
 CAUTION
CUTTING WHEN TEST/GOUGE/RUN 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 Test/Gouge/Run Switch
Use switch to safely adjust air/gas
pressure without activating cutting
1 output, and to set output for cutting
or gouging.
Place switch in Test position to ad-
just air/gas pressure. When Power
switch is turned On, the air sole-
noids activate.
Place switch in Gouge position to
gouge.
Place switch in Run position to cut.
2 Air Filter/Regulator
3 Pressure Adjustment Knob
Setting Air/Gas Pressure Lift knob and turn to adjust pres-
sure. Push knob down to lock in
setting.

Requires 80-150 psi Set To

(552-1034 kPa) Supply 60 psi (414 kPa)
2

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

Begin Cutting

Ref. SD-138 447 / Ref. ST-129 418-B

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

1 Power Switch
2 Pilot Light
Use switch to turn unit and pilot
light On and Off.
When turned On, torch and lines fill
1 2 with coolant. When turned Off,
coolant returns to tank.

Figure 4-6. Power Switch And Pilot Light

TM-205 Page 12 Spectrum 1500
 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 Owner’s
Manual).
• Do not operate torch without a tip or electrode in place.
• Use correct stand-off distance.

Install & Put On Personal Check Torch Check Air/Gas Set Turn On
Connect Safety (See Torch Pressure Controls Power Source
Equipment Equipment Owner’s Manual) (See Figure 4-5)

Begin
Cutting

Example Of Cutting 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 10 seconds
sparks go through metal and cut before releasing trigger. after releasing trigger; cutting arc
out bottom of cut. can be instantly restarted during postflow.

ST-161 698

Figure 4-7. Sequence Of Plasma Arc Cutting (PAC)

Spectrum 1500 TM-205 Page 13

 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 Owner’s
Manual).
• Do not operate torch without a tip or electrode in place.
• Use correct stand-off distance.

Install & Install Gouging Put On Personal Check Torch Check Air/Gas Set
Connect Tip (See Torch Safety (See Torch Pressure Controls
Equipment Owner’s Manual) Equipment Owner’s Manual) (See Figure 4-5)

Turn On Begin
Power Source Gouging

Example Of Gouging Operation

Place torch tip on met- Press trigger. After 2 seconds of preflow, Establish arc length of 1 to 1-1/2 in
al pilot arc starts. Pilot arc stops after 2 (25 – 38 mm), and slowly
at about a 40° angle. seconds if gouging arc does not start. start moving torch across metal.

Adjust torch speed, arc length and angle as needed. Release trigger. Postflow continues
Direct sparks away from torch. Do not gouge too for 10 seconds. Gouging arc can be
deeply in one pass; make repeated passes if needed. instantly restarted during postflow.

Ref. ST-162 317

Figure 4-8. Sequence Of Plasma Arc Gouging (PAG)

TM-205 Page 14 Spectrum 1500

 NOTES

Spectrum 1500 TM-205 Page 15

 SECTION 5 – THEORY OF OPERATION
1 Input Terminal Board TE1
Provides means for operation on
different input voltages.
2 Control Transformer T2
Supplies power to timer/control
board PC1, isolator/filter board 6
PC5, power switch S1/pilot light
PL1, and contactor W coil. Ener- Fan Motor
gized whenever line input power is FM
on.
3 Power Switch S1 230 VAC
Provides on/off control of power to 1 4
3φ
5
3φ
7
main transformer T1 through con- 3-Phase
tactor W. Line Input Line Main
Input Terminal Contactor Transformer Contactor
4 Line Contactor W Power Board TE1 W T1 CR3
Primary Secondary
Connects line input power to main
transformer T1. 8 3φ
5 Main Transformer T1 Synchronization
Coolant Signal
Supplies power to output circuit, 2 3 Pump 9
timer/control board PC1, firing M1
Control Power Firing
board PC2, and fan motor FM. Transformer Switch Board
6 Fan Motor FM T2 S1 8 PC2
Provides cooling of internal com- Control
ponents. Energized with contactor Relay
W. CR2 Command
Signal
7 Contactor CR3
Connects main transformer T1
secondary output power to main
10
rectifier SR1.
8 Cooling System 8
When S1 is on, water solenoid Water
WS1 opens, and control relay CR2 Solenoid
connects input power to coolant WS1
pump M1, allowing coolant circula-
tion through the torch and lines.
11
9 Firing Board PC2
Ready
Regulates output by changing gate Light
pulses (conduction times) to main PL2
rectifier SR1 SCR’s. Receives
control signal from timer/control
board PC1. 12 Timer/Control
Board PC1
10 Timer/Control Board PC1 Water
Pressure
Provides all timing and control Switch S3
functions, and monitors safety in-
terlocks. Figure 5-2 shows when 13
various machine functions are acti-
vated. Purge
Solenoid
11 Ready Light PL2 AS3
Lights when PC1 has checked all
safety interlocks and unit is ready 14
for operation.
Indicator
12 Water Pressure Switch S3 Board
PC3
Provides signal to PC1 to shut
down unit if coolant pressure is too
low.
13 Purge Solenoid AS3
16 17 18
Allows input air to purge coolant
lines when S1 is turned Off. Input 80-150 PSI 57 PSI Air Low Air
Air Air Filter/ Pressure Solenoid
14 Indicator Board PC3 Supply Regulator Switch S2 AS1
Has LED’s which light if PC1
senses air pressure, temperature,
torch tip, or water problems.

Figure 5-1. Functional Diagram

TM-205 Page 16 Spectrum 1500
 15 Main Rectifier SR1
Changes the ac input from T1 to
full-wave rectified dc.
16 Air Filter/Regulator
24 21 Filters and regulates pressure of
input air.
Stabilizer Reed
Switch 17 Air Pressure Switch S2
Z1 RS1 Provides signal to PC1 to shut
down unit if air pressure is too low.
18 Air Solenoids AS1/AS2
19
15 + AS1 allows airflow for preflow, pilot
Pilot Arc arc, cutting, and postflow. AS2 al-
Main Relay lows airflow for cutting. Orifice pro-
Rectifier CR1
SR1 vides path for low air flow when
25 AS2 is not activated.
– 19 Pilot Arc Relay CR1
Filter
Board Energized by PC1 to start pilot arc
PC4 when torch trigger is pressed. Re-
sistor R4 limits pilot current to 15
22 20
amperes. Deenergizes when reed
Hall Device High Pilot (+) switch RS1 senses cutting current.
HD1 Frequency
Circuit 20 High Frequency Circuit
Consists of HF transformer T3,
Electrode (–) spark gap G, capacitors C3/C16,
and coupling coil T4. Provides high
frequency energy to help pilot arc
jump from electrode to tip. When
Work (+)
work to electrode resistance is low
enough, output current flows
through work.
21 Reed Switch RS1

Current Feedback Senses when cutting current is

present and provides control signal
to PC1 to stop pilot arc and HF,
start high airflow, and activate the
27 trigger hold circuit.
28
Isolator/ 22 Hall Device HD1
Filter Board
PC5 Provides cutting current feedback
signal to PC1.
23
23 Thickness Control R1
Thickness 28 ♦
Selects cutting output level. PC1
Control
R1 Remote compares selected level with cur-
Contactor rent feedback signal from HD1 and
26 28 ♦ Terminal sends proper control signal to PC2.
Strip
Test/Gouge/ Output 1T 24 Stabilizer Z1
Run Switch Sensor Smooths out cutting current.
S4 Contacts 28 ♦
25 Filter Board PC4
Remote
Thickness Senses torch electrode-to-tip short
18 Control circuits and provides filtered signal
to PC1 to shut down unit.
High Air
Solenoid 26 Test/Gouge/Run Switch S4
AS2
Test position allows AS1 and AS2
to energize without activating cut-
AC Or DC Control Circuits ting output so air pressure can be
safely set.
3φ Power 27 Isolator/Filter Board PC5
18
Provides isolation to PC1 for torch
and shield cup circuits.
Orifice To Torch Cutting And Pilot Current Circuits
28 Terminal Strip 1T
External Circuits
Provides connection point for torch
♦ Optional
and remote controls.

Spectrum 1500 TM-205 Page 17

 ON OFF
Power Switch (S1)
Approx
2 sec
Trouble Lights (PC3)

Ready Light (PL2)

Approx
30 sec
Coolant Pump M1

Torch Switch

Postflow
Low Air Solenoid (AS1) 10
sec
High Air Solenoid (AS2)
2
Preflow Time sec
High Frequency Before HF

Pilot Arc

Reed Switch (RS1)

Output Current
Approx
30 sec
Gas Purge Solenoid (AS3)

S-0518-A

Figure 5-2. Operation Sequence

TM-205 Page 18 Spectrum 1500

 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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test STATIC ELECTRICITY can damage parts
equipment. on circuit boards.
• Disable high frequency by disconnecting lead 56 • Put on grounded wrist strap BEFORE handling
from HF transformer T3 before testing unit. boards or parts.
• Use proper static-proof bags.
HOT PARTS can cause severe burns.
• Allow cooling period before servicing unit. Have only qualified persons familiar with and following
standard safety practices perform troubleshooting
procedures.
smwarn1.1* 2/93

Table 6-1. Troubleshooting

Trouble Remedy Section
No cutting output; Power light PL1 off; Place Power switch in On position. Figure 4-7
Ready light PL2 off; Trouble Lights off;
fan motor FM does not run.
Place line disconnect switch in On position. 3-5B
Check line fuse(s), and replace if necessary or reset circuit 3-5B
breakers.
Check main fuse F1, and replace if necessary. 7-2A
Check coil voltage and connections of contactor W. Check con- 6-2
tinuity of coil and condition of contacts. Replace W if necessary.

No cutting output; no pilot arc; Power Check for proper torch switch lead connections on terminal strip 3-4, 7-4
light PL1 on; Ready light PL2 on; 1T.
Trouble lights off; fan motor FM run-
ning.
Check fuses on timer/control board PC1. 7-2A
Check coil voltage and connections of contactor W. Check con- 6-2
tinuity of coil and condition of contacts. Replace W if necessary.
Check coil voltage and connections of control relay CR3. Check 6-2
continuity of coil and condition of contacts. Replace CR3 if nec-
essary.
Check diode D4, and replace if necessary. 6-2
Check SCR power modules in main rectifier SR1, and replace if 6-2
necessary.
Check firing board PC2 and connections, and replace if neces- 6-5
sary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

No cutting output; pilot arc on; Power Be sure work clamp is connected. ––
light PL1 on; Ready light PL2 on;
Trouble lights off; fan motor FM running.
Check for proper position of jumper link on terminal strip 1T. 3-4
Check for proper torch switch lead connections on terminal strip 3-4, 7-4
1T.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

Spectrum 1500 TM-205 Page 19

 Trouble Remedy Section
No cutting output; pilot arc on; Power Check fuses on timer/control board PC1 and isolator/filter board 7-2A
light PL1 on; Ready light PL2 off; PC5.
Trouble lights off; fan motor FM run-
ning.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

No control of output. Check for proper position of jumper link on terminal strip 1T. 3-4
Check resistance and connections of Thickness control R1; R1 6-2
is 0 to 1000 ohms ±10%. Replace R1 if necessary.
Check input and output voltages of hall device HD1, and re- 6-2
place if necessary.
Check firing board PC2 and connections, and replace if neces- 6-5
sary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

No air/gas flow; Power light PL1 on; Check fuses on isolator/filter board PC5. 7-2A
Ready light PL2 on; Trouble lights off;
fan motor FM running.
Check torch connections. 3-4, 7-4
Check coil voltage and connections of air solenoids AS1 and 6-2
AS2, and replace if necessary.
Check to make sure orifice between air solenoids AS1 and AS2 6-2
is not plugged.

No air/gas flow; Power light PL1 on; Check fuses on timer/control board PC1 and isolator/filter board 7-2A
Ready light PL2 off; Trouble lights off; PC5.
fan motor FM running.

No pilot arc or high frequency; difficulty Check for damaged torch or torch cable. ––
in establishing an arc.
Check and adjust spark gap if necessary. 7-4
Check capacitors C3 and C16, and replace if necessary. 6-2
Check HF transformer T3 for signs of winding failure. Check conti- 6-2
nuity across windings, and check for proper connections. Replace
T3 if necessary.
Check fuses on timer/control board PC1 and isolator/filter board 7-2A
PC5.
Check coil voltage and connections of control relay CR1. Check 6-2
continuity of coil and condition of contacts. Replace CR1 if nec-
essary.
Check firing board PC2 and connections, and replace if neces- 6-5
sary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

Gas/Air Trouble Light on; Ready light Place Test/Gouge/Run Switch in Run position. Figure 4-6
PL2 off.
Check for correct air/gas pressure adjustment. Figure 4-6
Check for sufficient air/gas supply pressure. Figure 4-6
Check air pressure switch S2, and replace if necessary. Normal- 6-2
ly-open S2 requires minimum 35 psi (241 kPa) to close.
Clean air filter/regulator filter. ––

Torch Tip Trouble Light on; Ready light Check torch shield cup and shield cup detector pins. Check for ––
PL2 off; warning alarm sounds. tip to electrode short. See torch manual.

TM-205 Page 20 Spectrum 1500

 Trouble Remedy Section
Check to make sure torch connections are correct and tight on ter- 3-4, 7-4
minal strip 1T.
Check isolator/filter board PC5 and connections, and replace if 6-8
necessary.

Temperature Trouble Light on; Ready Thermostat TP1 and/or TP2 open (overheating). Allow fan to 7-2B
light PL2 off. run; the thermostat(s) closes when the unit has cooled.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

Water Trouble Light on; Ready light PL2 Check for proper coolant level. 3-3
off.
Check for plugged coolant filters. 7-3
Check fuses on timer/control board PC1. 7-2A
Check water pressure switch S3, and replace if necessary. Nor- 6-2
mally-open S3 requires 13 psi (90 kPa) to close.
Check coil voltage and connections of water solenoid WS1, and 6-2
replace if necessary.
Check coil voltage and connections of control relay CR2. Check 6-2
continuity of coil and condition of contacts. Replace CR2 if neces-
sary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.
Check coolant pump M1, and replace if necessary. 6-2

Coolant does not return to tank when Check for plugged coolant filters. 7-3
Power switch S1 is turned off.
Check for correct air/gas adjustment. Figure 4-6
Check for sufficient air/gas supply. Figure 4-6
Check coil voltage and connections of purge solenoid AS3, and re- 6-2
place if necessary.
Check coolant pump M1, and replace if necessary. 6-2

No high air/gas flow (cutting air), or de- Check for correct air/gas adjustment. Figure 4-6
creased cutting ability.
Check for sufficient air/gas supply. Figure 4-6
Check reed switch RS1, and replace if necessary. 6-2
Check coil voltage and connections of air solenoids AS1 and 6-2
AS2, and replace if necessary.
Check SCR power modules in main rectifier, and replace if nec- 6-2
essary.

Fan does not run; Power Light PL1 Check and clear blocked fan blade. ––
and Ready light PL2 both on.
Check fan motor FM, and replace if necessary. 6-2

Trouble lights not working. Check indicator board PC3 and connections, and replace if 6-6
necessary.
Check timer/control board PC1 and connections, and replace if 6-4
necessary.

Power light PL1 on; Trouble Lights on; Check timer/control board PC1 and connections, and replace if 6-4
cutting output available. necessary.

Electronic equipment in plasma arc cut- HF interference problem. Check for proper installation, and correct 8
ting area not working properly. problem.

Spectrum 1500 TM-205 Page 21

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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
from HF transformer T3 before testing unit. smwarn2.1* 2/93

R1 R1
Voltage Readings
a) Tolerance – ±10% unless V2
specified
V3
b) Reference – to circuit
common (lead 43) unless
noted
c) Wiring Diagram – see
Section 9

V1 230 volts ac with Power

switch S1 On V4
V2, V3, 205 volts ac with torch
V4 switch on
C C
V5, V6, 32 volts ac output
V7 C C
V5
V8, V9 18 volts ac output
V10 115 volts ac output V6
V11 24 volts ac output
V7
V12 18 volts ac output
V1
V13 24 volts ac output
V14 24 volts ac with Power
switch S1 On
V15 24 volts ac when coolant V8
pump is on
V16 270 volts dc with reed R2 V9
switch RS1 leads 49 and
V13 V10
51 jumpered together V15
V17 Pulsed 270 volts dc with
HF disabled
V18 Current feedback signal See Section 6-5
R2
of +0.026 volts dc per 1 for PC2 data
ampere output
V19 +15 volts dc input V11
V20 –15 volts dc input
V21, 22 115 volts ac with torch
V12
trigger pressed
V23 0 to +10 volts dc from
min to max of Thickness
Control R1
V24 24 volts ac when torch is
purging V14
Coolant
V25 115 volts ac during high Pump
airflow Relay CR2
V26 115 volts ac during low
and high airflow

See Section 3-5

for 1T information

Figure 6-1. Troubleshooting Circuit Diagram For Power Source

TM-205 Page 22 Spectrum 1500
 Resistance Values
Test Equipment Needed:
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
R2 All values for T2 are less than 1 ohm
R3 Less than 1 ohm
R4 6.1 k ohms
R3 R5 5.1 ohms

See Section See Section 6-3

6-7 for for waveforms
PC4 data A, B, C

V16, A, B

V17

V18
C C R4
V19

V20
R5

V21

V22

Pilot Arc
Relay CR1

See Section 6-4

V26 for PC1 data

See Section 6-8

for PC5 data

Contactor V25 V24 See Section 6-6 V23

Relay CR3 for PC3 data

SD-162 886-A / Ref. ST-800 255

Spectrum 1500 TM-205 Page 23

6-3. Waveforms For Section 6-2

WARNING
ELECTRIC SHOCK can kill. HIGH-FREQUENCY RADIATION can
• Do not touch live electrical parts. damage electrical components and test
• Turn Off power source before making or changing equipment.
any test equipment leads or cable connections. • Disable high frequency by disconnecting lead 56
from HF transformer T3 before testing unit.
Have only qualified persons familiar with and following
standard safety practices perform troubleshooting
procedures.

NOTE For waveform A, reed switch RS1 (see Parts List) contacts (leads 49 and 51) must
be jumpered together to get waveform shown.

5 ms 50 V 5 ms 20 V

gnd gnd

A. DC Open-Circuit Voltage, Thickness Con- B. 100 Volts DC, 56 Amperes (Resistive Load)
trol R1 At Midrange

5 ms 500 mV

gnd

Test Equipment Needed:

C. SCR Gate Pulses With Respect To Cathode

At No Load

Figure 6-2. Waveforms For Section 6-2

TM-205 Page 24 Spectrum 1500
6-4. Troubleshooting Timer/Control Board PC1

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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
smwarn2.1* 2/93
from HF transformer T3 before testing unit.

Be sure plugs are secure before

testing. Use Table 6-2 for specific
values during testing.
Test Equipment Needed:
1 Timer/Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC4
6 Receptacle RC5

5 1

4
6

Ref. ST-800 255 / SC-162 685

3

Figure 6-3. Timer/Control Board PC1 Testing Information (Use With Table 6-2)
Spectrum 1500 TM-205 Page 25
 Table 6-2. 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 1 +32 volts dc output with respect to pin RC1-2

2 Reference point for pin RC1-1

3 24 volts ac input with respect to pin RC1-5, protected by fuse F1

4 +32 volts dc output

5 24 volts ac input with respect to pin RC1-3

6 +32 volts dc if shield cup is installed and working properly; 0 volts dc if shield cup is removed

RC2 1 18 volts ac input, protected by fuse F2

2 Pulsing +24 volts dc output, continuous +24 volts dc output if pin RC4-2 is grounded

3 Command signal: 0 volts dc output with no output current present; 0 to –6 volts dc output from min to
max of Thickness control R1 with output current present

4 Current feedback signal of 0.026 volts per 1 ampere output

5 0 to + 10 volts dc ±1% input from wiper of remote thickness control potentiometer (if applicable)

6 –15 volts dc ±5% output

7 115 volts ac power supply input, protected by fuse F4

8 Switched ground for water alarm Y1

9 18 volts ac power supply input

10 +15 volts dc ±5% output

11 +15 volts dc ±5% output

12 Circuit common

13 Circuit common (lead 43)

14 –15 volts dc ±5% output

15 Circuit common

16 +10 volts dc ±1% output

RC3 1 +24 volts dc input with cutting output present, reed switch RS1 closed

2 +24 volts dc input with torch trigger pressed; 0 volts dc input with torch trigger released

3 +24 volts dc output

4 +24 volts dc input with Test/Gouge/Run switch S4 in Test position; 0 volts dc input with S4 in Run or
Gouge position

5 +24 volts dc output

6 +24 volts dc input with air pressure switch S2 closed

7 +24 volts dc output with Ready light PL2 on

8 +24 volts dc input with normally-closed thermostats TP1 and TP2 closed; 0 volts dc input with TP1
or TP2 open

9 Not used

10 +24 volts dc output

TM-205 Page 26 Spectrum 1500

 Receptacle Pin Value

11 +24 volts dc output

12 +24 volts dc output

13 +24 volts dc output

14 +24 volts dc input when Temperature Trouble light LED is on

15 +24 volts dc input when Gas/Air Trouble light LED is on

16 +24 volts dc input when Torch Tip Trouble light LED is on

RC4 1 Pins RC4-1 and RC4-7 are connected to normally-open contacts which close when cutting output is
present

2 Not used

3 115 volts ac output with pilot arc on; 0 volts ac output with pilot arc off

4 115 volts ac output when preflow, cutting, or postflow air is on

5 115 volts ac output with cutting air on; 0 volts ac output at all other times

6 +24 volts dc input (from transformer T2)

7 Pins RC4-1 and RC4-7 are connected to normally-open contacts which close when cutting output is
present

8 Circuit common

9 115 volts ac output with pilot arc on; 0 volts ac output with pilot arc off

10 +24 volts dc output with Ready light PL2 on and in power up delay; 0 volts dc output when Ready
light PL2 is off

RC5 1 24 volts ac with purge solenoid AS3 energized

2 18 volts ac input with respect to pin RC5-5

3 +24 volts dc output

4 115 volts ac output with coolant circulating

5 18 volts ac input with respect to pin RC5-2, protected by fuse F3

6 +24 volts dc output

7 +24 volts dc when Water Trouble light LED is on

8 +24 volts dc input with water pressure switch S3 closed

Spectrum 1500 TM-205 Page 27

6-5. Troubleshooting Firing Board PC2

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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
from HF transformer T3 before testing unit. smwarn2.1* 2/93

Be sure plugs are secure before

testing. Use Table 6-3 for specific
values during testing.
Test Equipment Needed: 1 Firing Board PC2
2 Receptacle RC1
3 Receptacle RC2

2 3

Ref. ST-800 255 / SN-090 437-C

Figure 6-4. Firing Board PC2 Testing Information (Use With Table 6-3)
TM-205 Page 28 Spectrum 1500
 Table 6-3. Firing 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

RC1 A Reference for gate pulse to SCR1A with respect to pin B

B Gate pulse to SCR1A with respect to pin A (see Section 6-3)

C Reference for gate pulse to SCR1B with respect to pin D

D Gate pulse to SCR1B with respect to pin C (see Section 6-3)

E Reference for gate pulse to SCR2A with respect to pin F

F Gate pulse to SCR2A with respect to pin E (see Section 6-3)

G Reference for gate pulse to SCR2B with respect to pin H

H Gate pulse to SCR2B with respect to pin G (see Section 6-3)

J Reference for gate pulse to SCR3A with respect to pin K

K Gate pulse to SCR3A with respect to pin J (see Section 6-3)

L Reference for gate pulse to SCR3B with respect to pin M

M Gate pulse to SCR3B with respect to pin L (see Section 6-3)

RC2 N Pulsing +24 volts dc input

P Circuit common (lead 43)

R Circuit common

S +15 volts dc input

T –15 volts dc input

U Not used

V Command ramp-down: 0 volts dc input with no output current present; 0 to –6 volts dc input from min
to max of Thickness control R1 with output current present

W 32 volts ac input for synchronization

X 32 volts ac input for synchronization

Y 32 volts ac input for synchronization

Spectrum 1500 TM-205 Page 29

6-6. Troubleshooting Indicator Board PC3

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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
from HF transformer T3 before testing unit. smwarn2.1* 2/93

Be sure plugs are secure before

testing. Use Table 6-4 for specific
values during testing.
1 Indicator Board PC3
2 Connector CN1
3 Trouble Lights (See Section
7-2B)

1 2

Test Equipment Needed:

Ref. ST-800 255 / SA-143 515-A

Figure 6-5. Indicator Board PC3 Testing Information (Use With Table 6-4)

Table 6-4. Indicator Board PC3 Test Point Values (Use With Figure 6-1 And Figure 6-5)

Voltage Readings:

a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 43) unless noted
Receptacle Pin Value
CN1 1 +24 volts dc input
2 Not used
3 +24 volts dc output when Gas/Air Trouble light LED is on
4 +24 volts dc output when Torch Tip Trouble light LED is on
5 +24 volts dc output when Temperature Trouble light LED is on
6 +24 volts dc output when Water Trouble light LED is on

TM-205 Page 30 Spectrum 1500

6-7. Troubleshooting Filter Board PC4

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.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
from HF transformer T3 before testing unit. smwarn2.1* 2/93

Be sure plugs are secure before

testing. Use Table 6-5 for specific
1 3 2 values during testing.
1 Filter Board PC4
2 Receptacle RC1
3 Receptacle RC2

Test Equipment Needed:

Ref. ST-800 255 / SA-162 881

Figure 6-6. Filter Board PC4 Testing Information (Use With Table 6-5)

Table 6-5. Filter Board PC4 Test Point Values (Use With Figure 6-1 And Figure 6-6)

Voltage Readings:

a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 43) unless noted
Receptacle Pin Value

RC1 A, B, C Not used

D Reference for pin RC1-E

E +24 volts dc output with respect to pin RC1-D if no torch tip-to-electrode short exists

F, G, H Not used

RC2 A +24 volts dc input with respect to pin RC2-C if no torch tip-to-electrode short exists

B Not used

C Reference for pin RC2-A

D Circuit common (lead 43)

E, F Not used

Spectrum 1500 TM-205 Page 31

6-8. Troubleshooting Isolator/Filter Board PC5

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts
• Do not touch live electrical parts. on circuit boards.
• Turn Off welding power source before making or • Put on grounded wrist strap BEFORE handling
changing meter lead connections and before boards or parts.
disconnecting or connecting any leads. • Use proper static-proof bags.
HIGH-FREQUENCY RADIATION can
damage electrical components and test Have only qualified persons familiar with and following
equipment. standard safety practices perform troubleshooting
• Disable high frequency by disconnecting lead 56
procedures.
from HF transformer T3 before testing unit. smwarn2.1* 2/93

Be sure plugs are secure before

3 2 testing. Use Table 6-6 for specific
values during testing.
1 Isolator/Filter Board PC5
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3

Test Equipment Needed:

1
4
Ref. ST-800 255 / SA-141 468-C

Figure 6-7. Isolator/Filter Board PC5 Testing Information (Use With Table 6-6)

Table 6-6. Isolator/Filter Board PC5 Test Point Values (Use With Figure 6-1 And Figure 6-7)

Voltage Readings:

a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 43) unless noted
Receptacle Pin Value
RC1 A 24 volts ac with torch switch pressed, 0 volts ac with torch switch released
B, C Not used
D 24 volts ac output, protected by fuse F1
E +24 volts dc output, protected by fuse F1
F, G Not used
H 24 volts ac when shield cup is installed, 0 volts ac when removed
RC2 A +24 volts dc input
B +24 volts dc with torch switch pressed, 0 volts dc with torch switch released or with Ready light PL2
off
C +24 volts dc input
D Circuit common (lead 43)
E +24 volts dc output
F +24 volts dc with shield cup installed, 0 volts dc with shield cup removed
RC3 A 18 volts ac with respect to pin RC3-B
B 18 volts ac with respect to pin RC3-A

TM-205 Page 32 Spectrum 1500

6-9. 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 Is On Unit
2 Terminal Strip TE1
If replacing or servicing trans-
former coils, connect coil leads 1
thru 6 to matching terminals 1 thru
6 on terminal board TE1.

Test Equipment Needed:

Ref. ST-800 248 / SA-126 728 / SA-130 638-B

Figure 6-8. Input Voltage Labels And Connection Diagrams

Spectrum 1500 TM-205 Page 33
 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. Do not throw away antifreeze coolant –
take to area recycling center.

Each Use 3 Months 3 Months

Check Service
Replace
Air/Gas Air Filter/
See Cracked
Pressure Regulator
Figure Regulator Parts
Filter ––
4-5 Manual Torch Body
Check
Torch Tip, Replace
Electrode, Unreadable
And Shield Labels
Torch Cup Parts
Manual List Air/Gas Hose Torch Cable

Tape
Every Week Torn 6 Months
Outer
Covering
Check –– Blow Out
Torch Tip OR Or
Shutdown Clean Vacuum
System And Inside
5-2B Tighten
Torch
7-5 Connections During Heavy Service,
–– Clean Monthly

Adjust
Spark Service
Gaps Cooling
Coolant System
7-4
7-3

Figure 7-1. Maintenance Schedule

TM-205 Page 34 Spectrum 1500

7-2. Overload Protection

WARNING READ SAFETY BLOCKS at start of

Section 7 before proceeding.

A. Fuses

Turn Off power source and discon-

nect input power.
Remove left side panel.
1 Main Fuse F1
2
2 Fuse Holder
F1 protects control transformer T2
from overload. If F1 opens, the
1 power source shuts down.
3 Timer/Control Board PC1
4 PC1 Fuse F1
5 PC1 Fuse F2
6 PC1 Fuse F3
7 PC1 Fuse F4
8 Isolator/Filter Board PC5
9 PC5 Fuse F1
Fuses on PC1 and PC5 protect the
circuit boards from overload. If any
fuse opens, Ready light goes off,
and the unit does not cut.
Check fuses and replace as need-
ed. See Parts List for fuse ratings.
Use proper tool when removing
fuses.
3 5 Reinstall side panel.

4
6

8 9

Tools Needed:

3/8 in
Ref. ST-800 255 / Ref. SC-162 685 / SA-141 468-C

Figure 7-2. Fuses

Spectrum 1500 TM-205 Page 35
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 air/gas pressure is
sensed by pressure switch S2.
Check for proper air/gas pressure
(see Figure 4-5).
2 Torch Tip Light
1 Lights if torch shield cup is loose, or
if a short exists between tip and
2 electrode. Warning alarm also
sounds. Check shield cup, tip, and
3 electrode (see torch manual).
4 Check torch tip shutdown system
once a week (see Figure 7-4).
3 Temperature Light
Lights if power source overheats
(see Figure 7-4).
4 Water Light
Lights if low coolant pressure is
sensed by pressure switch S3.
Turn power Off, and check coolant
level (see Section 3-3). If coolant
level is okay, see troubleshooting
table (see Section 6-1).

Ref. ST-138 447

Figure 7-3. Trouble Lights

15

minutes

When overheated, thermostat(s) Let fan run for When Ready light comes back
open, output stops, and cooling 15 minutes. on, start cutting.
fan keeps running.
ssb10.1* 1/94 – Ref. ST-129 409-B

Figure 7-4. Overheating Protection

1 1 Torch Shield Cup

Turn power On and loosen shield
cup. If shutdown system works
properly, Ready light goes off,
warning alarm sounds, and Torch
Tip light comes on. If not, turn pow-
er Off and check shield cup detec-
tor pins (see torch manual).
If system works properly, retighten
shield cup and turn power Off.

Ref. ST-134 696-A

Figure 7-5. Checking Torch Tip Shutdown System

TM-205 Page 36 Spectrum 1500
C. Warning Alarm

1 1 Warning Alarm
Sounds if torch shield cup is loos-
ened, or if torch tip problem occurs
to remind operator to wait until
torch coolant lines are purged be-
fore servicing torch.
If alarm sounds while cutting, turn
power Off to stop alarm, and check
troubleshooting table (see Section
6-1). Ref. ST-800 259

Figure 7-6. Warning Alarm

7-3. Changing Coolant And Servicing Coolant Filters

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.
FAILURE TO PROPERLY MAINTAIN
HOT PARTS can cause severe burns. COOLANT SYSTEM can cause damage
• Allow cooling period before maintaining or to the coolant system and torch.
servicing. • After a break-in period of about 100 hours of
operation, circulate and flush deionized or distilled
water through entire system, and replace coolant.
• After break-in period, service coolant filters and
change coolant every six (6) months. swarn8.1* 2/93

Turn Off power source and remove

input power. Remove left side pan-
el.
1 Drain Plug
Remove cap and drain plug to
drain coolant. Properly dispose of
coolant. Flush system if neces-
sary.
1 2 Return Filter Assembly
3 Retaining Nut
4 Sleeve
Remove large nut, and pull return
filter assembly from tank. Remove
retaining nut, and remove sleeve to
access foam filter. Clean or replace
3 4 filter as needed. Reassemble and
reinstall assembly in tank.
5 Supply Filter Assembly
6 Filter Screen
2 Remove supply filter assembly
from tank and clean filter screen.
Reinstall assembly in tank.
Reinstall drain plug, and refill tank
with proper coolant mixture (see
Section 3-3). Reinstall cap, and
side panel.
6
5

Ref. ST-800 255 / Ref. ST-129 410-A / ST-129 916

Figure 7-7. Changing Coolant And Servicing Coolant Filters

Spectrum 1500 TM-205 Page 37
7-4. Adjusting Spark Gap

WARNING READ SAFETY BLOCKS at start of

Section 7 before proceeding.

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.
4

Tools Needed:

3/8 in

5/32 in

0.030 in (0.762 mm)

Ref. ST-800 255 / S-0201

Figure 7-8. Adjusting Spark Gap

TM-205 Page 38 Spectrum 1500

7-5. Torch And Work Cable Connections

WARNING READ SAFETY BLOCKS at start of

Section 7 before proceeding.

Tools Needed:

1/2 in

3/8 in

9 3

7 8
1T 6

Detector 1
Lead 2
11 2
4
3
Torch
Switch
4

1 1
N.O. 5
Output
Sensor 6
Command
Ref. 7 12

Remote 8 13
Jumper 9
Common

Panel 10
Signal 11 10
Ground

Ref. S-126 622-B

Side View

Ref. ST-800 255 / ST-129 411

If torch or work cable needs to be removed 4 Torch/Coolant Out Cable 10 Terminal Strip 1T
or replaced, proceed as follows: 11 Connection Label
5 Torch (–) And Coolant Out Connector
Turn Off power source and remove input 12 Shield Cup Detector Leads
power. Remove left side panel. 6 Pilot/Coolant In Cable
7 Pilot (+) And Coolant In Connector 13 Torch Switch Leads
1 Access Hole
8 Air/Gas Hose Refer to label and connect leads as shown.
Insert cables through access hole. See Section 3-5 for remote control connec-
2 Work Cable 9 Air/Gas Input Connector tions.
3 Work (+) Output Terminal Connect as shown. Reinstall side panel.

Figure 7-9. Torch And Work Cable Connections

Spectrum 1500 TM-205 Page 39
 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

TM-205 Page 40 Spectrum 1500
 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
conduit every 50 ft (15 m). specifications.
required).
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
Bolt or weld building panels together, install Ground the track.
4 Torch And Work Cables
copper straps or braided wire across
Keep cables close together. seams, and ground frame.

Figure 8-3. Correct Installation

Spectrum 1500 TM-205 Page 41
 NOTES

TM-205 Page 42 Spectrum 1500

 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 1500 KC286939 thru KD420806 SC-137 333-B D-145 977-A♦♦

KD420807 and following SC-162 886-A SD-162 887-B Removed capacitor C2,
changed coupling coil T4

Circuit Board PC1 KC286939 thru KD396961 D-137 067♦♦

KD396962 and following SD-162 686

Circuit Board PC2 KC286939 and following SB-096 589-A

Circuit Board PC3 KC286939 and following SA-143 674

Circuit Board PC4 KC286939 thru KD420806 A-141 533♦♦

KD420807 and following SA-162 879

Circuit Board PC5 KC286939 and following SA-141 470

Circuit Board HD1 KC286939 and following SA-110 758-A

♦♦ Not included in this manual

Spectrum 1500 TM-205 Page 43

 SC-137 333-B

Figure 9-1. Circuit Diagram For Spectrum 1500 Effective With Serial No. KC286939 Thru KD420806
TM-205 Page 44 Spectrum 1500
 SC-162 886-A

Figure 9-2. Circuit Diagram For Spectrum 1500 Effective With Serial No. KD420807 And Following

Spectrum 1500 TM-205 Page 45

 Figure 9-3. Wiring Diagram For Spectrum 1500 Effective With Serial No. KD420807 And Following
TM-205 Page 46 Spectrum 1500
 SD-162 887-B

Spectrum 1500 TM-205 Page 47

 Figure 9-4. Circuit Diagram For Timer/Control Board PC1 Effective With
Serial No. KD396962 And Following (Part 1 Of 2)
TM-205 Page 48 Spectrum 1500
 SD-162 686 (1 Of 2)

Spectrum 1500 TM-205 Page 49

 Figure 9-5. Circuit Diagram For Timer/Control Board PC1 Effective With
Serial No. KD396962 And Following (Part 2 Of 2)
TM-205 Page 50 Spectrum 1500
 SD-162 686 (2 Of 2)

Spectrum 1500 TM-205 Page 51

 SB-096 589-A

Figure 9-6. Circuit Diagram For Firing Board PC2 Effective With Serial No. KC286939 And Following

SA-143 674

Figure 9-7. Circuit Diagram For Display Board PC3 Effective With Serial No. KC286939 And Following
TM-205 Page 52 Spectrum 1500
 SA-162 879

Figure 9-8. Circuit Diagram For Filter Board PC4 Effective With Serial No. KD420807 And Following

SA-141 470

Figure 9-9. Circuit Diagram For Isolator/Filter Board PC5 Effective With
Serial No. KC286939 And Following

SA-110 758-A

Figure 9-10. Circuit Diagram For Hall Device HD1 Effective With Serial No. KC286939 And Following
Spectrum 1500 TM-205 Page 53
 NOTES

TM-205 Page 54 Spectrum 1500

 July 1996 Form: TM-205A
Effective With Serial No. KC286939

SECTION 10 – PARTS LIST

Spectrum 1500
For Plasma Arc Cutting (PAC) And Plasma Arc Gouging (PAG)

Spectrum 1500 TM-205 Page 55

TM-205 Page 56

3 Figure 10-7 Figure 10-3

13 27
2 28 29 30
4 12
5 26
1
23 24 25

7
6
8
9
10 22
21
11* 31
20 19 18
42 14 Figure 10-4
Figure 10-5 17
32
43 Figure 10-6

44 21 15 16

22
45

46

34
35
33

14
36
Figure 10-4

41 40 39 38 37

Figure 10-2
Spectrum 1500

*Includes
Items 12 & 13 ST-129 469-D

Figure 10-1. Main Assembly

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

. . 1 . . . . . . . . . . . . 015 531 . . HOOK, lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 2 . . . . . . . . . . . . 125 710 . . GROMMET, rbr 2.125 ID x 2.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . +126 699 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . 128 391 . . LABEL, caution incorrect coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . 126 704 . . BRACKET, mtg tank water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . 143 156 . . WATER TANK ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . 124 253 . . . . BUSHING, tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . 124 252 . . . . FITTING, hose stl elbow 1/4tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460-.545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . . . . . . . . . 603 106 . . . . HOSE, nprn brd No. 1 x .250 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. 11 . . . . . . . . . . . 143 168 . . . . WATER TANK ASSEMBLY, (Fig 10-8) (consisting of) . . . . . . . . . . . . . . . . . . . 1
. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . PACKING, rbr (see Fig 10-8 Item 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, (see Fig 10-8 Item 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . . . . . . . . . Fig 10-4 . . VALVE AND PRESSURE SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 15 . . . SR1 . . . 135 688 . . RECTIFIER, main (Prior to KE654752) (Fig 10-6) . . . . . . . . . . . . . . . . . . . . . . . . 1
. 15 . . . SR1 . . . 168 592 . . RECTIFIER, main (Eff w/KE654752) (Fig 10-6) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 16 . . . . . . . . . . . 126 701 . . BRACKET, mtg heat sink RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . . . . . . . . . 126 986 . . HF PANEL, (Prior to KD420807) (Fig 10-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . . . . . . . . . 162 888 . . HF PANEL, (Eff w/KD420807) (Fig 10-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 18 . . . CR1 . . . 605 855 . . CONTACTOR, def prp 40A 3P 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 19 . . . . W . . . . 124 886 . . CONTACTOR, def prp 60A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 095 317 . . LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 20 . . . . . . . . . . . 603 106 . . HOSE, nprn brd No. 1 x .250 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ft
. 21 . . . . . . . . . . . 010 323 . . CLAMP, hose .250-.625clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. 22 . . . CR3 . . . 114 780 . . CONTACTOR, def prp 60A 3P 115V (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 114 787 . . . . COIL, cntor 115V 60A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 114 786 . . . . LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 23 . . . . . . . . . . . 124 960 . . HOSE, water 22 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 24 . . . 2T . . . . 072 253 . . STUD, connection single 10-32 x .500 x 1.250mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 010 913 . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 835 . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 25 . . . C20 . . . 141 233 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 26 . . . HD1 . . . 134 826 . . CIRCUIT CARD, hall boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27 . . . T2 . . . . 145 957 . . TRANSFORMER, kVA 1/3 24-18-200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27 . . . T2 . . . . 145 958 . . TRANSFORMER, kVA 1/3 24-18-230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 28 . . . TE1 . . . 038 126 . . TERMINAL ASSEMBLY, pri 3ph triple voltage (Prior to KE629034) (Fig 10-7) 1
. 28 . . . TE1 . . . 168 854 . . TERMINAL ASSEMBLY, pri 3ph triple voltage (Eff w/KE629034) (Fig 10-7) . . 1
. 29 . C21-23 . . 091 141 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. 30 . . . . . . . . . . . Fig 10-3 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 31 . . . CR2 . . . 059 266 . . RELAY, encl 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 32 . . . . . . . . . . . 132 939 . . FRAME, center base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 150 311 . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 131 559 . . . . COIL, pri/sec 200/230/460 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 149 734 . . . . COIL, pri/sec 200/230/460 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 150 310 . . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 135 984 . . . . COIL, pri/sec 230/460/575 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 149 736 . . . . COIL, pri/sec 230/460/575 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 020 520 . . THERMOSTAT, NC open 135C w/insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 36 . . . . . . . . . . . 152 516 . . BASE, (Prior to KD478407) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 36 . . . . . . . . . . . 164 328 . . BASE, (Eff w/KD478407 thru KE629033) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 36 . . . . . . . . . . . 168 851 . . BASE, (Eff w/KE629034 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 37 . . . Z1 . . . . 139 709 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 38 . . . . . . . . . . . Fig 10-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 39 . . . . . . . . . . . 126 628 . . WIRE, strd 4ga blk 600V 125c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ft
. 40 . . . . . . . . . . . 026 843 . . INSULATOR, vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 41 . . . . . . . . . . . 010 368 . . CLAMP, ground 200A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 42 . . . . . . . . . . . 132 940 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 43 . . . . . . . . . . . 132 941 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 44 . . . . . . . . . . . . . . . . . . . . . . See Fig 10-4 Item 20
. 45 . . . M1 . . . . 125 058 . . PUMP, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spectrum 1500 TM-205 Page 57
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-1. Main Assembly (Continued)

. 46 . . . . . . . . . . . 126 700 .. BRACKET, mtg water/air valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

................ 010 021 .. CLAMP, stl cush .562dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 128 705 .. COOLANT, solution plasma cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1gal
................ 132 463 .. SLEEVE, step guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 132 657 .. GUIDE, stand-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
................ 138 738 .. TIP, gouge G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-205 Page 58 Spectrum 1500

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 38)

. . 1 . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . PL2 . . . 125 521 . . LIGHT, ind grn lens 28/v snap mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . Y1 . . . . 126 411 . . ALARM, sonalert 24VAC/DC max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . PL1 . . . 048 573 . . LIGHT, ind red lens 28V snap mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . 115 443 . . STAND-OFF, No. 6-32 x .750 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 6 . . . . PC3 . . . 165 552 . . CIRCUIT CARD, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG8 . . 134 859 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . S4 . . . . 088 409 . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . R1 . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG4,5 . . 131 052 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG6,11 . 131 056 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG6 . . 115 091 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG11 . . 131 054 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 2 3 4 5 6

8*

10

25
11
12
13

14
15
24 16

17

18

23

21 20

19

*Includes Item 9 22 ST-129 470-C

Figure 10-2. Panel, Front w/Components

Spectrum 1500 TM-205 Page 59
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 38) (Continued)

. . . . . PLG3,13,
15,17 . . 115 093 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . PLG2 . . 090 469 . . CONNECTOR, rect modu 10skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 081 378 . . CONNECTOR, rect skt 22-18ga Amp 102100-2 . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . PLG1 . . 081 379 . . CONNECTOR, rect 12skt plug Amp 1-87159-2 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 081 378 . . CONNECTOR, rect skt 22-18ga Amp 102100-2 . . . . . . . . . . . . . . . . . . . . . . . . . 12
. 10 . . . S1 . . . . 111 997 . . SWITCH, rocker SPST 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 11 . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . As Req’d
. 12 . . . PC1 . . . 162 684 . . CIRCUIT CARD, control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 13 . . . F2 . . . *012 633 . . . . FUSE, mintr gl 1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . F4 . . . *012 633 . . . . FUSE, mintr gl slo-blo 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 15 . . . F1 . . . *012 653 . . . . FUSE, mintr gl .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 16 . . . F3 . . . *012 643 . . . . FUSE, mintr gl slo-blo 1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . PC2 . . . 097 772 . . CIRCUIT CARD, SCR firing circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 18 . . . PC4 . . . 162 880 . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . PLG7,12,14 115 092 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. 19 . . . PC5 . . . 141 467 . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 20 . . . F1 . . . *012 653 . . . . FUSE, mintr gl .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 21 . . . . . . . . . . . 126 368 . . STAND-OFF SUPPORT, PC card No. 6 screw w/post . . . . . . . . . . . . . . . . . . . . 1
. 22 . . . . . . . . . . . 141 234 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 23 . . . . . . . . . . . 004 214 . . BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . 1
. 24 . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 25 . . . . . . . . . . . 136 156 . . LABEL, warning precautionary plasma cutting equipment . . . . . . . . . . . . . . . . . 1

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-205 Page 60 Spectrum 1500

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-3. Panel, Rear w/Components (Fig 10-1 Item 30)

. . 1 . . . R2,3 . . . 126 736 . . RESISTOR, WW fxd 375W 20-161 ohm dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . F1 . . . *604 259 . . FUSE, crtg 3A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . . 070 404 . . HOLDER, fuse crtg 30A 600V 1P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . 032 611 . . BLADE, fan 14 in 3wg 23deg .375 bore CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . 126 695 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . 168 252 . . NUT, .187-12knrl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . . . . . . . . . 168 253 . . BRACKET, mtg air filter/regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . . . . . . . . . 153 277 . . GAUGE, air 0-160PSI 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . 127 115 . . HOSE, air 28 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 10 . . . . . . . . . . . 153 276 . . REGULATOR/FILTER, 150PSIG in 0-125PSIG out 1/4NPT . . . . . . . . . . . . . . . 1
. 11 . . . . . . . . . . . 044 426 . . CONNECTOR, clamp cable .690/1.070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 12 . . . . . . . . . . . 030 170 . . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 13 . . . . . . . . . . . 605 288 . . FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . . . . . . . . . 602 956 . . FITTING, pipe brs adapter bhd 1/4NPT x .937 lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 15 . . . . . . . . . . . 602 958 . . FITTING, brs barbed M 1/4tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 16 . . . . . . . . . . . . . . . . . . . . . . See Fig 10-1 Item No. 22
. 17 . . . . . . . . . . . . . . . . . . . . . . See Fig 10-1 Item No. 21
. 18 . . . R4 . . . . 126 841 . . RESISTOR, w/mtg hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 19 . . . FM . . . 116 190 . . MOTOR, 1/12hp 230V 1550RPM 50/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 20 . . . . . . . . . . . 131 361 . . CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 045 852 . . CLIP, component .687dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
. . . . . . . . . . . . . . . . 059 712 . . CLIP, component .437dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4
3 5

2
6

20

11 10

13 12

19
14
15
16
17
18 ST-129 471-A

Figure 10-3. Panel, Rear w/Components

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Spectrum 1500 TM-205 Page 61
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-4. Valve And Pressure Switch Assembly (Fig 10-1 Item 14)

. 1 . . . . . . . . . . . . . . . . . 124 963 . . HOSE, air 22 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. 2 ............................ See Fig 10-1 Item No. 22
. 3 . . . . . . . . . . . . . . . . . 602 957 . . FITTING, brs barbed fem 1/4tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 4 . . . . . . . . . . . . . . . . . 082 614 . . VALVE, check 1PSIG 1/4MNPT both ends . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 5 . . . . . . AS3 . . . . . . 109 930 . . VALVE, 24VAC 2 way 1/4 IPS 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 5 . AS1,AS2,WS1 . 003 538 . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . 3
. 6 . . . . . . . . . . . . . . . . . 071 270 . . FITTING, pipe brs tee st 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. 7 . . . . . . . . . . . . . . . . . 010 605 . . FITTING, hose brs bushing 1/4NPT x .625-18 LH . . . . . . . . . . . . . . . . . . . 1
. 8 . . . . . . . . . . . . . . . . . 124 962 . . HOSE, water 22 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 9 . . . . . . . . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT (Prior to KD412179) . . . . . . . 1
. 9 . . . . . . . . . . . . . . . . . 602 958 . . FITTING, brs barbed M 1/4tbg x 1/4NPT (Eff w/KD412179) . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (Prior to KD412179) (order by ft) . . . . . . 2ft
10 . . . . . . . . . . . . . . . . . 107 816 . . HOSE, SAE .250 ID x .500 OD (Eff w/KD412179) (order by ft) . . . . . . . . 2ft
11 . . . . . . . . . . . . . . . . . 010 604 . . FITTING, hose brs bushing 1/4NPT x .625-18RH . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . . 124 961 . . HOSE, air 40 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . 126 989 . . FITTING, brs barbed M 1/4tbg x 1/4NPT .0145 ID
(Prior to KD412179) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . 161 307 . . FITTING, brs barbed M 1/4tbg x 1/4NPT .028 ID orf (Eff w/KD412179) 1
14 . . . . . . . . . . . . . . . . . 010 830 . . FITTING, pipe brs nipple hex 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . S2,3 . . . . . . 094 963 . . SWITCH, pressure air 0-90 lb adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . 010 869 . . FITTING, pipe brs bushing 1/4 x 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 2
17 ............................ See Fig 10-3 Item No. 9
18 . . . . . . . . . . . . . . . . . 010 296 . . FITTING, hose brs elbow M 1/4NPT x .625-18RH . . . . . . . . . . . . . . . . . . 2
19 . . . . . . . . . . . . . . . . . 010 295 . . FITTING, pipe brs elbow M 1/4NPT x .625-18 LH . . . . . . . . . . . . . . . . . . . 1
20 . . . . . . . . . . . . . . . . . 124 964 . . HOSE, water 8.500 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 10 12
2
2 11
9
3

4
6
13

5 5

6
10
7 6
4 2
8
5 14
5

1
6 15
15

16

6 16
20
18
17
19 6

18 ST-151 404

Figure 10-4. Valve And Pressure Switch Assembly

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-205 Page 62 Spectrum 1500
 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-5. HF Panel (Fig 10-1 Item 17)

. . . 1 . . . . . RS1 . . . . . 125 508 . . RELAY, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . C4,14 . . . . 142 133 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . WORK . . . 026 947 . . STAND-OFF, insul .250-20 x 1.000 lg x .312thd . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 038 328 . . STUD, brs .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 126 702 . . PANEL, mtg HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 125 054 . . FITTING, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 125 055 . . FLANGE, mtg gas fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......................... See Fig 10-1 Item No. 22
... 8 .......................... See Fig 10-4 Item No.12
. . . 9 . . . . PILOT . . . . 125 053 . . TERMINAL, pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . See Fig 10-4 Item No. 8
. . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . See Fig 10-1 Item No. 23
. . . 12 . . . TORCH . . . 125 052 . . TERMINAL, torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 605 538 . . CABLE TIE, 0-4.500 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . 113 146 . . CABLE TIE MOUNT, for lashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . T4 . . . . . 128 833 . . COIL, HF coupling (Prior to KD420806) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . T4 . . . . . 162 884 . . COIL, HF coupling (Eff w/KD420807 and on) . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . C2,3,16 . . . 096 761 . . CAPACITOR, mica .002uf 10000V (Prior to KD420807) . . . . . . . . . . 3
. . . 16 . . . . C3,16 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V (Eff w/KD420807) . . . . . . . . . . . . 2
. . . 17 . . . . . . . . . . . . . . . 010 886 . . STRIP, conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . T3 . . . . . 074 398 . . TRANSFORMER, high voltage 115V pri 3600V sec 30mA . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 113 000 . . STRIP, mtg spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . . 020 622 . . HOLDER, points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . ♦601 219 . . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . 1T . . . . ♦073 586 . . BLOCK, term 20A 11P screw term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . G . . . . . *020 603 . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . 103 947 . . TUBING, stl .312 OD x 17ga wall x .937 . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 025 338 . . BUSHING, nyl univ 23/32 hd dia .625mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . C18,19 . . ♦126 450 . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 7 8
6
1 3 4 5 9

10

11

12 13

27 26

14

25
15
23 24

16

21 22
17

20 19 18 ST-129 610-A

Figure 10-5. HF Panel

♦Item is not part of HF Panel.

*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Spectrum 1500 TM-205 Page 63
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-6. Rectifier, Main (Fig 10-1 Item 15) 135 688 168 592

... 1 . SCR1-3A,B . . 126 283 .. POWER BLOCK, thyristor 40A 400PIV . . . . . . . . . . . . . . . . . . . . . . 3

... 1 . . . SCR-3 . . . . 168 065 .. POWER BLOCK, thyristor 55A 1200PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 2 ............... 112 250 .. FOIL, interface heat transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
... 3 ............... 126 282 .. HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 4 . . . . TP2 . . . . . 129 552 .. THERMOSTAT, NC open 203F close 178F . . . . . . . . . . . . . . . . . . 1 . . . . 1
... 5 . . . . . D4 . . . . . . 126 213 .. DIODE BLOCK, rect 85A 1000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . D4 . . . . . . 168 167 .. DIODE BLOCK, rect 110A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............... 126 710 .. TUBING, cop hd drn .500 OD x .281 ID x .187 . . . . . . . . . . . . . . . 3 . . . . 3
... 7 ............... 126 495 .. BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
... 8 . . . C1,7-12 . . . . 127 082 .. CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 7
... 9 . . . . VR1 . . . . . 105 779 .. VARISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
4

1 2

6 5

SB-129 611-B

Figure 10-6. Rectifier, Main

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-205 Page 64 Spectrum 1500

Item Part
No. No. Description Quantity

Figure 10-7. Terminal Assembly, Pri 3Ph Triple Voltage (Fig 10-1 Item 28) 038 126 168 854

. 1 . 601 835 .. NUT, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . 51

. 2 . 038 887 .. STUD, primary board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . 23
. 3 . 010 913 .. WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . 23
. 4 . 038 618 .. LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .... 7
. 5 . 038 058 .. TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .... 1
. 6 . 010 915 .. WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .... 6
. 7 . 601 836 .. NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 .... 6
. 8 . 038 888 .. STUD, primary board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 .... 3

4 1

5 6 7

6
7 SA-138 574

Figure 10-7. Terminal Assembly, Pri 3Ph Triple Voltage

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Spectrum 1500 TM-205 Page 65

 Item Part
No. No. Description Quantity

Figure 10-8. Water Tank Assembly (Fig 10-1 Items 6 & 11)

... 1 .......... 165 748 . . CAP, tank water screw-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .......... 165 749 . . PACKING, rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .......... 125 466 . . PACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .......... 125 310 . . FILTER, water return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .......... 125 314 . . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .......... 125 224 . . FITTING, pipe brs elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 125 307 . . NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 125 311 . . PACKING, rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 .......... 125 308 . . FILTER ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 125 313 . . . . FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 125 312 . . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . 125 309 . . NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 125 306 . . TANK, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 5 6

2 3

12

8
8 9

11 10

ST-129 916-A

Figure 10-8. Water Tank Assembly

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-205 Page 66 Spectrum 1500

Notes
Notes