TM 219

February 1996 Form: TM-219
Effective With Serial No. KE736265
TECHNICAL MANUAL
Service And Parts
Spectrum Plus
For Plasma Arc Cutting (PAC) And Plasma Arc Gouging (PAG)
KW Maximum
Rated Output Type Of Input
(Varies With Type Of Open-Circui Plasma Plasma Gas
Range @ (Welding Power
Output Of Output t Voltage Gas Flow/Pressure
110 Volts DC Source/Generator)
Power Supply) DC
Standard 25 ft
20 To 50 A @ (7.6 m) Torch
Low 5.8
50% Duty Cycle Cable: 4 CFM
(115 L/min) 70
3-Phase Power,
Power 40 To Direct Current,
Current
Air Or PSI (483 kPa)
125 Volts DC; 185 Straight
35 To 80 A @ 200 Nitrogen Optional 50 ft
Amperes DC Polarity
50% Duty Cycle Only (15.2 m) Machine
Maximum (DCEN)
High (Input Voltage 9.8 Or Torch Cable:
Greater Than 60 4 CFM (115
Volts DC) L/min) 90 PSI
(921 kPa)
cover_tm 4/95 – ST-800 868  1996 MILLER Electric Mfg. Co. PRINTED IN USA
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3. Changing Current Range Setting At DIP Switch And Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4. Input Terminal, Selecting Cable Sizes, And Weld Cable Preparation . . . . . . . . . . . . . . . . . . . 5
2-5. Connecting Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-6. Input Power Connections To Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Cutting Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Operation Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-5. Power/Circuit Breaker Switch And Power Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Troubleshooting Circuit Diagram For Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Waveforms for Section 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-4. Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-6. Diagnostic LED’s On Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-7. LED Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-8. LED Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-9. Trigger/Filter Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-10. Trigger/Filter Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-11. Capacitor Board PC5 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-12. Capacitor Board PC5 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-13. Arc Starter Board PC6 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-14. Arc Starter Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-15. Current Sensing Board CT1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-16. Current Sensing Board CT1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-17. Current Sensing Board CT2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-18. Current Sensing Board CT2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WHO DO I CONTACT FOR HELP?

H CALL: H FAX: H WRITE:
Miller Customer Service 800-637-2348 (in USA), Miller Electric Mfg. Co.
Department at or P.O. Box 1079
414-735-4505 414-735-4136 (outside USA) Appleton, WI 54912 USA
Always provide Model Name and Serial or Style Number
OM-219 8/95
SECTION 6 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Removing Case And Discharging Input And Output Capacitors . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-5. Filter/Regulator Assembly And Extractor/Dryer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-6. Torch Hose And Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-7. Checking Trigger Disabled System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 7 – HF IN PLASMA CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-1. High Frequency In Plasma Arc Cutting (PAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-2. Sources Of High-Frequency Radiation From Incorrect Installation . . . . . . . . . . . . . . . . . . . . . 32
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_ptm1 4/95
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this Y Marks a special safety message.
procedure! The possible hazards are shown in the adjoining symbols. . Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2. Servicing Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts

on circuit boards.
1. Do not touch live electrical parts.
1. Put on grounded wrist strap BEFORE handling
2. Turn OFF power source, and disconnect and boards or parts.
lockout input power using line disconnect switch,
circuit breakers, or by removing plug from 2. Use proper static-proof bags to store, move, or
receptacle before servicing unless the procedure ship PC boards.
specifically requires an energized unit.
FIRE OR EXPLOSION can result from
3. Insulate yourself from ground by standing or placing unit on, over, or near
working on dry insulating mats big enough to combustible surfaces.
prevent contact with the ground.
1. Do not place unit on, over, or near combustible
4. Do not leave live unit unattended. surfaces.
2. Do not service unit near flammables.
5. When testing a live unit, use the one-hand
method. Do not put both hands inside unit. Keep
one hand free.
FLYING PIECES OF METAL or DIRT can
injure eyes.
6. Do not touch torch parts if in contact with the work 1. Wear safety glasses with side shields or face
or ground. shield during servicing.
7. Turn off power before checking, cleaning, or 2. Be careful not to short metal tools, parts, or wires
changing torch parts. together during testing and servicing.
8. Do not bypass or try to defeat the safety interlock HOT PARTS can cause severe burns.
systems.
1. Do not touch hot parts bare handed.
9. Use only torch(es) specified in Owner’s Manual.
2. Allow cooling period before servicing torch.
10. Point torch away from your body and toward
workpiece when pressing the torch trigger – pilot
arc comes on immediately. EXPLODING PARTS can cause injury.
11. The pilot arc can cause burns – keep away from 1. Failed parts can explode or cause other parts to
torch tip when trigger is pressed. explode when power is applied to inverters.
12. Disconnect input power conductors from 2. Always wear a face shield and long sleeves when
deenergized supply line BEFORE moving power servicing inverters.
source.
ELECTRIC SHOCK HAZARD from
incorrect use of test equipment.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters. 1. Turn Off power source before making or changing
meter lead connections.
13. Turn Off inverter, disconnect input power, and
2. At least one meter lead should be a self-retaining
discharge input capacitors according to
spring clip such as an alligator clamp.
instructions in Maintenance Section before
touching any parts. 3. Read instructions for test equipment.
Spectrum Plus TM-219 Page 1

HIGH-FREQUENCY RADIATION can MOVING PARTS can cause injury.
interfere with radio navigation, safety 1. Keep away from moving parts such as fans.
services, computers, and
communications equipment. 2. Keep all doors, panels, covers, and guards closed
and securely in place.
1. Have only qualified persons familiar with
electronic equipment perform this installation. CUTTING can cause fire or explosion.
2. The user is responsible for having a qualified
electrician promptly correct any interference 1. Protect yourself and others from flying sparks and
problem resulting from the installation. hot metal.
3. If notified by the FCC about interference, stop 2. Do not cut where flying sparks can strike
using the equipment at once. flammable material.
4. Have the installation regularly checked and 3. If test cuts are required, follow Safety Precautions
maintained. in Owner’s Manual and on safety label(s).
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, OVERUSE can cause OVERHEATED
and use grounding and shielding to minimize the EQUIPMENT.
possibility of interference.
1. Allow cooling period.
FALLING EQUIPMENT can cause
serious personal injury and equipment 2. Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
damage.
1. Use lifting eye to lift unit only, NOT running gear, 3. Follow rated duty cycle.
gas cylinders, or any other accessories.
READ INSTRUCTIONS.
2. Use equipment of adequate capacity to lift unit.
1. Use MILLER Testing Booklet (Part No. 150 853)
MAGNETIC FIELDS FROM HIGH when servicing this unit.
CURRENTS can affect pacemaker
operation. 2. Consult the Owner’s Manual for cutting safety
precautions.
1. Pacemaker wearers keep away from servicing
areas until consulting your doctor. 3. Use only genuine MILLER replacement parts.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
The following is a quotation from the General Conclusions Section 1. Keep cables close together by twisting or taping them.
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields – 2. Arrange cables to one side and away from the operator.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very 3. Do not coil or drape cables around the body.
large volume of scientific findings based on experiments at the
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
allow us to draw definite conclusions about questions of possible About Pacemakers:
risk or to offer clear science-based advice on strategies to minimize The above procedures are also recommended for pacemaker
or avoid potential risks.” wearers. Consult your doctor for complete information.
TM-219 Page 2 Spectrum Plus

SECTION 2 – INSTALLATION
2-1. Dimensions And Weight
Dimensions
C A 17 in (432 mm)
B 10 in (254 mm)
A C 19 in (483 mm)
Weight
Net: 68 lb (31 kg)*

Ship: 87 lb (40.5 kg)*
B
ST-800 868 *Without Torch
2-2. Selecting A Location

1 Lifting Handles
Use lifting handles to lift unit.
2 Hand Cart
Use hand cart or similar device to
Movement And Airflow move unit.
1 3 Rating Label
3 Use rating label to determine input
power needs.
Locate unit near welding power
source/generator.
18 in
Y Special installation may be
(460 mm)
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
18 in
(460 mm)
move_loc1 4/95 – ST-800 869

2-3. Changing Current Range Setting At DIP Switch And Bus Bars
Current changeover dip switches
and bus bars allow operation on
two current range settings:
a High Range: 35 to 80 Am-
peres
See rear cover for welding power
1 source/generator cutting capacity.
Current range is factory set for the
2 high current range. If welding pow-
er source/generator cutting capac-
3 3 ity is 3/4 to 7/8 in (19 to 22 mm),
keep cutter set for the high current
O O range.
P 1 P 1 b Low Range: 20 to 50 Am-
E OR E
2 2 peres
N N
Use low range position when 50
volts or less input operating volt-
age is available. To change current
range setting, proceed as follows:
S1 S1 Remove bottom and top of case
High Range Low Range according to Section 6-2.
Position Position 1 Main Control Board
Means place switch 2 Dip Switch S1 Location
in this position. 3 Dip Switch S1
Move switches to low range posi-
tions.
4 Current Changeover Bus
Bars
To move bus bars, peel back vinyl
coating covering bus bars. Move
bus bars to match operating volt-
age. Tighten bus bars, and cover
connections with suitable vinyl
coating.
Reinstall top and bottom of case
and go on to Section 2-4.
4
4 OR
High Low
Range Range
Tools Needed: Position Position
3/8, 7/16 in
Ref. ST-800 870-A

2-4. Input Terminal, Selecting Cable Sizes, And Weld Cable Preparation
NOTE If job requires cable larger than 3/0 AWG, use 2 ft (610 mm) or shorter piece of 3/0
AWG cable for Dinse-Type connector installation. Connect other end of short cable
to the 4/0 or larger weld cable.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 – 60% 60 – 100%
Weld Output Welding
Duty Duty 10 – 100% Duty Cycle
Terminals Amperes
Cycle Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0

Negative Input
Terminal
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
7/32 in
1 in
(26 mm)
ST-162 032-A

2-5. Connecting Air Compressor
1 Filter/Regulator Assembly
2 Air Input Fitting (1/4 NPT
Pipe Fitting)
3 Hose (3/8 To 1/2 in)
4 Air Compressor
Obtain air compressor and hose. A
quick connect fitting may also be
installed onto air input fitting. Con-
nect hose to air input fitting and
route to air compressor.
Adjust air pressure according to
Section 3-4.
. Use only clean, dry gas/air at

70 PSI (482 kPa) for 25 ft (7.6
m) long torch cable or 90 PSI
(621 kPa) for 50 ft (15.2 m)
long torch cable.
1
2 3
Tools Needed:
1-1/8, 5/8 in
Ref. ST-800 871 / Ref. ST-800 872-A

2-6. Input Power Connections To Cutter
1 Cutter
2 Negative (–) Input Terminal
3 Air Compressor
4 Welding Power Source
5 Negative (–) Cable
Connect one end of negative (–)
cable to negative (–) output termi-
nal of welding power source/gen-
erator. Connect remaining connec-
tor of negative (–) cable to negative
(–) input terminal on cutter.
6 Torch
Install torch according to its own-
er’s manual instructions.
7 Work Clamp/Positive (+)
Cable
Connect work clamp positive (+)
weld input cable to positive (+)
weld output terminal on welding
power source/generator.
8 Workpiece
9 Work Clamp
Connect work clamps from cutter
and welding power source/genera-
tor to workpiece.
See welding power source/gener-
ator Owner’s Manual for its input
power requirements.
+
2
–
6 5
7
8
9
Tools Needed:
Ref. ST-800 870-A / Ref. ST-155 048-A / ST-800 871

SECTION 3 – OPERATION
3-1. Controls
1 Power/Circuit Breaker Switch
2 Cutting Current Control
3 Operation Mode Switch
1 4 Power And Trouble Lights
ST-800 873
3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
50% Duty Cycle At 50 Amperes In Low Range; fan runs. Wait fifteen minutes for
80 Amperes In High Range unit to cool or temperature light to
go off. Reduce amperage or duty
cycle before cutting or gouging.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
5 Minutes Cutting 5 Minutes Resting
Overheating
A
0
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 – Ref. ST-800 868
3-3. Cutting Current Control

1 Cutting Current Control
2 2 Low Range Scale
(20 to 50 Amperes)
1 3
3 High Range Scale
(35 to 80 Amperes)
Control scales are in amperes. Set
control to desired cutting current
output.
Ref. ST-171 324

3-4. Operation Mode Switch
2 3 1 Operation Mode Switch
Use switch to safely adjust gas/air
pressure without activating cutting
output.
1
2 Torch Mode (Standard)
V Use these mode positions for stan-
dard cutter units.
POWER ON ON 3 Air Assist Mode (Optional)
Use these mode positions for cut-
ters equipped with optional air am-
Set Switches plifier kit.
Place switch in applicable Gas Set
position to adjust gas/air pressure.
Only gas/air is activated when the
5 Power/circuit breaker switch is
Requires turned On.
80-150 psi
(552-1034 kPa) Place switch in the Cut position to
Supply 4 cut or gouge.
4 Air Filter/Regulator
5 Pressure Adjustment Knob
Lift knob and turn to adjust pres-
sure. Push knob down to lock in
setting.
Turn On Gas/Air Supply Adjust Pressure Set To

70 PSI (483 kPa)
For 25 ft (7.6 m)
Long Torch Cable
Or 90 PSI (921 kPa)
For 50 ft (15.2 m)
Long Torch Cable
Set Switch To Begin Cutting

Ref. ST-171 002 / Ref. ST-800 872-A / ST-801 326
3-5. Power/Circuit Breaker Switch And Power Light

2 Power Light
Use power/circuit breaker switch
1 to turn unit and power light On and
2 Off.
Power/circuit breaker switch CB1
also protects the unit from over-
OFF OFF load. If CB1 trips, the unit shuts
down.
If CB1 trips, reduce welding power
source/generator cutting amper-
age by 10 amperes. If CB1 trips
again while cutting, see Section
5-1.
Ref. ST-171 002

SECTION 4 – THEORY OF OPERATION
CB1
Provides protection for cutter and
welding power source/generator
and on/off control of power to cut-
ter.
2 LED Board PC2
LED’s indicate status of trigger,
transfer, gas/torch, temperature,
and polarity.
3 Power Light D3
Lights when cutter is ready for op-
eration. 2 7 8
4 Cutting Current Control R8 LED Pilot Arc
Board Control
Selects cutting current output lev- PC2 Relay CR1
el. PC1 compares selected level to
current feedback signal from CT2
and sends proper gating signal to 3 9
SCR Q2. Power Pressure
5 Operation Mode Switch S1 Light Sensing
D3 Switch S2
Selects cutting and gas/air pres-
sure adjustment modes.
4 10
6 Fan Motor FM
Cutting Control Air
Provides cooling of internal com- Board PC1
Current Solenoid
ponents. Control R8 AS1
7 Control Board PC1
Receives signals from CT1, CT2, 5 11
front panel, gas/air sensor, torch
trigger, and sends proper gating Operation Trigger/Filter
signals to SCR’s Q1 and Q2 to con- Mode Control Board
trol the inverter boost circuitry. PC1 Switch S1 PC3
also controls air solenoid AS1 and
pilot arc control relay CR1.
6 12
8 Pilot Arc Control Relay CR1
Fan Thermostats
Energized by PC1 to start pilot arc Motor
FM TP1, TP2
when trigger is pressed. Deener-
gized when CT2 senses cutting
current. Gating Signal
9 Pressure Sensing Switch S2 Current Gating
Feedback Signal
Provides signal to PC1 to shut
down cutter if gas/air pressure is
too low.
10 Air Solenoid AS1
Allows airflow for preflow, pilot arc, 14 7 18
cutting, and postflow. Capacitor
Capacitor SCR Board
11 Trigger/Filter Board PC3 Q1
C2 PC5
Provides isolation to PC1 for trig-
ger/shield cup circuits. 16
12 Thermostats TP1, TP2
Current
Shut down cutter if temperature of 15 Sensing 17 7
L1 or L2 gets too high. Main Board CT1 Commutating
Inductor Inductor SCR
13 Air Filter/ Regulator Q2
L1 L2
Filters and regulates input air pres-
sure.
1
Power/Circuit
Breaker To Negative (–)
Switch CB1 Weld Output
Terminal

14 Capacitor C2
AC Or DC Control Signals Provides added input energy stor-
age for welding power sources/
Cutting Current Circuit generators with low voltage or slow
output response.
15 Main Inductor L1
Main energy storage device for the
inverter boost circuitry.
16 Current Sensing Board CT1
Monitors the boost current from the
power supply.
17 Commutating Inductor L2
Input Provides reverse voltage to turn
Air SCR Q1 off.
Supply
18 Capacitor Board PC5
80-150 PSI Regulates cutter input voltage to
13 approximately 60 volts dc.
19 Filter Board PC4
70 Or 90 PSI Air Filter/
Regulator Filters arc start initiation signal to
arc starter board PC6.
20 Pilot Fuse F1
Protects cutter from faults in pilot
Gas/Air arc circuit. If F1 opens, there will be
To Torch no pilot or arc starting.
21 Arc Starter Board PC6
Provides high frequency signal to
arc start transformer T1.
Trigger/Shield Cup 22 Output Inductor L3
Filters (smooths) output cutting
Current Feedback current.
23 Arc Start Transformer T1
Provides high frequency energy to
help pilot arc jump from electrode
19 to tip. When work to electrode re-
sistance is low enough, output cur-
Filter rent flows through work.
Board
PC4 24 Current Sensing Board CT2
Provides cutting current feedback
signal to PC1 for output current
regulation.
20 21
Pilot Arc Starter
Fuse Board
F1 PC6 CR1
24
22 23 Current
Sensing
Output Board CT2 Electrode (–)
Arc Start
Inductor Transformer
L3 T1
Pilot (+)
To Positive (+)
Weld Output Terminal
Work (+)

SECTION 5 – TROUBLESHOOTING
5-1. Troubleshooting Table
Y Disable high frequency by disconnecting lead

from connection P1 on arc starter board PC6
before testing unit.
. See Section 5-2 for test points and values and

Section 9 for parts location.
Trouble Remedy
No cutting output; Power light D3 off; Place cutter and welding power source Power switch in On position (see also welding power source/
trouble lights off; fan motor does not generator Owner’s Manual).
run.
If applicable, place line disconnect device in On position (see welding power source Owner’s Manual).
If applicable, check line fuse(s) and replace if needed or reset circuit breakers (see welding power
source Owner’s Manual).
If Polarity light D5 is On, correct connections between welding power source/generator and cutter (see
Section 6-4).
Be sure work clamps from welding power source/generator and cutter are connected to the same work-
piece (see Section 2-6).
Check main fuse F1, and replace if necessary (see Section 6-3).
Check control board PC1 and connections, and replace if necessary (see Section 5-4).
No cutting output; Power light D3 on; Be sure work clamps are connected.
trouble lights off; fan motor running.
Check for proper installation of torch parts and consumables. See torch Owner’s Manual.
Check for secure torch lead connections.
Check pilot fuse F1, and replace if necessary (see Section 6-3).
Check continuity of torch trigger switch and leads. Repair or replace torch. See Torch Owner’s
Manual.
Power/Circuit Breaker switch CB1 trips Reduce welding power source/generator cutting amperage by 10 amperes. (Do not exceed 200 am-
when cutting. peres cutting output.)
If possible, change to welding power source/generator with higher cutting capacity.
Check for proper connections to Power/Circuit Breaker switch CB1, and replace if necessary.
Check current sensing boards CT1 and CT2 and connections, and replace if necessary (see Sec-
tions 5-15 and 5-17).
Power/Circuit Breaker switch CB1 trips Check continuity of Power/Circuit Breaker switch CB1, and replace if necessary.
immediately when turned On.
Check SCR Q1, and replace if necessary.
No control of output. Check resistance and connections of Cutting Current control R8; R8 is 0 to 5 k ohms ±10%. Replace
R8 if necessary.
Check current sensing board CT2 and connections, and replace if necessary (see Section 5-17).
Gas/air flows in Gas Set position, but Check torch connections.
does not flow when trigger is pressed.
No gas/air flow; Power light D3 on; Check torch connections.
trouble lights off; fan motor FM running.
Check for blocks in hose and sufficient gas/air supply pressure.
Check coil voltage and connections of gas/air solenoid AS1. Check continuity of coil. Replace AS1 if
necessary.

Trouble Remedy
No pilot arc. If cutting arc does not start within 5 seconds of pilot arc, release torch trigger and wait 20 seconds for
arc starter circuit to reset before trying to restart pilot arc.
Check torch connections.
Check pilot fuse F1, and replace if necessary (see Section 6-3).
Check for damaged torch or torch cable. See torch Owner’s Manual.
Check for correct gas/air pressure adjustment (see Section 3-4).
If Temperature light D4 is On, thermostat TP1 and/or TP2 are open (overheating). Allow fan to run; the
thermostat closes when the unit has cooled.
Check coil voltage and connections of pilot control relay CR1. Check continuity of coil. Replace
CR1 if necessary.
Check arc starter board PC6 and connections, and replace if necessary (see Section 5-13).
Erratic pilot arc, difficulty in establishing Shorten standoff distance to within 1/8 in (3 mm) between torch tip and workpiece.
an arc, and lowered cutting capacity.
Be sure work clamps are connected.
Check current range setting at DIP switch and bus bars (see Section 2-3).
Check for excessive moisture and/or contaminants in gas/air supply.
If possible, change to welding power source/generator with higher cutting capacity.
Check for dirty filter/regulator and clean, if needed (see manufacturer’s instructions supplied with unit).
Check for damaged torch or torch cable. See torch Owner’s Manual.
Gas/Torch light D3 on; Power light D3 Place Operation Mode switch in Cut position.
off.
Check torch cup, and check for blocked hoses. See torch Owner’s Manual.
Clean filter/regulator filter. See instructions supplied with filter/regulator assembly.
Check coil voltage and connections of gas/air solenoid AS1. Check continuity of coil. Replace AS1 if
necessary.
Temperature light D4 on; Power light Thermostat TP1 and/or TP2 open (overheating). Allow fan to run; the thermostat closes when the unit
D3 off. has cooled.
Unit pilots, but does not transfer. Shorten standoff distance from 1/8 to 1/16 in (3 to 1.6 mm). See torch Owner’s Manual.
Be sure work clamps are connected.
Increase welding power source/generator output setting to highest range. See power supply’s Owner’s
Manual.
If Polarity light D5 is On, AC input is improperly being used. If single-phase welding power source/gener-
ator is being used, it may not be compatible with cutter. Change to three-phase, DC welding power
source/generator.
For engine-driven welding generators, be sure auto idle is Off and run engine at weld/cut RPM.
Check current sensing board CT2 and connections, and replace if necessary (see Section 5-17).
Fan motor FM does not run; Power light Check coil voltage and connections of fan motor FM. Check continuity of coil. Replace FM if necessary.
D3 on.
Trouble lights not working. Check LED board PC2 and connections, and replace if necessary (see Section 5-7).
Power light D3 on; trouble lights on; Check control board PC1 and connections, and replace if necessary (see Section 5-4).
cutting output available.

5-2. Troubleshooting Circuit Diagram For Power Source
Y Discharge input capacitors according to

Section 6-2, and be sure voltage is near Test Equipment Needed:
zero before touching any parts.
Y Disable high frequency by disconnecting
lead from connector P1 on arc starter
board PC6 before testing unit.
See Section 5-7 See also Section 5-4

for PC2 data for PC1 data
V1 See Section 5-3 for

waveforms C, D
C D
V2
R1 See Section 5-15 See Section 5-11 R2

for CT1 data for PC5 data

Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance Voltage Readings
R1 Less than 1 ohm

a) Tolerance – ±10% unless specified
R2 Less than 1 ohm b) Reference – to circuit common
unless noted
R3 Less than 1 ohm
R4 Less than 1 ohm V1 0 to –11.88 volts dc from min to max of
Cutting Current control R8
V2 48 volts dc
V3 24 volts dc with trigger switch open,
0 volts dc with trigger switch closed
V4 12 volts dc with trigger switch open,
0 volts dc with trigger switch closed
V3 Pilot arc control
relay CR1
See Section 5-9

for PC3 data
V4
See Section 4 for

PC4 information
A, B
R3 R4
See Section 5-13 See Section 5-17 See Section 5-3 for
for PC6 data for CT2 data waveforms A, B
SC-171 596-B

5-3. Waveforms for Section 5-2
100 ms 50 V 5 ms 20 V
gnd
gnd
A. DC Open-Circuit Voltage, Cutter Set In B. DC Output, Load Bank At 25 A, Cutting

High Range Current Control R8 At 50 A, Cutter Set In
High Range
200 µs 2 V 200 µs 2 V
gnd
gnd
C. Q1 Gate Pulses With Respect To Cathode, D. Q2 Gate Pulses With Respect To Cathode,
Load Bank At 25 A, Cutting Current Control Load Bank At 25 A, Cutting Current Control
R8 At 50A, Cutter Set In High Range R8 At 50A, Cutter Set In High Range
Y Disable high frequency by disconnecting lead from

connection P1 on arc starter board PC6 before testing
unit.
Test Equipment Needed:
Readings may be lower when using a welding power source
with low open-circuit voltage and cutter set in Low Range.

5-4. Control Board PC1 Testing Information
Y Discharge input and output
capacitors according to
Section 6-2, and be sure
voltage is near zero before
touching any parts.
9 6 7 1
Y Disable high frequency by
disconnecting lead from re-
ceptacle P1 on arc starter
DS4 DS1 DS5 DS6 board PC6 before testing
J12 unit.
Be sure plugs are secure before
testing. See Section 5-5 for specif-
U2 U7
ic values during testing and Sec-
J10 tion 5-6 for troubleshooting LED’s.
1 Control Board PC1
U4 U8 2 Receptacles J1, J2, J3, J8,
J9, J10, J11, J12
J3 3 Receptacle J4, J5, J6, J7
4 Receptacle J13
J14
S1 J13 5 Receptacle J14
J8 U1 U5
6 LED’s DS1, DS4
7 LED’s DS5, DS6
2
8 LED’s DS2, DS3
J1 5
U10 U6 9 Dip Switch S1 (See
DS2 DS3 Section 2-3)
J9 10 Main Fuse F1 (See
Section 6-3)
U3
J11
F1
J2
T2 T3
T1
10 4 8 3
Ref. ST-800 870-A

5-5. Control Board PC1 Test Point Values
a) Tolerance – ±10% unless spe-

cified
PC1 Voltage Readings
b) Reference – to circuit common
unless noted
Receptacle Pin Value
J1 1 Not used
2 Not used
3 Not used
J2 1 Reference for pin J2-3
2 Not used
3 +48.3 volts dc output with respect to pin J2-1
2 With respect to pin J3-1: 0 volts dc output with trigger switch open, –24 volts dc output with trigger
switch closed
3 Reference for pin J3-4
4 With respect to pin J3-3: +0.5 volts dc output for normal condition, +12 volts dc output with thermo-
stat TP1 or TP2 open
5 Momentary full open-circuit voltage (OCV) output with respect to pin J1-2 on arc starter board PC6
J4 –– Gate pulse to Q1 with respect to receptacle J5 (see Section 5-3)
J5 –– Reference for gate pulse to Q1
J6 –– Gate pulse to Q2 with respect to receptacle J7 (see Section 5-3)
J7 –– Reference for gate pulse to Q2
J8 1 +12 volts dc output with respect to pin J8-6
2 Not used
3 0 to –11.88 volts dc input with respect to pin J8-6 from min to max of Cutting Current control R8
4 With respect to pin J8-6: 0 volts dc with
5 –11.88 volts dc with respect to pin J8-6
6 Reference for pins J8-1, J8-3, J8-4, and J8-5
J9 1 With respect to pin J9-2: +23.3 volts dc with trigger switch open, 0 volts dc with trigger switch closed
3 Not used
J10 1 Not used
2 Reference for pins J10-3 thru J10-7
switch closed
4 With respect to pin J10-2: –2 volts dc output with cutting current, 0 volts dc output with no cutting
current
switch closed
6 With respect to pin J10-2: –2 volts dc output with polarity reversed to cutter, 0 volts dc output with
proper polarity to cutter
7 With respect to pin J10-2: –2 volts dc output with thermostat TP1 or TP2 open, 0 volts dc output
with TP1 and TP2 normally-closed

Receptacle Pin Value
2 Not used
3 Not used
4 Not used
5 Approximate open-circuit voltage (OCV) input from welding power source with respect to pin J11-1
6 Not used
7 Not used
8 Not used
9 Approximate open-circuit voltage (OCV) input from welding power source with respect to pin J11-10
J12 1 With respect to pin J12-2: +24 volts dc output with trigger switch open, 0 volts dc output with trigger
switch closed
3 With respect to pin J12-4: +12 volts dc output with trigger switch open, 0 volts dc output with trigger
switch closed
6 With respect to pin J12-5: +12.5 volts dc input with no gas, 0 volts dc input with gas
7 Not used
8 Not used
3 +0.25 to +1.55 volts dc input with respect to pin J13-2 from min to max of Cutting Current control R8
4 –7.8 volts dc output with respect to pin J13-1
3 +0.27 to +0.6 volts dc input with respect to pin J14-2 from min to max of Cutting Current control R8
4 –7.8 volts dc output with respect to pin J14-1
5-6. Diagnostic LED’s On Control Board PC1
LED Status
DS1 (Red) On dimly during proper plasma cutting
DS2 (Green) On bright when +12 volts dc is okay
DS3 (Green) On bright when –12 volts dc is okay
DS4 (Red) On when torch trigger is pressed
DS5 (Red) On when open-circuit voltage (OCV) (approximately 200 volts) is present at torch
DS6 (Red) On when gas solenoid is energized

5-7. LED Board PC2 Testing Information
touching any parts.
disconnecting lead from
connection P1 on arc starter
board PC6 before testing
unit.
testing. See Section 5-8 for specif-
ic values during testing.
1 LED Board PC2
2 Connections E1, E6, E2
3 Connections E3, E4, E5
4 Trouble Lights DS1 Thru DS6
(See Section 6-4)
1 2 3
E1 E6 E2
E3 E4 E5
DS1 DS2 DS3 DS4 DS5
ST-800 868
5-8. LED Board PC2 Test Point Values

cified
unless noted
Connection Value
E1 With respect to connection E6: 0 volts dc input with trigger switch open, –2 volts dc input with trigger switch closed
E2 With respect to connection E6: –2 volts dc input with cutting current, 0 volts dc input with no cutting current
E3 With respect to connection E6: 0 volts dc input with trigger switch open, –2 volts dc input with trigger switch closed
E4 With respect to connection E6: –2 volts dc input with thermostat TP1 or TP2 open, 0 volts dc input with TP1 and TP2
normally-closed
E5 With respect to connection E6: –2 volts dc input with polarity reversed to cutter, 0 volts dc input with proper polarity to
cutter
E6 Reference for connections E1 thru E5

5-9. Trigger/Filter Board PC3 Testing Information
touching any parts.
unit.
testing. See Section 5-10 for spe-
cific values during testing.
1 Trigger/Filter Board PC3
2 Connection E0
Front 3 Connection E1
4 Connection E2
5 Connections P0-1, P0-2
E0 E1
2
3
L1 L0 C1 E2 C0 L2 L3
4
5
Rear
TB1 1 P0
1
Ref. 800 870-A
5-10. Trigger/Filter Board PC3 Test Point Values

cified
unless noted
Connection Value
E0 Reference for connection E1
E1 With respect to connection E0: +23.3 volts dc output with trigger switch open, 0 volts dc output with trigger switch closed
E2 Same as Positive (+) input to cutter
P0-1 With respect to connection P0-2: +23.3 volts dc input with trigger switch open, 0 volts dc input with trigger switch closed
P0-2 Reference for connection P0-1

5-11. Capacitor Board PC5 Testing Information
touching any parts.
unit.
5 1 1 Capacitor Board PC5
2 Connection J13
3 Connection J14
J16 4 Connection J15
VR3 VR4
C10 5 Connection J16
R7 6 Connections J17, J18, J20
4
J15
J17
C5
K2 R8
6
J20
VR1
C6 J18
2
J13
3
J14
C7
C8 C9
Ref. ST-800 870-A
5-12. Capacitor Board PC5 Test Point Values

cified
unless noted
Connection Value
J13 Approximate open-circuit voltage (OCV) input from welding power source with respect to connection J14
J14 Reference for connection J13
J15 +1.3 volts dc output with respect to connection J16
J17 +53 to +59 volts dc input with respect to connection J20; reference for connection J18
J18 Approximate 75 volts dc input with respect to connection J17

5-13. Arc Starter Board PC6 Testing Information
touching any parts.
unit.
1 Arc Starter Board PC6
2 Connections J1-1 Thru J1-6
3 Connection P1
4 Connection P2

4
3
Ref. ST-801 446
5-14. Arc Starter Board PC6 Test Point Values

cified
unless noted
Connection Value
J1-1 Momentary open-circuit voltage (OCV) with respect to connection J1-2
J1-2 Reference for connections J1-1 and J1-2
J1-3 Not used
J1-4 Momentary open-circuit voltage (OCV) with respect to connection J1-2
J1-5 Reference for connection J1-6
J1-6 +24 volts dc input with respect to connection J1-5 with trigger switch closed
J1-7 Not used
J1-8 Not used
P1 Output connection to primary of high-frequency coupling coil T1
P2 Output connection to primary of high-frequency coupling coil T1

5-15. Current Sensing Board CT1 Testing Information
touching any parts.
unit.
2 Connections E1, E2
. When using a MILLER Load
Bank, cutter may latch on. To
unlatch cutter, use contactor
switch on power source.
R1 R2
R3
CS1
E1 E4
Test Equipment Needed: CR1 R4
E2 E3
2 3
Ref. ST-801 446
5-16. Current Sensing Board CT1 Test Point Values

cified
CT1 Voltage Readings
unless noted
Connection Value
E1 +0.25 to +1.55 volts dc output with respect to connection E4 from min to max of Cutting Current control R8
E2 –7.8 volts dc input with respect to connection E3

5-17. Current Sensing Board CT2 Testing Information
touching any parts.
unit.
R1 R2
R3
CS1
E1 E4
CR1 R4
E2 E3

2 3
Ref. ST-801 446
5-18. Current Sensing Board CT2 Test Point Values

cified
CT2 Voltage Readings
unless noted
Connection Value
E1 +0.27 to +0.6 volts dc output with respect to connection E4 from min to max of Cutting Current control R8
E2 –7.8 volts dc input with respect to connection E3

SECTION 6 – MAINTENANCE
6-1. Routine Maintenance
Y Disconnect power before maintaining.
Each Use
Check Torch Check For Air Bleeding

Check Gas/Air
Tip, Electrode, From Extractor/Dryer
Pressure
And Shield Cup Assembly (See Section 6-5)
Every Week
Check Trigger Drain Moisture From

Disabled System Filter/Regulator Assembly
(See Section 6-7) (See Section 6-5)
3 Months
Replace Service
Unreadable Filter/Regulator
Labels Assembly Filter
Clean And Tape Torn Outer

Tighten Weld Covering Or
Terminals Replace Cable
Replace
Cracked
Parts
Gas/Air Hose Torch Body
6 Months
Blow Out Or Vacuum

OR
Inside. During Heavy
Service, Clean Monthly

6-2. Removing Case And Discharging Input And Output Capacitors
Y Significant DC voltage can
remain on capacitors after
unit is Off. Always discharge
capacitors as shown to be
sure they have discharged
before working on unit.
Y Turn Off welding power
source and cutter, and dis-
Bleeder Resistor connect input power and in-
Specifications put air hose. Stop engine on
welding generator.
1 Approx. 1 Bleeder Resistor (Not
3 in Supplied, Part No.172 264)
(76 mm)
Leads Obtain or construct bleeder resis-
tor with specifications shown. Lead
connections must be soldered to
resistor.
5 Ohms, At Least 50 Watts, 2 Top Of Case
#16 AWG 600 Volts DC 3 Guards
Insulation Rating 4 Bolts
5 Nuts
Remove top of case as shown.
6 Input Capacitors C1, C2
2 Peel back vinyl coating covering
capacitor terminals. Connect
3 bleeder resistor across terminals
4 of one capacitor, and wait for at
least 10 seconds.
Repeat procedure for remaining
capacitor.
7 Output Capacitor Discharge
Terminals
Peel back vinyl coating covering
capacitor terminals. Connect
3 bleeder resistor across discharge
terminals, and wait for at least 10
seconds. Remove bleeder resis-
tor.
8 Bottom Of Case
To remove bottom of case, discon-
nect wiring harness of arc start
board (see Parts List).
After task is complete, reconnect
harness (if needed), cover capaci-
tor terminals with suitable vinyl
7 coating, and reinstall case.
5
Tools Needed:
3/8, 7/16 in
Ref. ST-800 870-A

NOTE If cutting arc is not started within 5 seconds of pilot arc, wait 20 seconds for circuit to
reset before trying to restart pilot arc.
6-3. Overload Protection

connect input power. Stop
engine on welding genera-
tor.
1 Pilot Fuse F1 (See Parts List
For Rating)
Pilot fuse protects unit from faults
in pilot arc circuit. If pilot fuse
opens, there will be no pilot or arc
1 starting.
2 Control Board PC1
3 Main Fuse F1 (See Parts List
For Rating)
Main fuse protects unit from over-
load. If main fuse opens, cutter
shuts down.
Remove top of case according to
Section 6-2, and check and re-
place main fuse as needed. Rein-
stall case according Section 6-2.
Tools Needed:
Ref. ST-800 872-A / Ref. ST-800 185-A / Ref. ST-800 870

6-4. Trouble Lights
1 Trigger Light
Lights when torch trigger is
pressed.
2 Transfer Light
Lights when the transfer from pilot
to plasma arc occurs. Stays lit as
long as plasma arc is present.
1
If certain problems occur, the Pow-
er light goes off, one of the follow-
TRIGGER ing trouble lights comes on, and
2
output stops.
TRANSFER 3 Gas/Torch Light
3
Lights if gas/air pressure is low and
stops plasma and pilot arcs. Also,
GAS/TORCH lights if torch tip is not installed
4
when trigger is pressed. Check for
proper gas/air pressure, and torch
TEMPERATURE tip (see torch Owner’s Manual).
5
4 Temperature Light
POLARITY Lights if cutter overheats (see Sec-
tion 3-2).
5 Polarity Light
Lights if polarity of welding power
source/generator connections to
cutter is incorrect. Check connec-
tions (see Section 2-6).
Ref. ST-171 002
6-5. Filter/Regulator Assembly And Extractor/Dryer Assembly

tor.
1 Filter/ Regulator Assembly
Drain Plug
To drain moisture from filter/regula-
tor assembly, rotate drain plug
counterclockwise. Close drain
plug after moisture is completely
drained from filter/regulator as-
sembly.
2 Extractor/Dryer Assembly
Bleeder Screw
Check for air bleeding from extrac-
tor/dryer assembly. Be sure that
bleeder screw is turned in com-
pletely to allow air to bleed from as-
sembly.
Ref. ST-800 872-A

6-6. Torch Hose And Lead Connections
If torch or work cable needs to be
removed or replaced, proceed as
follows:
tor.
Remove top of case according to
Section 6-2.
1 Boot
4 3 2 Insert torch hose and leads
through boot.
2 Gas Hose
3 Gas Connector
4 Trigger Switch Connector
5 Pilot Lead
6 Pilot Terminal
Connect hose and leads as shown.
Reinstall top of case.
5 6
Tools Needed:
3/8, 5/8 in
Ref. ST-800 896

6-7. Checking Trigger Disabled System
1 Torch Cup
Turn Power On, loosen cup, and
press trigger for one second. If trig-
ger disabling system works prop-
erly, the Trigger light does not
come on. Tighten cup and turn Off
power.
If Trigger light does comes on, sys-
tem is not working properly. Turn
1 Off power. Check torch parts and
consumables (see torch Owner’s
Manual).
Ref. ST-800 895

SECTION 7 – HF IN PLASMA CUTTING
ÉÉÉÉÉÉÉÉÉ
7-1. High Frequency In Plasma Arc Cutting (PAC)
1
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
1 Plasma Arc Torch
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉ
2 High-Frequency Voltage
ÉÉÉÉÉÉÉÉÉ
Used inside torch to ionize gap
ÉÉÉÉÉÉÉÉ
between electrode and tip to help
2 start the pilot arc.
ÉÉÉ ÉÉÉ 6 3 Electrode
ÉÉÉ
4 Pilot Arc
3
5 5 Tip
Work 6 Shield Cup
Plasma Arc Cutting (PAC)

4 high_freq2 4/95 – S-0753
7-2. Sources Of High-Frequency Radiation From Incorrect Installation
Cutting Zone
11, 12
50 ft
(15 m)
10
9 14
3
13 2
1 6
4 5
S-0754
Sources Of Direct High-Frequency Radi- 5 Workpiece Sources Of Reradiation Of High Fre-

ation 6 Work Table quency
1 High-Frequency Source (Plasma Arc Sources Of Conduction Of High Fre- 10 Ungrounded Metal Objects
Cutting Power Source) quency 11 Lighting
2 Cables 7 Input Power Cable 12 Wiring
3 Torch 8 Line Disconnect Device 13 Water Pipes And Fixtures
4 Work Clamp 9 Input Supply Wiring 14 External Phone And Power Lines

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

SECTION 8 – 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 Plus KE736265 and following SC-171 596-B Not available
Circuit Board PC1 KE736265 and following SD-172 275
Circuit Board PC2 KE736265 and following SA-178 645
Circuit Board PC6 KE736265 and following SC-172 456
Circuit Board CT1, CT2 KE736265 and following SA-172 457

SC-171 596-B
Figure 8-1. Circuit Diagram For Spectrum Plus Effective With Serial No. KE736265 And Following
Figure 8-2. Circuit Diagram For Control Board PC1 Effective With Serial No. KE736265 And Following
SD-172 275

SA-178 645
Figure 8-3. Circuit Diagram For LED Board PC2 Effective With Serial No. KE736265 And Following
SA-178 646
Figure 8-4. Circuit Diagram For Trigger/Filter Board PC3 Effective With Serial No. KE736265 And Following
SA-178 647
Figure 8-6. Circuit Diagram For Filter Board PC4 Effective With Serial No. KE736265 And Following
SA-178 648
Figure 8-8. Circuit Diagram For Capacitor Board PC5 Effective With Serial No. KE736265 And Following
SC-172 456
Figure 8-9. Circuit Diagram For Arc Starter Board PC6 Effective With Serial No. KE736265 And Following
SA-172 457
Figure 8-10. Circuit Diagram For Current Sensing Boards CT1, CT2
Effective With Serial No. KE736265 And Following

February 1996 Form: TM-219
Effective With Serial No. KE736265
SECTION 9 – PARTS LIST
Spectrum Plus
For Plasma Arc Cutting (PAC) And Plasma Arc Gouging (PAG)

3
4
Figure 9-2
43 44 45 46 47
42
41
40
36
39
37
38 35
Figure 9-1. Main Assembly

15
16
17
13
18
12
11 14
10
9
8
7
19
20
21
22
6
23
24 25
26
31
32
33
34 28 27
29
30
ST-800 867-A

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . +171 320 . . KIT, replace case top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 171 824 . . LABEL, warning electric shock and sparking . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 171 321 . . KIT, replacement handle black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 136 156 . . LABEL, warning precautionary plasma cutting . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . Figure 9-2 . . CENTER BAFFLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . FM . . . . . . 171 280 . . ASSEMBLY, fan w/mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 171 465 . . PLATE, remote cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 466 . . SCREW, No. 4-40 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 8 . . . . . . . . . . . . . . . 171 461 . . REAR PANEL, silkscreened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 171 512 . . FITTING, coupler 1/4-18NPT to male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 171 514 . . SCREW, 8-32 x .500 socket cap w/nylock . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 171 513 . . MOUNT, regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 515 . . WASHER, flat No. 10 .354 x .195 x .032 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 171 516 . . SCREW, No. 10-32 x .625 Phillips pan head w/nylock . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 171 511 . . GAUGE, 1-160PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 171 510 . . FILTER/REGULATOR, 125PSI (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 526 . . . . KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 529 . . . . FILTER, 5 micron element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 171 517 . . ASSEMBLY, extractor/dryer (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 542 . . . . KIT, cartridge (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 534 . . . . . . CAP, gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . 171 535 . . . . . . FIRST STAGE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 536 . . . . . . SECOND STAGE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 15 . . . . . . . . . . . . . . . 171 521 . . . . FITTING, 90 deg fem 1/4NPT x fem 1/4NPT . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 171 522 . . . . FITTING, long nipple 1/4NPT x 1/4NPT x 2.000 . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 171 523 . . . . FITTING, 90 deg street elb 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 171 524 . . . . FITTING, close nipple 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . F1 . . . . . . 171 469 . . FUSE, non-time delay 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 171 468 . . FUSE HOLDER, w/.187 Faston connectors . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 171 467 . . HOLE PLUG, .375 diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . 171 475 . . STRAIN RELIEF, –16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 171 474 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . Input . . . . . 171 151 . . CONNECTOR, input jack dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . Work . . . . . 171 142 . . ASSEMBLY, work clamp and cable (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 171 143 . . . . WORK CABLE, 12ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 171 144 . . . . WORK CLAMP WITH VINYL GRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 171 290 . . PANEL GUARD, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 171 470 . . BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 171 471 . . FRAME, boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 171 472 . . MOUNT, boot grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 473 . . SCREW, No. 10-10 x .500 Phillips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 31 . . . . . . . . . . . . . . . 171 152 . . WASHER, flat 1.000 x .438 x .083 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 171 148 . . WASHER, flat .812 x .406 x .083 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 171 149 . . WASHER, split lock .683 x .393 x .094 brs . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 171 155 . . NUT, 3/8-16 hex brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 171 323 . . CASE BOTTOM, blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . R8 . . . . . . 171 337 . . POTENTIOMETER, 5K ohm single turn . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . 171 324 . . FRONT PANEL, silkscreened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . 171 335 . . KNOB, round w/indictor dot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . 171 336 . . KNOB, small control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . 171 291 . . PANEL GUARD, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . 171 334 . . FRONT PANEL INDICATOR LENS, clear . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 42 . . . . . D3 . . . . . . 171 332 . . FRONT PANEL POWER ON INDICATOR LAMP . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . PC2 . . . . . 171 276 . . FRONT PANEL INDICATOR PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . 171 325 . . BEZEL, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 326 . . SCREW, No. 6-32 x .500 Allen flat head . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 45 . . . . . S1 . . . . . . 171 338 . . SWITCH, 4 position 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . CB1 . . . . . 171 327 . . CIRCUIT BREAKER, DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 9-1. Main Assembly (Continued)
..................... 171 329 .. PLATE, circuit breaker shorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . VR1 . . . . . 171 328 .. VARISTOR, 130V 20J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 295 .. LEADS & TERMINAL, 6AWG red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 297 .. BUSS WIRE, circuit breaker to hex stud . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+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.

5
3 6
TM-219 Page 46
2
4
7
1
25
10 8 28
27
26
9
19
11
12
13
14 20
18
15
16
17 22
23
24
29 21
Figure 9-2. Center Baffle

Includes
Item 25
33
30
34
37 32
31
38 35
36
ST-800 885–A
Spectrum Plus
Item Dia. Part
Figure 9-2. Center Baffle (Figure 9-1 Item 5)
. . . 1 . . . . . PC1 . . . . . 171 272 . . CONTROL BOARD, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . F1 . . . . . . 171 273 . . . . FUSE, non-time delay 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 ............... 171 298 . . ASSEMBLY, capacitor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . C1 . . . . . . 171 293 . . CAPACITOR, al electrolytic 31K uf 60VDC . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . C2 . . . . . . 171 294 . . CAPACITOR, al electrolytic 3.4KK uf 200VDC . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 295 . . LEAD AND TERMINAL, 6AWG red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 296 . . BUSS WIRE, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 297 . . BUSS WIRE, circuit breaker to hex stud . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . PC5 . . . . . 171 281 . . CAPACITOR BOARD, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............... 171 487 . . . . MOUNTING BRACKET, PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . R6 . . . . . . 171 486 . . . . RESISTOR, WW 30 ohm 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 ............... 171 490 . . . . THREADED ROD, No. 10-32 x 5.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 ............... 171 489 . . . . NUT, No. 10-32 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . 171 488 . . . . SCREW, No. 10-32 x .38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..................... 171 145 . . BUSS WIRE, cap PWB to shoulder screw . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 146 . . SCREW, special shoulder 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..................... 171 147 . . BUSS WIRE, cap PWB to hex stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 274 . . SCREW, No. 8-32 Phillips w/nylock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..................... 171 279 . . ASSEMBLY, sensing harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CR1 . . . . . 171 316 . . ASSEMBLY, pilot relay (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 317 . . . . MAGNET, .500dia x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..................... 171 318 . . . . TAPE, circle double-sided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
..................... 171 319 . . . . CAP, vinyl .468 x .250 black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 171 314 . . NUT, No. 1/4-20 hex brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 13 . . . . . . . . . . . . . . . 171 310 . . WASHER, split lock 1/4-.489 x .263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . . 171 313 . . HEX STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 171 315 . . WASHER, flat 1/4-.500 x .281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
..................... 171 312 . . BUSS WIRE, output jack to hex stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 126 026 . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . . 153 178 . . LABEL, warning exploding parts can cause serious injury . . . . . . . . . . . . 4
. . . 18 . . . . . . . . . . . . . . . 171 138 . . ASSEMBLY SOLENOID & PRESSURE SWITCH, (consisting of) . . . . . 1
. . . 19 . . . . . S2 . . . . . . 171 139 . . . . PRESSURE SENSING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . AS1 . . . . . 171 140 . . . . SOLENOID VALVE, 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
..................... 171 141 . . . . SOLENOID & RELAY, harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 171 299 . . ASSEMBLY CONNECTOR BRACKET, (consisting of) . . . . . . . . . . . . . . . 1
. . . 22 . . . . . CT2 . . . . . 171 271 . . . . CURRENT SENSING, PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 171 301 . . . . BRACKET, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . 171 302 . . . . BRACKET, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . PC3 . . . . . 171 278 . . . . TRIGGER FILTER, PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 171 148 . . WASHER, flat .812 x .406 x .083 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . 171 149 . . WASHER, split lock .683 x .393 x .094 brs . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . 171 150 . . NUT, 3/8-24 steel hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 171 284 . . SPACER, 5/16 hex 10-32 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . L2/TP2 . . . . 171 268 . . COMMUTATING INDUCTOR, tall w/PTC temperature sensor . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 171 285 . . SCREW, No. 10-32 x 5.000 Phillips stnstl . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . L3 . . . . . . 171 269 . . ASSEMBLY, output inductor (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . D2 . . . . . . 171 287 . . . . DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . VR2 . . . . . 171 288 . . . . VARISTOR, 175V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 171 289 . . . . BUS BAR, current changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . Q2 . . . . . . 171 267 . . HEAT SINK ASSEMBLY, rectifier SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . Q1 . . . . . . 171 266 . . HEAT SINK ASSEMBLY, switch SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . D1 . . . . . . 171 156 . . HEAT SINK ASSEMBLY, short diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.

3
4 5
2 8
7
18
12
17
16
9
15
13
10
14
11
ST-800 889
Figure 9-3. Arc Starter Assembly

Item Dia. Part
171 157 Figure 9-3. Arc Starter Assembly
. . . 1 . . . . . L1 . . . . . . 171 491 . . MAIN INDUCTOR, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . TP1 . . . . . 171 492 . . . . PTC, temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 171 495 . . MOUNT ARC START BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . ♦171 304 . . ASSEMBLY OUTPUT CAPACITOR, (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . C3,4 . . . . . 171 305 . . . . CAPACITOR, al electrolytic 1.5K uf 100VDC . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . R2,3 . . . . . 171 306 . . . . BLEEDER, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 171 307 . . . . TERMINAL, .250 Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 308 . . . . SCREW, 1/4-28 x .500 Phillips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 309 . . . . WASHER, flat .468 x .255 x .064 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 310 . . . . WASHER, split lock 1/4-.489 x .263 x .062 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 311 . . . . BUS WIRE, output capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . PC4 . . . . ♦171 282 . . ASSEMBLY, capacitor filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 171 490 . . THREADED ROD, No. 10-32 x 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 171 507 . . NUT, No. 10-32 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . R5 . . . . . . 171 501 . . SURGE RESISTOR, 3 ohm 150W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . R4 . . . . . . 171 486 . . RESISTOR, WW 30 ohm 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 503 . . SCREW, No. 8-32 x .31 Phillips pan head . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 505 . . WASHER, split lock No. 8 .293 x .175 x .040 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 171 504 . . NUT, No. 8-32 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . . . . . . . . . . 171 509 . . WASHER, location ryton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 12 . . . . . T1 . . . . . . 171 493 . . ARC START TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . PC6 . . . . . 171 494 . . ARC START BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 277 . . ASSEMBLY, arc starter harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 171 499 . . CABLE TIE, 1.88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . 171 498 . . CARD LOCK BAR w/HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . . . . 171 496 . . BRACKET, PWB support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 171 497 . . PWB CARD GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . CT1 . . . . . 171 271 . . CURRENT SENSING, PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . C11,R1 . . . . 171 270 . . SNUBBER, switch SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 171 283 . . SCREW, No. 10-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
♦Not included w/Arc Starter Assembly.


WELDING POWER SOURCE/GENERATOR CUTTING CAPACITY
MANUFACTURER: MILLER ELECTRIC MANUFACTURER: LINCOLN ELECTRIC CO.

Material Thickness Material Thickness
Welding Power Source Model Welding Power Source Model
1/2 in 3/4 in 7/8 in 1/2 in 3/4 in 7/8 in
DELTAWELD 451 or 452 L or H INVERTEC V-300 PRO H
DELTAWELD 651 or 652 H IDEALARC R3R 300 H
DIMENSION 302 H IDEALARC R3R 400 H
DIMENSION 400 H IDEALARC R3R 500 H
DIMENSION 452 H IDEALARC DC 600 H
DIMENSION 652 H Engine Driven Welding Power Source
GOLD STAR 302 H SA-200 H
GOLD STAR 452 H SA-250 H
GOLD STAR 652 H SAE-350 H
GOLD STAR 300SS, 400SS, 500SS, H SAE-400 H
And 600SS
SAM-650 H
MARK IV EXPRESS H H*
SAM-400 H
MARK VIII-2 H H*
SAE-400 ELECTRIC MOTOR H
MAXTRON 450 H
SRH-333 H
SRH-444 H MANUFACTURER: Pow Con
XMT 300 Series H Material Thickness
Engine Driven Welding Power Source Welding Power Source Model
1/2 in 3/4 in 7/8 in
BIG 30A DIESEL H 200, 225 L or H
BIG 40G H 300/400 Series (Single Phase) L or H
BIG 40 DIESEL H 300/400 Series (Three Phase) H
BIG 50 DIESEL H 500SM/500SM AC/DC H
BIG BLUE 251D H 550SMP/630SMP H
BIG BLUE 400D H 300STP L or H
BIG BLUE 600D H
LEGEND L
MILLER AIR PAK H MANUFACTURER: KEMPII
TRAILBLAZER 250G H Material Thickness
Welding Power Source Model
TRAILBLAZER 55G & D (CC) H 1/2 in 3/4 in 7/8 in
PS3500 L or H
*When paralleled PS5000 H
MANUFACTURER: HOBART
Material Thickness MANUFACTURER: L-TEC/AIRCO/ESAB
Welding Power Source Model
1/2 in 3/4 in 7/8 in Material Thickness
R-400-S (MEGA ARC) H Welding Power Source Model
1/2 in 3/4 in 7/8 in
RCC-450 RVS H
SVI 450I CV/CC H
RCC-650 RVS H
L-TEC 400I CV/CC H
Engine Driven Welding Power Source
L = set plasma arc cutter in Low range
TITAN COMBO D L or H H = set plasma arc cutter in High range
MA-350-D H Set controls on welding power source/generator for CC mode, high
range, maximum output. If welding power source/generator has a
MA-400-D H high and low stabilizer weld output terminal, connect plasma arc
cutter to low stabilizer terminal.
L = set plasma arc cutter in Low range . Due to certain field conditions, such as very long weld cables, ac-
H = set plasma arc cutter in High range tual results may vary.

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February 1996 Form: TM-219

Effective With Serial No. KE736265

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

WHO DO I CONTACT FOR HELP?

Always provide Model Name and Serial or Style Number

SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1-1. Symbol Usage

1-2. Servicing Hazards

ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts

Spectrum Plus TM-219 Page 1

1-3. EMF Information

TM-219 Page 2 Spectrum Plus

2-1. Dimensions And Weight

Net: 68 lb (31 kg)*

ST-800 868 *Without Torch

2-2. Selecting A Location

move_loc1 4/95 – ST-800 869

Spectrum Plus TM-219 Page 3

TM-219 Page 4 Spectrum Plus

Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

Spectrum Plus TM-219 Page 5

. Use only clean, dry gas/air at

TM-219 Page 6 Spectrum Plus

Ref. ST-800 870-A / Ref. ST-155 048-A / ST-800 871

Spectrum Plus TM-219 Page 7

3-2. Duty Cycle And Overheating

5 Minutes Cutting 5 Minutes Resting

duty1 4/95 – Ref. ST-800 868

3-3. Cutting Current Control

Ref. ST-171 324

TM-219 Page 8 Spectrum Plus

Turn On Gas/Air Supply Adjust Pressure Set To

Set Switch To Begin Cutting

3-5. Power/Circuit Breaker Switch And Power Light

Ref. ST-171 002

Spectrum Plus TM-219 Page 9

TM-219 Page 10 Spectrum Plus

Spectrum Plus TM-219 Page 11

5-1. Troubleshooting Table

Y Disable high frequency by disconnecting lead

. See Section 5-2 for test points and values and

TM-219 Page 12 Spectrum Plus

Check for correct gas/air pressure adjustment (see Section 3-4).

Check for correct gas/air pressure adjustment (see Section 3-4).

Be sure work clamps are connected.

Check for excessive moisture and/or contaminants in gas/air supply.

If possible, change to welding power source/generator with higher cutting capacity.

Clean filter/regulator filter. See instructions supplied with filter/regulator assembly.

Be sure work clamps are connected.

Spectrum Plus TM-219 Page 13

Y Discharge input capacitors according to

See Section 5-7 See also Section 5-4

V1 See Section 5-3 for

R1 See Section 5-15 See Section 5-11 R2