July 1996 Form: TM-205

Effective With Serial No. JK628764 Thru

KC286938

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
 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
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information. mod10.1 4/93

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . 1

1-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 – SHIPPING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2-1. Preparation For Reshipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2-2. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3-1. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3-2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-3. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 4 – INSTALLATION OR RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4-1. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4-2. Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4-3. Work Clamp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-4. Connections For Remote Operation (Optional) . . . . . . . . . . . . . . . . . . . 5
4-5. Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-6. Gas/Air Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-7. Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-8. Stop Guide Sleeve And Stand-Off Guide Installation . . . . . . . . . . . . . . 10

SECTION 5 – OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5-1. Power Switch And Power Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5-2. Ready Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-3. Thickness Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-4. Test/Run Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-5. Water Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-6. Warning Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 Section No. Page No.

SECTION 6 – SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6-1. Plasma Arc Cutting (PAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6-2. Plasma Arc Gouging (PAG) (PAG For Units Effective with
Serial No. KA880069) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6-3. Cutting Problems And Recommendations . . . . . . . . . . . . . . . . . . . . . . . 14
6-4. Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 7 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7-1. Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 8 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8-1. Testing Instruments And Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8-2. Disabling Of HF Output For Testing Procedures . . . . . . . . . . . . . . . . . . 18
8-3. Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8-5. Regulator Board PC1 Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . 27
8-6. Timer/Control Board PC2 Testing Procedures . . . . . . . . . . . . . . . . . . . . 30
8-7. Relay Board PC3 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-8. Trouble Light Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-9. Filter Board PC5 Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-10. Hall Device HD1 Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 9 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10-2. Shield Cup, Tip, And Electrode Inspection And Replacement . . . . . . . 41
10-3. Torch And Work Cable Inspection And Connections . . . . . . . . . . . . . . . 42
10-4. Shield Cup Detector Pin Inspection And Replacement . . . . . . . . . . . . . 43
10-5. Cleaning The Coolant System, Changing Coolant, And Servicing
Coolant Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10-6. Spark Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10-8. Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

 SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
This manual provides theory of operation along with
specific operating, testing, and troubleshooting proce-
dures. It also includes precautionary information rele-
vant to these procedures. This manual can be an effec-
tive tool in the hands of a trained serviceperson. Howev-
er, it does not and cannot take the place of previous
training nor safety-conscious service work. If any doubt
arises about the specific application of procedures pre-
sented, or if problems arise which are not covered in this
manual, contact the factory Service Department before
proceeding further.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
1-3. SAFETY PRECAUTIONS
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Protect yourself with dry insulating gloves
and clothing.
• Insulate yourself from ground by using rub-
ber gloves and rubber or wooden floor mats
when power is applied to the unit.
• Shut down unit and disconnect input power
when servicing unless the procedure specifi-
cally requires an energized unit.
Spectrum 1500
• Do not leave live unit unattended.
• Do not use cables or torch with damaged in-
sulation.
• Turn off power source, and remove input pow-
er before cleaning slag from torch tip or re-
placing any torch parts.
PILOT ARC can cause burns.
• Keep torch tip away from personnel when
switch is pressed.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
FLYING SPARKS AND HOT METAL can
cause fire and burns.
• Do not cut where flying sparks can strike flam-
mable material.
• Protect yourself and others from flying sparks
and hot metal.
• Watch for fire.
• Have a fire extinguisher nearby, and know
how to use it.
• Allow work and equipment to cool before han-
dling.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage
• Use equipment of adequate capacity to lift the
unit.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
• Wearers should consult their doctor before
going near the servicing of arc cutting equip-
ment or any arc cutting operations.
TM-205 Page 1
 SECTION 2 – SHIPPING AND STORAGE
2-1. PREPARATION FOR RESHIPMENT 2-2.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before preparing unit for shipping.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
1. Disconnect input power conductors from deener-
gized supply.
2. If applicable, disconnect gas cylinder, water sup-
ply, and/or coolant system; remove unit from run-
ning gear.
3. Bolt unit to a proper wooden skid or wooden rails.
4. Tape plastic around top and sides of unit.
5. Securely tie and/or tape cardboard over top and
around sides of unit. Use original shipping carton
if available.
IMPORTANT: Do not ship without a cardboard carton.
Not only do costs increase dramatically, but the unit is
more subject to loss or damage without a carton.
6. If sending unit to factory, ship unit as directed by
factory Service Department or Transportation
Department. 10.
TM-205 Page 2
STORAGE
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before starting unit.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
1. Disconnect input power conductors from deener-
gized supply.
2. Clean outside of unit.
3. Remove top cover and side panels (or wrapper
as applicable).
4. Using dry compressed air, clean inside of unit.
5. Reinstall top cover and side panels or wrapper as
applicable.
6. Apply touch-up paint to any nicks or scratches to
prevent rusting, etc.
7. Select a storage location that least subjects the
unit to wide temperature variation, dust, dirt, and
corrosive vapors.
8. Move unit to storage location.
9. Place unit on suitable blocks such as 2 x 4’s or
4 x 4’s to keep it off the floor.
Cover unit with plastic or a suitable tarp.
Spectrum 1500
 SECTION 3 – SPECIFICATIONS

Table 3-1. Specifications

Input At
Rated Load Output Plasma Gas
Rated Maximum 60 Hz Three-Phase Nitrogen/Air Weight
Output Open- Coolant
Only Tank
At 100% Circuit Amperes At
Duty Cycle Voltage Capacity
200V 230V 460V 575V KVA KW Flow/Pressure Net Ship

80 Amperes 1.8 CFM

At 270 Volts 72 62 31 25 25 12.5 (50 L/min.) 3.2 qts 470 lbs. 478 lbs.
DC At 57 PSI (3 L) (213 kg) (217 kg)
120 Volts DC (393 kPa)

Table 3-2. Idling Data (No Load)

Idle Amperes At No Load

60 Hz Three-Phase

200V 230V 460V 575V KVA KW

During Torch
Coolant Prefill* 3.87 3.37 1.68 1.35 1.34 0.61

After Torch
Coolant Prefill* 3.59 3.21 1.56 1.25 1.24 0.43

*When POWER switch S1 is placed in the ON position, the coolant

system prefills the torch and lines.

3-1. DUTY CYCLE
The duty cycle is the percentage of a ten minute period
that the power source and torch can be operated at a
given output without overheating and damaging the
power source and torch. This power source and torch
are rated at 100 percent duty cycle; therefore, the unit
can be operated at 80 amperes continuously without
causing damage to the unit.
CAUTION: EXCEEDING THE DUTY CYCLE
RATINGS will damage the power source and
torch.
• Do not exceed indicated duty cycles.
3-2. DESCRIPTION
CAUTION: INCORRECT PLASMA GAS can
cause torch and power source damage.
• Use only air or nitrogen for the plasma gas
supply.
• Do not use any other gas or combination of
gases.
This unit is a direct current, straight polarity (electrode
negative), Plasma Arc Cutting (PAC) power source re-
quiring 60 Hz three-phase electrical input. The unit can
Spectrum 1500
cut through all metals with the capacity to cut 1-3/16 in.
(30 mm) mild steel, stainless steel, and aluminum using
the Plasma Arc Cutting (PAC) process.
This unit is designed to be used with the supplied model
APT-8000 water-cooled, 93° torch. An optional model
APT-8000M water-cooled, 180° (straight) torch is also
available.
This unit has capabilities for making connections for re-
mote operation.
Rated output is 80 amperes at 120 volts dc, 100 percent
duty cycle.
Plasma is gas/air which has been heated to an extreme-
ly high temperature and ionized so that the gas/air be-
comes electrically conductive. The electrode is located
inside the tip of the torch. The torch tip has a small open-
ing (orifice) which constricts the arc. The compressed
gas/air flows through the arc where it is heated to the
plasma temperature range. Since the gas/air cannot ex-
pand due to the constriction of the tip, the gas/air is
forced through the orifice and emerges in the form of a
highly compressed airstream. The heat formed by the
arc and the plasma melts the metal, and the airstream
forces the molten metal from the cut.
TM-205 Page 3
3-3. CUTTING SPEED (Chart 3-1)
The Cutting speed chart enables the operator to deter-
mine the maximum cutting speed for various thickness
of mild steel within the capabilities of the power source.
The curve indicates the proper speeds at which cutting
may be done, although the speeds indicated may not be
achieved instantaneously. Cutting may have to begin at
a slower speed, with an increase in speed until the opti-
mum speed is reached. Cutting at speeds above the
proper speeds shown by the curve will cause rapid ero-
sion of the tip and electrode and should be avoided.
CAUTION: EXCEEDING REC-
OMMENDED CUTTING SPEEDS will
cause rapid erosion of the tip and elec-
trode.
• Do not exceed indicated cutting speeds.
SECTION 4 – INSTALLATION OR RELOCATION
4-1. SITE SELECTION
Select an installation site which provides the following:
1. Correct input power supply (see unit nameplate)
2. Shielding gas supply (if applicable)
3. Water supply (if applicable)
4. Adequate ventilation and fresh air supply
5. No flammables
6. A clean and dry area
7. Proper temperature that avoids extremes of heat
or cold
8. Proper airflow around unit
9. Adequate space for removing top cover and outer
panels for installation, maintenance, and repair
functions.
Base mounting holes provide the capability to install and
secure the unit in a permanent location. Holes are also
provided in the base for installing an optional running
gear.
WARNING: FIRE OR EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIR FLOW causes
overheating and possible damage to internal
parts.
• Do not locate unit over combustible surfaces.
• Maintain at least 18 inches (457 mm) of unre-
stricted space on all sides of unit, and keep
underside free of obstructions.
• Do not place any filtering device over the in-
take air passages of this power source.
Warranty is void if any type of filtering device is
used.
TM-205 Page 4
Chart 3-1. Cutting Speed
SB-130 081-B
4-2. TRANSPORTING METHODS (Figure 4-1)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from
deenergized supply line BEFORE moving
power source.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Use equipment of adequate capacity to lift the
unit.
• If using lift forks to handle this unit, be sure the
lift forks are long enough to extend beyond
opposite side of the base.
Using lift forks too short can damage internal
parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks.
TRANSPORTING UNIT BY LIFTING HOOKS
can cause serious personal injury and
equipment damage.
• Use spreader bar (not supplied) when trans-
porting this unit using the supplied lifting
hooks (see Figure 4-1).
• Use cable(s) of adequate capacity to lift and
support unit.
Installation And Use Of Lifting Hooks (Figure 4-1)
Install and use the supplied Lifting hooks as follows:
1. Locate the mounting holes for the lifting hooks on
the left and right side of the unit.
2. Using the supplied bolts, mount the lifting hooks
on the left and right side of unit. Tighten bolts to 25
ft/lbs. (34 N·m).
Spectrum 1500
 3. When lifting unit by lifting hooks, be sure to use a Step 6
spreader bar (not supplied) of adequate size to
prevent the lifting cable(s) from putting pressure
on the sides of the unit causing the cover to bend
(see Figure 4-1).

Step 2

Lifting Cable(s)
Step 4
Spreader Bar Step 3
(Not Supplied)

Steps 1 and 5
S-0250

Figure 4-2. Work Clamp Installation

4-4. CONNECTIONS FOR REMOTE OPERATION

(Optional) (Figure 4-3)
Unit
WARNING: ELECTRIC SHOCK can kill.
Lift Hooks
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
S-0439 dures before inspecting or installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
Figure 4-1. Lifting Unit Using Lift Hooks moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.

Terminal strip 1T located behind the left side panel pro-

4-3. WORK CLAMP INSTALLATION (Figure 4-2) vides a junction point for making remote connections to
the control circuitry of the power source. Terminal strip
Install the work clamp onto the free end of the work cable 1T connections for torch and remote operation are as
as follows: follows:
1. Insert free end of work cable through one of the Terminal 1: Shield cup detector circuit lead 1 connec-
two supplied insulating sleeves. tion.
Terminal 2: Shield cup detector circuit lead 2 connec-
2. Lay the work cable inside the half of the work tion.
clamp which has the flattest inner surface.
Terminal 3: Torch switch lead 3 connection.
3. Align the smaller hole in the work clamp with the Terminal 4: Torch switch lead 4 connection.
hole in the work cable terminal lug. Secure the
terminal lug to the work clamp with the supplied Terminal 5: Output sensor connection; normally open
nut and bolt. with respect to terminal 6 when cutting cur-
rent is not present; contact closure when
4. Bend the tabs on the end of the work clamp cutting current is present.
around the work cable. Terminal 6: Output sensor connection; normally open
with respect to terminal 5 when cutting cur-
5. Slide the insulating sleeve on the work cable over
rent is not present; contact closure when
the work clamp handle.
cutting current is present.
6. Slide the remaining insulating sleeve over the Terminal 7: Thickness potentiometer connection
other work clamp handle. (maximum side); command reference.
Spectrum 1500 TM-205 Page 5
Terminal 8: Jumper link connection with respect to ter-
minal 9 when remote operation is used.
Terminal 9: Thickness potentiometer connection (wip-
er contact); jumper link connection with re-
spect to terminal 8 when remote operation
is used; jumper link connection with re-
spect to terminal 10 when remote opera-
tion is not used.
Terminal 10: Jumper link connection with respect to ter-
minal 9 when remote operation is not
used.
Terminal 11: Thickness potentiometer connection
(minimum side); ground.
To make connections for remote operation, proceed as
follows:
1. Shut down power source.
2. Remove left side panel.
3. Disconnect jumper link connected between ter-
minals 9 and 10, and reconnect jumper link be-
tween terminals 8 and 9 on 1T.
4. Connect one current sense lead from remote to
terminal 5 on 1T.
5. Connect remaining current sense lead from re-
mote to terminal 6 on 1T.
6. Connect the maximum side lead of thickness po-
tentiometer from remote to terminal 7 on 1T.
7. Connect the wiper contact lead of thickness po-
tentiometer from remote to terminal 9 on 1T.
8. Connect the ground side lead of thickness poten-
tiometer from remote to terminal 11 on 1T.
9. Reinstall and secure left side panel onto unit.

Work (+) Output Terminal

Gas/Input Conductor

Pilot (+)/Coolant In
Torch (-)/Coolant Connector
Out Connector

1T
Work Cable

1
Detector Lead
2
3 Torch
Torch Switch Cable
4
5
N.O. Output Sensor
6
Command Ref. 7
Remote 8
Shield Cup
Jumper Common 9 Detector Leads
1 And 2
Panel 10
Signal Ground 11

Torch Switch
Leads 3 And 4

Connection
Label
Terminal Strip T1

Left Front
Corner Of Unit

SB-129 411

Figure 4-3. Remote Connections And Information

TM-205 Page 6 Spectrum 1500
4-5. COOLANT (Figures 4-4 And 5-1)
A. Coolant Tank Cap Vent Seal Removal
CAUTION: FAILURE TO REMOVE SEAL
FROM VENT ON COOLANT TANK CAP may
cause coolant system damage.
• Remove and discard seal from vent on
coolant tank cap BEFORE operating unit.
CAUTION: INCORRECT COOLANT will dam-
age unit.
• Do not use tap water or automotive anti-
freeze.
• Use only deionized or distilled water or a solu-
tion of pure ethylene glycol and deionized or
distilled water where temperature is likely to
be below freezing.

A seal has been placed over the vent on the coolant tank
cap to prevent coolant from leaking out during shipment.
This seal must be removed before operating to prevent
damage to the coolant tank fittings.
B. Coolant System Specifications And Coolant Re-
placement
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting or installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
Ethylene glycol containing cooling system lubri-
cants and/or corrosion inhibitors must NOT be
used.
FAILURE TO COMPLY WITH THESE IN-
STRUCTIONS MAY VOID THE WARRANTY.
Coolant tank capacity of this power source is approxi-
mately 3.2 quarts (3 liters). The power source is shipped
with the proper amount of deionized water and ethylene
glycol base coolant to permit operation at temperatures
down to 0° F (-18° C). Check the coolant level before op-
eration.
IMPORTANT: If the power source will be operated in
temperatures below 0° F (-18° C), use a solution of pure
ethylene glycol and deionized or distilled water mixed
according to the manufacturer’s recommendations for
the ambient temperature expected.

Input Power Cable

Retaining
Ring
Mounting
Bracket

Air Filter/
Locking Regulator In
Screw Adjustment Port
Knob

Arrow Indicates
Direction Of Airflow

In Port

Air Filter/
Regulator

Air Pressure
Gauge
Air/Filter Air
Regulator Drain Hose
Air Filter/ Coolant
Regulator Drain
Plug SC-129 418-A

Figure 4-4. Rear Panel View And Component Locations

Spectrum 1500 TM-205 Page 7
To replace coolant, proceed as follows:
CAUTION: INCORRECT COOLANT LEVEL
can damage coolant system and torch.
• Maintain correct coolant level at all times.
• Do not overfill coolant tank.
1. Shut down power source.
2. Remove drain plug (see Figure 4-4), and properly
dispose of coolant.
3. Reinstall and secure drain plug.
4. Remove cap from coolant tank (see Figure 5-1).
5. Fill coolant tank with correct coolant to top arrows
on WATER LEVEL indicator.
6. Reinstall cap onto coolant tank.
IMPORTANT: Be sure cap is left on coolant tank when
not being serviced to keep dirt out of tank.
IMPORTANT: After approximately 100 hours of break-
in time, flush system and change coolant according to
Section 10-5.
4-6. GAS/AIR INPUT CONNECTION (Figure 4-4)
CAUTION: INCORRECT PLASMA GAS can
cause torch and power source damage.
• Use only air or nitrogen for the plasma gas
supply.
• Do not use any other gas or combination of
gases.
IMPORTANT: Be sure that this unit is supplied by a
clean, dry gas/air supply (see Table 3-1. Specifications
for pressure requirements). For proper regulation, the
recommended output from the gas/air supply should
provide a minimum of 80 psi (5.4 bars) and a maximum
of 150 psi (10.2 bars).
To make connection, connect air hose from gas/air sup-
ply to In Port of air filter/regulator (see Figure 4-4).
4-7. ELECTRICAL INPUT CONNECTIONS
(Table 4-1 And Figure 4-5)
INPUT
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting or installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
TM-205 Page 8
A. Electrical Input Requirements
Operate the power source from a three-phase, 60 Hz, ac
power supply. The input voltage must match one of the
electrical input voltages shown on the input data label on
the unit nameplate. Contact the local electric utility for in-
formation about the type of electric service available,
how proper connections should be made, and inspec-
tion required.
B. Jumper Link Installation (Figure 4-5)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 4-7 before
proceeding.
Jumper links are used to allow the equipment to operate
from different line voltages. The jumper links may be in a
bag attached to the input terminal board or installed on
the input terminal board for the highest voltage shown
on the input voltage label.
1. Remove top cover and right side panel.
2. Compare position of jumper links on the input ter-
minal board to the voltage link arrangement
shown on the input voltage label.
CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.
• Position jumper links as shown on the input
voltage label (see Figure 4-5).
• Store unused jumper links across linked ter-
minals.
3. Install jumper links onto the terminal board to
match the available input line voltage.
C. Power Source Input Power Connections (Figure
4-5)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Install a fusible line disconnect switch in the
input circuit to the power source.
• Connect input conductors to the power
source before connecting to three-phase in-
put power.
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the power source whenev-
er it is necessary to inspect or service the unit.
• Employ lockout/tagging procedures on input
line before making input connections to the
power source.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
Spectrum 1500
 Ground
Conductor

Input Voltage
Jumper Links
Three-Phase Line
Disconnect Switch

Input Terminal
Board

Input
Voltage Label

Line
Terminals (3)

Ground
Terminal

Input Power Cable

SC-129 410

Figure 4-5. Location Of Electrical Input Connections And Components

1. Use Table 4-1 as a guide to select input conduc-
tors for the installation. The input conductors
should be covered with an insulating material that
complies with national, state, and local codes.
2. Install terminal lugs of adequate amperage ca-
pacity and correct stud size onto the input and
ground conductors.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not connect an input conductor to the
ground terminal in the unit.
• Do not connect the ground conductor to an in-
put line terminal.
Incorrect input connections can result in an elec-
trically energized power source chassis. The
ground terminal is connected to the power
source chassis and is for grounding purposes
only.
3. If necessary, obtain and install a standard strain
relief connector into the rear panel access hole.
4. Insert conductors through strain relief installed in
Step 3. Route conductors to the input terminal
board.
5. Connect input conductors to line terminals on the
input terminal board (see Figure 4-5).
6. Connect the ground conductor to the ground ter-
minal (see Figure 4-5).
7. Connect remaining end of ground conductor to a
suitable ground. Use a grounding method that
complies with all applicable electrical codes.
8. Connect remaining ends of input conductors to a
deenergized line disconnect switch.
9. Secure the input cable in the strain relief.
10. Reinstall and secure right side panel and top cov-
er onto unit.
11. Use Table 4-1 as a guide to select line fuses for
the disconnect switch. Obtain and install proper
fuses.

Spectrum 1500 TM-205 Page 9

 Table 4-1. Input Conductor And Fuse Size* When cutting material thicker than 3/8 in. (9.5 mm), it is
necessary to use the Stand-Off Guide to maintain the
recommended stand off distance of 1/8 in. (3 mm).
Install the Stop Guide Sleeve and Stand-Off Guide ac-
Input Voltage 200 230 460 575
cording to Figure 4-6.
Input Conductor 4 6 10 10
Size (AWG)
Stand-Off Guide
Ground Conductor 8 8 10 10
Size (AWG) Stop Guide Sleeve
Torch
Fuse Size 110 100 50 40
In Amperes
*Conductor size is based on the 1990 Edition of the Nation-
al Electrical Code (NEC) specifications for allowable ampa-
cities of insulated copper conductors, having a temperature
Stand-Off Guide
rating of 167°F (75°C), with not more than three single cur-
rent-carrying conductors in a raceway (Article 310 of NEC). Stop Guide Sleeve
(The ground conductor is not counted as a current-carrying
Torch
conductor.)
*Fuse size is based on not more than 200 percent of the
rated input amperage of the power source (Article 630 of
NEC).
S-0092/9-90

4-8. STOP GUIDE SLEEVE AND STAND-OFF

GUIDE INSTALLATION (Figure 4-6)

CAUTION: FAILURE TO INSTALL STOP S-0435

GUIDE SLEEVE when using Stand-Off
Guide can damage torch.
• Always install Stop Guide Sleeve when us- Figure 4-6. Installation Of The Stop Guide Sleeve
ing Stand-Off Guide. And Stand-Off Guide

SECTION 5 – OPERATOR CONTROLS

5-1. POWER SWITCH AND POWER LIGHT (Fig-
ure 5-1)
V POWER
Placing the POWER switch in the ON position energizes
the power source. The POWER light and fan motor
come on whenever the POWER switch is placed in the
ON position and indicate that the unit is receiving input
power. Placing the POWER switch in the OFF position
turns off the power source, POWER light, and fan motor.
READY light does not come on when the POWER
switch is placed in the ON position, check the TROUBLE
LIGHTS (see Section 9-8).
5-3. THICKNESS OUTPUT CONTROL (Figure 5-1)
The THICKNESS OUTPUT CONTROL provides a
means for selecting the cutting capacity of the power
source for the metal being cut. Rotating the control
clockwise increases the cutting capacity of the power
source. The scale surrounding the control is calibrated
in inches for mild steel.

CAUTION: INCORRECT STANDOFF DIS-

5-2. READY LIGHT (Figure 5-1) TANCE can damage torch.
• When THICKNESS OUTPUT CONTROL is
When the READY light comes on, all of the safety shut- set above 3/8 in. (9.5 mm), always use 1/8 in. (3
down devices within the control circuitry have been mm) standoff distance between torch tip and
monitored, and the unit is ready for operation. If the workpiece (see Section 4-8).
TM-205 Page 10 Spectrum 1500

Coolant
Tank Cap
Work Clamp Water Level
And Cable Indicator
Plasma Arc
Cutting Torch
Torch Switch
Trouble Lights
(see Section 9-8)
Figure 5-1. Operator Controls
5-4. TEST/RUN SWITCH (Figure 5-1)
The TEST/RUN switch provides a means for adjusting
the air filter/regulator without energizing the cutting cir-
cuit. Placing the TEST/RUN switch in the TEST position
energizes the air solenoids allowing the air filter/regula-
tor to be properly set to 57 psi (3.9 bars). Placing the
TEST//RUN switch in the RUN position provides gas/air
to the torch for normal cutting operations when the torch
switch is pressed.
IMPORTANT: For Units Effective with Serial No.
KA880002, a GOUGE position was added to the TEST/
RUN switch.
Placing the TEST/GOUGE/RUN switch in the GOUGE
position provides gas/air to the torch for normal gouging
operations when the torch switch is pressed.
CAUTION: CUTTING WHEN THE TEST/
GOUGE/RUN SWITCH IS IN GOUGE POSI-
TION 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.
Spectrum 1500
Warning
Alarm Ready Light
Thickness Output Control
Power Switch
Power Light
Test/Run Switch
IMPORTANT: For Units Effective with
Serial No. KA880002, a GOUGE position
was added to the TEST/RUN switch.
SB-129 409-A
IMPORTANT: For gouging operations, install a ”G” style
gouging tip in the torch (see Section 9-2).
5-5. WATER LEVEL INDICATOR (Figure 5-1)
The WATER LEVEL indicator provides a means for
checking the amount of coolant in the cooling system.
The correct amount of coolant is indicated when coolant
is maintained between the upper and lower arrows on
the WATER LEVEL indicator with the POWER switch in
the OFF position. When the POWER switch is placed in
the ON position, the torch hoses are filled from the cool-
ant tank, and therefore it is normal for the coolant to re-
cede on the WATER LEVEL indicator. Coolant may go
below the lower arrows during normal operation and
coolant should not be added since the coolant tank
could overflow when the coolant returns to the coolant
tank. When the POWER switch is placed in the OFF
position, the coolant in the torch hoses returns to the
coolant tank within thirty seconds.
5-6. WARNING ALARM (Figure 5-1)
The warning alarm sounds if there is a problem with any
of the torch safety shutdown devices. If the warning
alarm sounds while cutting, stop the cutting operation,
and check the TROUBLE LIGHTS for an indication of
the problem (see Section 9-8).
TM-205 Page 11
 SECTION 6 – SEQUENCE OF OPERATION
WARNING: PLASMA ARC CUTTING can be
hazardous; FIRE OR EXPLOSION can result
from placing unit on or near combustible
surfaces.
• Only qualified persons are to operate this
equipment according to all codes and em-
ployer’s safety practices.
• Do not locate unit over combustible surfaces.
• Use torch(es) specified in Owner’s Manual.
• Keep children away.
CUTTING CONTAINERS, such as barrels,
tanks, and pipes, can result in explosions,
fire, or poisonous fumes.
• Cut containers only after they have been
properly cleaned and prepared.
• Never cut pressurized lines, pipes, or contain-
ers.
ELECTRIC SHOCK can kill; IMPROPER AIR-
FLOW AND EXPOSURE TO ENVIRONMENT
can damage internal parts.
• Do not touch live electrical parts.
• Keep all covers, panels, and guards securely
in place.
• Wear dry insulating gloves and body protec-
tion.
• Do not use cables or torch with damaged in-
sulation.
• Turn off power source before cleaning slag
from torch tip or replacing any torch parts.
• Maintain at least 18 inches (457 mm) of unre-
stricted space on all sides of power source,
and keep underside free of obstructions.
• Do not place any filtering device over the in-
take air passages of this power source.
Warranty is void if the power source is operated
with any portion of the outer enclosure removed.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of any fumes.
• Ventilate area, or use approved breathing de-
vice.
• Read Material Safety Data Sheets (MSDSs)
and manufacturer ’s instructions for any mate-
rials used.
• When possible cut over a water table or work
table designed to minimize fumes, gases, and
sparks, except aluminum – see next state-
ment.
• Cutting aluminum on a water table may cause
hydrogen detonation beneath the workpiece.
Contact equipment manufacturer for recom-
mended practices for cutting aluminum.
TM-205 Page 12
FLYING SPARKS AND HOT METAL can
cause fire and burns.
• Do not cut where flying sparks can strike flam-
mable material.
• Protect yourself and others from flying sparks
and hot metal.
• Allow work and equipment to cool before han-
dling.
• Watch for fire, and keep a fire extinguisher
nearby.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
• Wear safety goggles with correct filter shade.
• Wear a face shield.
• Cover skin.
• Protect ears.
PILOT ARC can cause burns.
• Keep torch tip away from personnel when
switch is pressed.
CUTTING WORKPIECE ON CONCRETE
FLOOR can cause concrete to explode.
• Do not place workpiece directly on concrete
floor.
HOT METAL SPARKS will mark glass and
burn trim.
• Remove, cover, or protect any glass or trim.
CUTTING CURRENT can damage vehicle
computer(s) and other electronic compo-
nents.
• Disconnect both battery cables before cutting
on a vehicle.
• Place work clamp as close to the cut as pos-
sible to avoid long electrical paths.
• Be sure torch to power source as well as cable
connections to work clamp are clean and
tight.
• To minimize risk, disconnect the computer(s)
from the vehicle.
LACK OF COOLANT FLOW will damage
torch.
• Do not cut if workpiece is more than 32 feet
(10 m) above bottom of power source.
• Reduce cutting height to prevent torch dam-
age.
See Section 1 – Safety Rules For Plasma Arc
Cutting (PAC) in the Owner’s Manual for basic
safety information.
Spectrum 1500
6-1. PLASMA ARC CUTTING (PAC)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 6 before
proceeding.
IMPORTANT: For Units Effective with Serial No.
KA880002, a GOUGE position was added to the TEST/
RUN switch.
1. Install and connect unit according to Section 4.
CAUTION: TIP AND ELECTRODE WEAR BE-
YOND RECOMMENDED VALUES or OPERA-
TION WITHOUT TIP OR ELECTRODE can
damage torch.
• Inspect shield cup, tip, and electrode before
each use, hourly during operation, or when-
ever cutting speed has been significantly re-
duced (see Section 9-2).
• Do not operate torch without a tip or electrode
in place.
2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at work-
piece.
4. Place the TEST/GOUGE/RUN switch in the
TEST position.
5. Place the POWER switch in the ON position. The
POWER light will come on.
CAUTION: INCORRECT PLASMA GAS can
cause torch and power source damage.
• Use only air or nitrogen for the plasma gas
supply.
• Do not use any other gas or combination of
gases.
6. Turn on gas/air supply at the source, and adjust
air filter/regulator to 57 psi (3.9 bars) while ob-
serving air pressure gauge on rear of unit. For
proper regulation, the recommended output from
the gas/air supply should provide a minimum of
80 psi (5.5 bars) and a maximum of 150 psi (10.3
bars). Make pressure adjustment according to
Figure 4-4 as follows:
a. Loosen locking screw in center of air filter/regu-
lator adjustment knob.
b. Turn air filter/regulator adjustment knob clock-
wise to increase pressure setting or counter-
clockwise to decrease pressure setting.
c. Tighten locking screw.
7. Place the THICKNESS OUTPUT CONTROL in
the desired position (see Section 5-3).
8. Place the TEST/GOUGE/RUN switch in the RUN
position. The READY light will come on indicating
that the unit is ready for operation.
9. Wear safety goggles with correct filter shade ac-
cording to ANSI Z49.1.
Spectrum 1500
10. Place tip of torch at edge of metal to be cut with
hole in tip just over metal edge.
11. Press torch switch. There will be approximately 2
seconds of preflow air before arc starts.
12. Once arc starts, move tip slowly and smoothly
across material.
IMPORTANT: If THICKNESS OUTPUT CONTROL is
set above 3/8 in. (9.5 mm), dragging the torch tip directly
on the material will cause excessive tip and electrode
wear and produce cuts of reduced quality. Maintain a 1/8
in. (3 mm) standoff distance between tip and material
whenever THICKNESS OUTPUT CONTROL is set
above 3/8 in. (9.5 mm) by attaching the supplied Stop
Guide Sleeve and Stand-Off Guide (see Section 4-8).
13. Adjust torch speed so that sparks are directed
through material away from torch tip. Proper cut-
ting speed is being used when sparks go out bot-
tom of cut.
14. Pause briefly at end of cut to allow metal bridge to
be cut, and then release torch switch. Postflow air
will flow for approximately 10 seconds, and cool-
ant will continue to flow for cooling the torch. If
another cut is started before postflow ends, the
arc will start immediately.
IMPORTANT: This unit can also be used to pierce mate-
rial up to 3/4 in. (19 mm) maximum thickness to start a
cut away from the metal edge. Optimum piercing thick-
ness is 1/2 in. (12.7 mm). On light gauge material, there
will be little or no additional wear on torch parts, but as
the material becomes thicker, the wear will increase ac-
cordingly. Always pierce using a slight standoff or 10°
angle to the material so that molten metal will be blown
away from the torch tip. Molten metal blowing back onto
the torch tip will further reduce the tip life. Wear a face
shield if any piercing is to be part of the operation.
6-2. PLASMA ARC GOUGING (PAG) (PAG For
Units Effective with Serial No. KA8800699)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 6 before
proceeding.
1. Install and connect unit according to Section 4.
CAUTION: TIP AND ELECTRODE WEAR
BEYOND RECOMMENDED VALUES or OP-
ERATION WITHOUT TIP OR ELECTRODE in
place can damage torch.
• Inspect shield cup, tip, and electrode before
each use, hourly during operation, or when-
ever cutting speed has been significantly re-
duced (see Section 9-2).
• Do not operate torch without a tip or elec-
trode in place.
IMPORTANT: For gouging operations, install a ”G” style
gouging tip in the torch (see Section 9-2).
TM-205 Page 13
 2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at work-
piece.
4. Place the TEST/GOUGE/RUN switch in the
TEST position.
5. Place the POWER switch in the ON position. The
POWER light will come on.
CAUTION: INCORRECT PLASMA GAS can
cause torch and power source damage.
• Use only air or nitrogen for the plasma gas
supply.
• Do not use any other gas or combination of
gases.
6. Turn on gas/air supply at the source, and adjust
air filter/regulator to 57 psi (3.9 bars) while ob-
serving air pressure gauge on rear of unit. For
proper regulation, the recommended output from
the gas/air supply should provide a minimum of
80 psi (5.5 bars) and a maximum of 150 psi (10.3
bars). Make pressure adjustment according to
Figure 4-4 as follows:
a. Loosen locking screw in center of air filter/regu-
lator adjustment knob.
b. Turn air filter/regulator adjustment knob clock-
wise to increase pressure setting and counter-
clockwise to decrease pressure setting.
c. Tighten locking screw.
7. Place the THICKNESS OUTPUT CONTROL in
the desired position (see Section 5-3).
8. Place the TEST/GOUGE/RUN switch in the
GOUGE position. The READY light will come on
indicating that the unit is ready for operation.
CAUTION: CUTTING WHEN THE GAS/AIR
SWITCH IS IN GOUGE POSITION will dam-
age 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.
9. Wear safety goggles with correct filter shade ac-
cording to ANSI Z49.1.
10. Place tip of torch on metal to be gouged at
approximately a 40° angle to the line of travel and
press torch switch. There will be approximately 2
seconds of preflow air followed by approximately
2-1/2 seconds of pilot arc. If the gouge arc is not
started within the 2-1/2 seconds of pilot arc, the
pilot arc will stop. The torch switch will have to be
released, and the startup procedure repeated.
TM-205 Page 14
11. Once gouging arc starts, establish an arc length
of approximately 1 to 1-1/2 in. (25 mm to 38 mm)
and slowly begin moving torch across material.
12. Adjust torch speed and angle for desired depth of
groove and so that sparks are directed away from
the operator. Do not attempt to remove too much
metal in one pass. Additional passes can be
made to achieve the desired depth.
13. Pause briefly at end of gouge, and then release
torch switch. Postflow gas/air will flow for approxi-
mately 10 seconds, and coolant will continue to
flow for cooling the torch. If another gouge is
started before postflow ends, the arc will start im-
mediately.
6-3. CUTTING PROBLEMS AND RECOMMEN-
DATIONS
1. If sparks come out top of cut or cut is not clean:
a. The torch is being moved too fast; slow torch
travel.
b. The workpiece being cut is too thick.
c. Tip or electrode worn; replace tip or electrode
(see Section 9-2).
2. If arc goes out while cutting:
a. The torch was lifted too far from workpiece;
place torch on workpiece if THICKNESS OUT-
PUT CONTROL is set below 3/8 in. (9.5 mm) or
observe proper standoff distance of 1/8 in. (3
mm) if THICKNESS OUTPUT CONTROL is set
above 3/8 in. (9.5 mm) while cutting (see Sec-
tion 4-8).
b. Work clamp disconnected; connect work clamp
to clean, bare metal at workpiece.
c. Check READY light (see Section 5-2) and
TROUBLE LIGHTS (see Section 9-8).
3. If arc goes on/off while cutting:
a. The torch is being moved too slowly; increase
torch travel.
b. Tip or electrode worn; replace tip or electrode
(see Section 9-2).
4. See Table 8-1. Troubleshooting for additional
remedies.
6-4. SHUTTING DOWN
1. Stop cutting.
2. Place the POWER switch in the OFF position.
3. After coolant returns to coolant tank (approxi-
mately 30 seconds), turn off gas/air supply at the
source.
Spectrum 1500
 SECTION 7 – THEORY OF OPERATION
7-1. THEORY OF OPERATION
The basic power source operation is not difficult to un-
derstand when it is divided into sections. The block dia-
gram shown in Diagram 7-1 includes the components
which make up the main circuitry of the power source.
IMPORTANT: The following Theory Of Operation Is
written in steps which match the block numbers on Dia-
gram 7-1.
IMPORTANT: For Units Effective with Serial No.
KA880002, a GOUGE position was added to the TEST/
RUN switch.
1. Control transformer T2 supplies 24 volts ac to the
POWER switch circuit and 18 volts ac to Timer /
Control Board PC2. T2 is energized whenever
the input line has power applied to it.
2. POWER switch S1 supplies 24 volts ac from con-
trol transformer T2 to contactor W coil.
3. Contactor W supplies three-phase power to main
transformer T1.
4. Main transformer T1 high current windings sup-
ply machine output and are fed into secondary
contactor CR3. Tertiary windings provide 32 volts
ac for line synchronization, 36 volts ac (center
tap) for Regulator Board PC1 power supply, 115
volts ac for the high-frequency circuitry, 24 volts
ac for POWER light PL1 and Timer/Control Board
PC2, and 18 volts ac for PC2 and Relay Board
PC3 power supplies.
5. When power is applied, Timer/Control Board PC2
locks out all machine functions for two seconds.
During this power-up delay all displays are turned
on for testing. After the power-up delay, PC2 con-
trols all switching functions in the unit, including
interlocks and operator controls. PC2 also pro-
vides circuitry to vary the command ramp voltage
that is used to control Regulator Board PC1.
6. Air pressure (80 min. to 150 max. P.S.I.) is applied
to the adjustable air pressure regulator and is
regulated to 57 P.S.I. output. Air solenoid AS1
provides low air flow which is used for preflow, pi-
lot arc, cutting, gouging, and postflow modes.
AS1 activates immediately after torch switch PB1
is pressed and remains activated for about ten
seconds after PB1 is released. The low air flow
rate is determined by the size of the air orifice.
Gas bypass solenoid GS1 bypasses the air ori-
fice and activates immediately after transfer of
amperage to the workpiece to provide the cutting
gas flow rate. GS1 deactivates when transfer is
broken. With TEST/GOUGE/RUN switch S4 in
GOUGE position, GS1 remains deactivated.
Spectrum 1500
7. Control relay CR2 turns on coolant pump motor
M1.
8. Coolant pump motor M1 circulates coolant
through the torch and back to the coolant tank.
M1 prefills the torch with coolant after the power-
up delay. M1 turns on whenever torch switch PB1
is pressed. When PB1 is released, M1 continues
to circulate coolant for about 30 seconds.
9. Fan motor FM cools the unit and turns on when-
ever POWER switch S1 is closed.
10. Gas purge solenoid GS2 activates when POW-
ER switch S1 is opened and allows air pressure to
purge coolant from the torch and lines back into
the coolant tank. Purging air is vented out the
coolant tank cap. A check valve prevents coolant
from reaching GS2.
11. Water solenoid WS1 allows coolant to flow from
the coolant tank into the torch. WS1 activates
when control relay CR2 turns on coolant pump
motor M1.
12. Water alarm Y1 sounds when the operator at-
tempts to remove the torch shield cup before
coolant is purged from the torch. Y1 also sounds
when there is a torch tip problem to remind the op-
erator to wait until coolant is purged before disas-
sembling torch.
13. The interlocks monitor main transformer T1 tem-
perature, main rectifier SR1 temperature, air
pressure, and water coolant pressure. If any of
the interlock conditions are not met, Timer/Con-
trol Board PC2 shuts down the unit and turns on
the appropriate LED on Trouble Light Board PC4.
14. TEST/GOUGE/RUN switch S4 applies 24 volts
dc to Timer/Control Board PC2 when in TEST
position which energizes air solenoid AS1 and
gas bypass solenoid GS1. This allows high air
flow for adjusting the air regulator. Other machine
functions are locked out during this mode.
READY light PL2 turns off and the GAS/AIR
trouble light turns on.
15. POWER light PL1 (red) turns on when POWER
switch S1 is closed. READY light PL2 (green)
turns on when the interlocks are satisfied and the
machine is ready for operation. Trouble Light
Board PC4 has LED’s which turn on when air
pressure, coolant pressure, torch tip, or tempera-
ture problems occur.
16. THICKNESS OUTPUT CONTROL R1 controls
output amperage by supplying a control voltage
to Timer/Control Board PC2.
17. Terminal block 1T provides a junction point for
making torch and remote connections to the ma-
chine control circuitry.
TM-205 Page 15
18. Filter Board PC5 blocks high frequency from en-
tering the control circuitry.
19. Relay Board PC3 senses an electrode-to-nozzle
short and locks the machine out by means of the
shield cup interlock circuit. Built-in delays provide
relay isolation of the sense circuits during high-
frequency operation.
20. Mechanical contactor CR3 is energized whenev-
er air solenoid AS1 is activated. If CR3 is deener-
gized, voltage from main transformer T1 is
blocked from entering main rectifier SR1.
21. Regulator Board PC1 regulates the output am-
perage by comparing the output amperage sig-
nal from Hall Device HD1 with the control voltage
from THICKNESS OUTPUT CONTROL R1. PC1
controls the firing of the main rectifier SR1
SCR’s.
22. Main rectifier SR1 converts ac input from main
transformer T1 to regulated dc output. The six
SCR’s are fired at the proper time to obtain the
desired output amperage. Varistor VR1 prevents
high-frequency noise from entering SR1, and ca-
pacitors C7 thru C12 protect the SCR’s from volt-
age transients.
TM-205 Page 16
23. Stabilizer Z1 removes ripple voltage from main
rectifier SR1 output. Resistor R3 bypasses Z1
and allows a faster amperage rise during initial
starting of the pilot arc.
24. Hall Device HD1 senses output amperage and
derives a corresponding voltage which is fed into
Regulator Board PC1 for regulating the machine
output.
25. Pilot arc relay CR1 energizes during the pilot arc
mode only and isolates the pilot circuit from the
power circuit when high-frequency is not on. CR1
reduces the amount of power dissipated in the
torch head. Resistor R4 limits pilot arc amperage
capability.
26. The high frequency panel produces high frequen-
cy energy for starting the cutting arc.
27. Reed switch RS1 senses output amperage to the
workpiece when torch switch PB1 is pressed and
signals Timer/Control Board PC2 to stop the pilot
arc, start high air flow, start the command ramp,
and after a short delay, turn off the high-frequency
unit. When PB1 is released, RS1 opens and sig-
nals PC2 to reset the entire operating sequence
of the machine.
Spectrum 1500
Spectrum 1500

7 8 9 20 27

Control Coolant Fan Motor Secondary Reed (+) Work

Relay Pump Motor FM Contactor Switch
CR2 M1 CR3 RS1

3 4 22 23 25 26

Input Main Main Main (+) Pilot (+) Pilot

Contactor Stabilizer Arc Relay High-Frequency
Power W Transformer Rectifier Panel
T1 SR1 Z1 CR1 (–) Torch

1 2 21 24
Main (–)
Control Power Regulator Hall
Transformer Switch Board Device HD1
T2 S1 PC1

5 19 18

Timer/Control Relay Filter

Board Board Board
PC2 PC3 PC5

10 11 12 13 14 15 16 17

Interlocks Indicator/ Thickness

Gas Purge Water Water Test/Gouge/Run Output Terminal Torch
Solenoid Solenoid Alarm S2, S3, Trouble Lights Control Block Control
GS2 WS1 Y1 TP1, TP2 Switch S4* PL1, PL2, PL4 R1 1T Leads

6
Gas
Solenoid
6 GS1

Air 80-150 PSI Unit Air 57 PSI Air

In Pressure Solenoid Torch Air
Regulator AS1 Air IMPORTANT: The block numbers match the steps
Orifice in the Theory Of Operation (Section 7-1).
TM-205 Page 17

*IMPORTANT: For Units Effective with Serial No.

KA880069, a GOUGE position was added to the
TEST/RUN switch.

Diagram 7-1. Block Diagram

 SECTION 8 – TROUBLESHOOTING
8-1. TESTING INSTRUMENTS AND INFORMA-
TION
The service procedures in this manual require proper
testing instruments. Use a good quality digital multime-
ter DMM with one megohm input impedance or greater
and diode check capability (use an analog VOM for vari-
able resistor testing). If an oscilloscope is specified, use
a good quality unit with one megohm input impedance or
greater. If a circuit board has a protective coating, it will
be necessary to remove coating or use needle probes in
the test area to obtain proper contact. Recoat areas if
necessary to retain corrosion protection. Digital multi-
meters (DMM’s) do not require lead polarity attention
when making connections. However, the meter may in-
dicate a – (negative) voltage when the test procedure
specified a + (positive) voltage. If the incorrect polarity
appears on the display, reverse meter lead connections
to test points.
8-2. DISABLING OF HF OUTPUT FOR TESTING
PROCEDURES (Figure 8-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting,maintaining, or ser-
vicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE removing circuit board receptacle.
To disable HF output for testing procedures, proceed as
follows:
1. Shut down power source.
2. Remove right side panel.
3. Locate Timer/Control Board PC2 (see Parts List
for PC2 location).
TM-205 Page 18
4. Locate and disconnect receptacle RC5 on PC2
(see Figure 8-2 for RC5 location).
8-3. CIRCUIT BOARD HANDLING PRECAUTIONS
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting, maintaining or ser-
vicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
8-4. TROUBLESHOOTING (Table 8-1)
WARNING: ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting,maintaining, or ser-
vicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury
• Keep away from moving parts.
HOT SURFACES can cause severe burns
• Allow cooling period before servicing.
Troubleshooting to be performed only by quali-
fied persons.
The troubleshooting table is designed to diagnose some
of the troubles that can develop in this power source.
The table is based on the assumption that no short cir-
cuit exists between any isolated circuits and ground or
Spectrum 1500
between any two isolated circuits. In addition, any circuit
normally tied to ground must be at ground potential.
Use the table in conjunction with the circuit diagram(s)
and wiring diagram(s) in this manual and the exploded
views and component values in the Parts List while per-
forming troubleshooting procedures.
When replacing components, use only genuine MILLER
replacement parts. MILLER parts are required for war-
ranty repair by authorized warranty service agency.
Resistance and continuity measurements must be
made with the unit shut down. Isolate components be-
fore making resistance and continuity measurements.
IMPORTANT: Before beginning troubleshooting proce-
dures, visually examine internal components for signs of
overheating and failure. Many major problems, such as
winding(s) failure are usually apparent by discoloration,
smoke, and smell. Fortunately, most electrical problems
are relatively simple: blown fuses, tripped circuit break-
ers, incorrect switch positions, loose connections, cor-
rosion, and the like. A complete, careful inspection often
saves considerable time, money, and frustration.
IMPORTANT: Be sure that all connections are correct
and secure according to Section 4 and that all controls
and switches are in proper positions before proceeding
with troubleshooting.

Table 8-1. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Unit completely inoperative; Line disconnect switch in the Place line disconnect switch in the ON position.
POWER light PL1 off; READY OFF position.
light PL2 off; TROUBLE
LIGHTS off; fan motor FM does
not run.
Line fuse or circuit breaker Check and replace line fuse or reset circuit
open. breaker.
Main fuse F1. Check and replace F1 if necessary (see Section
9-7).
POWER switch S1. Check S1 for proper operation with an ohm-
meter, and replace if necessary.
Contactor W coil. Check and replace W if necessary.
Does not cut; POWER light PL1 Work clamp not connected. Connect work clamp to clean, bare metal at
on; READY light PL2 on; workpiece.
TROUBLE LIGHTS off; fan mo-
tor FM runs.
Torch switch lead connections. Check, clean, and tighten torch switch lead con-
nections (see Section 9-3).
Jumper on terminal strip 1T in Place jumper in proper position (see Section
wrong position. 4-4).
Contactor W. Check and replace W if necessary.
Control relay CR3. Check and replace CR3 if necessary.
Diode D4 open. Check and replace D4 if necessary.
Main rectifier SR1 or poor con- Check and replace SR1 if necessary.
nections to SR1.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
poor connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
Regulator Board PC1 or poor Check connections for continuity to PC1. Check
connections to PC1. PC1 according to Diagram 8-2, Figure 8-1, and
Section 8-5. Replace PC1 if necessary.
Does not cut; POWER light PL1 Fuse F1 open on Timer/Control Check and replace F1 if necessary (see Sec-
on; READY light PL2 off; Board PC2. tions 8-6 and 9-7, and Figure 8-2).
TROUBLE LIGHTS off; fan mo-
tor FM runs.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
poor connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.

Spectrum 1500 TM-205 Page 19

 Table 8-1. Troubleshooting (Continued)

TROUBLE PROBABLE CAUSE REMEDY

Uncontrolled output. Jumper on terminal strip 1T in Place jumper in proper position (see Section
wrong position. 4-4).
THICKNESS OUTPUT CON- Check and replace R1 if necessary.
TROL R1.
Hall Device Board HD1 or con- Check connections for continuity to HD1. Check
nections to HD1. HD1 according to Diagram 8-7, Figure 8-6, and
Section 8-10. Replace HD1 if necessary.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
Regulator Board PC1 or poor Check connections for continuity to PC1. Check
connections to PC1. PC1 according to Diagram 8-2, Figure 8-1, and
Section 8-5. Replace PC1 if necessary.
No gas/air flow; POWER light Fuse F3 open on Timer/Control Check and replace F3 if necessary (see Figure
PL1 on; READY light PL2 on; Board PC2. 8-2).
TROUBLE LIGHTS off; fan mo-
tor FM runs.
Torch switch. Check and replace torch switch if necessary
(see torch manual).
Air solenoid AS1. Check and replace AS1 if necessary.
Orifice in parallel with gas sole- Check and clean orifice if necessary. Check and
noid GS1 plugged or GS1. replace GS1 if necessary.
No gas/air flow; POWER light Fuse F1 open on Timer/Control Check and replace F1 if necessary (see Sec-
PL1 on; READY light PL2 off; Board PC2. tions 8-6 and 9-7, and Figure 8-2).
TROUBLE LIGHTS off; fan mo-
tor FM runs.
Fuse F5 open on Timer/Control Check and replace F5 if necessary (see Sec-
Board PC2. tions 8-6 and 9-7, and Figure 8-2).
No pilot arc (high frequency) or Fuse F1 open on Timer/Control Check and replace F1 if necessary (see Sec-
lack of high frequency; difficulty Board PC2. tions 8-6 and 9-7, and Figure 8-2).
in establishing an arc.
Fuse F4 open on Timer/Control Check and replace F4 if necessary (see Sec-
Board PC2. tions 8-6 and 9-7, and Figure 8-2).
Spark gap G spacing incorrect. Check and adjust spark gap G (see Section 9-6).
Leakage of high frequency from Check and replace torch cable and/or torch if
torch cable or torch shorted. necessary (see Sections 9-1 thru 9-4).
Control relay CR1. Check and replace CR1 if necessary.
Relay Board PC3 or connec- Check connections for continuity to PC3. Check
tions to PC3. PC3 according to Diagram 8-4, Figure 8-3, and
Section 8-7. Replace PC3 if necessary.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
poor connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
Regulator Board PC1 or poor Check connections for continuity to PC1. Check
connections to PC1. PC1 according to Diagram 8-2, Figure 8-1, and
Section 8-5. Replace PC1 if necessary.
GAS/AIR trouble light on; TEST/GOUGE/RUN switch S4 Place S4 in the RUN position.
READY light PL2 off. in TEST position.
Incorrect gas/air pressure ad- Adjust air filter/regulator according to Step 6 of
justment. Section 6-1.
TM-205 Page 20 Spectrum 1500
 Table 8-1. Troubleshooting (Continued)

TROUBLE PROBABLE CAUSE REMEDY

GAS/AIR trouble light on; Insufficient gas/air supply (see Check gas/air supply pressure.
READY light PL2 off (contin- Table 3-1. Specifications for re-
ued). quirements).
Air pressure switch S2. Check and replace S2 if necessary.
Dirty air filter/regulator. Clean air filter/regulator according to manufac-
turer’s instructions (supplied with unit).
TORCH TIP trouble light on; Shield cup not tight or shield Check, clean, and tighten shield cup on torch
READY light PL2 off; warning cup contact surface dirty. (see torch manual).
alarm sounds.
Electrode touching tip inside Check and tighten electrode (see torch manual).
torch.
Shield cup detector pins dirty. Check shield cup detector pins (see torch manu-
al).
Shield cup detector lead con- Check, clean, and tighten shield cup detector
nections. lead connections (see torch manual).
Plug PLG12 or PLG13 loose on Check and secure PLG12 and PLG13 on PC5
Filter Board PC5 or loose con- (see Figure 8-5) and tighten loose connections
nections on terminal strip 1T. on 1T.
Relay Board PC3 or connec- Check connections for continuity to PC3. Check
tions to PC3. PC3 according to Diagram 8-4, Figure 8-3, and
Section 8-7. Replace PC3 if necessary.
TEMPERATURE trouble light Thermostat TP1 and/or TP2 Allow a cooling period of approximately ten min-
on; READY light PL2 off. open (thermal shutdown). utes (see Section 9-7C).
Thermostat TP1 and/or TP2. Check and replace TP1 and/or TP2 if necessary.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
WATER trouble light on; Insufficient coolant pressure. Check WATER LEVEL indicator (see Section
READY light PL2 off. 5-5).
Plugged Coolant filters. Check and clean filters if necessary (see Section
9-5).
Fuse F2 on Timer/Control Check and replace F2 if necessary (see Figure
Board PC2. 8-2).
Water pressure switch S3. Check and replace S3 if necessary.
Water solenoid SW1. Check and clean filters if necessary (see Section
9-5)
Control relay CR2. Check and replace CR2 if necessary.
Water pump M1. Check and replace M1 if necessary.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
Coolant does not return to cool- Plugged Coolant filters. Check and clean filters if necessary (see Section
ant tank when POWER switch 9-5).
is placed in the OFF position.
Cup not secured to torch. Secure cup to torch.
No air supply. Check gas/air supply.
Gas solenoid GS2. Check and replace GS2 if necessary.
No low gas/air flow (preflow/ Orifice in parallel with gas sole- Check and clean orifice if necessary.
postflow air). noid GS1 plugged.
No high gas/air flow or de- Insufficient gas/air supply (see Check gas/air supply.
creased cutting ability. Table 3-1. Specifications for re-
quirements).
Spectrum 1500 TM-205 Page 21
 Table 8-1. Troubleshooting (Continued)

TROUBLE PROBABLE CAUSE REMEDY

No high gas/air flow or de- Reed switch RS1. Check and replace RS1 if necessary.
creased cutting ability (contin-
ued).
Gas Solenoid GS1. Check and replace GS1 if necessary.
Gas Solenoid GS2. Check and replace GS2 if necessary.
Main rectifier SR1. Check and replace SR1 if necessary.
Fan does not run; POWER light Fan motor FM. Replace FM.
PL1 and READY light PL2 both
on.
TROUBLE LIGHTS not work- Trouble Light Board PC4 or Check connections for continuity to PC4. Check
ing. connections to PC4. PC4 according to Diagram 8-5, Figure 8-4, and
Section 8-8. Replace PC4 if necessary.
Timer/Control Board PC2 or Check connections for continuity to PC2. Check
connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
Section 8-6. Replace PC2 if necessary.
POWER light PL1 on; Timer/Control Board PC2 or Check connections for continuity to PC2. Check
TROUBLE LIGHTS on; ma- connections to PC2. PC2 according to Diagram 8-3, Figure 8-2, and
chine output available. Section 8-6. Replace PC2 if necessary.

Chart 8-1. Operation Sequence Chart

ON OFF
POWER Switch (S1)
Approx.
2 sec.
TROUBLE LIGHTS (PC4)

READY Light (PC2)

Approx.
30 sec.
Coolant Pump M1

Torch Switch

Postflow
Low Air Solenoid (AS1) 10
sec.
High Air Solenoid (GS1)
2
Preflow Time sec.
High Frequency Before HF

Pilot Arc

Reed Switch (RS1)

Output Current
Approx.
30 sec.
Gas Purge Solenoid (GS2)
S-0518

TM-205 Page 22 Spectrum 1500

 NOTES

Spectrum 1500 TM-205 Page 23

 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
can cause serious injury.
• Do not touch live electrical parts. • Follow standard ESD precautions to prevent damaging
• Shut down power source and place line disconnect static-sensitive parts during testing.
switch in the off position before making or changing meter • See Table 8-1 if values are not present.
lead connections and before disconnecting or connecting
any machine leads.
• Disconnect HF input receptacle RC5 from Timer/Control
Board PC2 BEFORE troubleshooting, maintaining, or
servicing power source (see Section 8-2). During preflow, cutting and
See Section 8-5
• Have only qualified persons familiar with and following
postflow modes, contactor CR3
energizes and holds while for PC1 data
standard safety practices perform troubleshooting proce- Torch Switch PB1
dures. is depressed. C C

Voltage Readings
a) Tolerance – ±10% V4
unless specified
b) Reference – to
circuit common C C
(lead 43) unless
noted
c) Wiring Diagram –
see Section 10
V2
V1 230 volts ac
V2 205 volts ac V3
V3 205 volts ac
V4 205 volts ac
PC1
V5 270 volts ac* REGULATOR BOARD
1-29 ON RC1/PLG2
*With THICKNESS OUTPUT
CONTROL R1 in maximum
position.

V1

PC2
TIMER/CONTROL BOARD
RC1/PLG3
Control Transformer T2 RC2/PLG4
activates when input RC3/PLG5
power is applied Power Light RC4/PLG6
to unit. PL1 (Red) RC5/PLG7

Power Switch S1

See Section 8-6

for PC2 data

Diagram 8-1. Troubleshooting Circuit Diagram For Power Source

TM-205 Page 24 Spectrum 1500
 Reed Switch RS1 detects IMPORTANT: Reed Switch RS1 contacts
current transfer to work and (leads 49 and 51) must be shorted to check
switches on Gas Solenoid GS1. the open-circuit voltage and the command
See Section 8-10 RS1 also resets HF circuit. voltage to PC1. Jumper leads connected to a
for HD1 data switch work well.
HF
Protection
C

See Chart 8-2

for waveforms
C A, B, C

V5 Coil Windings V5, A, B

–15 volts are series aided
dc

+15 volts +24 volts dc sent to

dc electrode to nozzle interlock
circuit during idle for indicating
See Section an electrode to nozzle short.
Trouble Lights 8-8 for If a short is present, the
Board inputs PC4 data TORCH TIP Trouble Light
go low to will come on, the READY
turn on LED’s light will go off, the water
alarm will sound, and the
Torch arc will not start.
Warning
Alarm
Spark gap .030 in.
(0.762 mm)

Pilot Arc Contactor

Air Pressure Water Pressure Switch See Section 8-7

Switch S2 S3 requires 13 PSI for PC3 data
requires 35 PSI (90 kPa) to close.
(241 kPa) to close.

0 to +10 volts dc

See Section 8-9

for PC5 data

Ready Shield Cup To ring on bottom

Light PL2 Detector of shield cup
If TEST/RUN Switch S4 is (Green)
in the TEST position, the GAS/AIR
Trouble Light will come on and IMPORTANT: For Units Effective with Serial No. KA880069,
the READY Light will go off. a GOUGE position was added to the TEST/RUN switch. SC-138 425-A

Spectrum 1500 TM-205 Page 25

 Chart 8-2. Waveforms

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

C. SCR Gate Pulses With Respect To Cathode

At No Load (See Section 8-5C)

* IMPORTANT: For waveform A, Reed Switch RS1 contacts (leads 49 and 51)
must be jumpered together. Jumper leads connected to a switch work well.

TM-205 Page 26 Spectrum 1500

8-5. REGULATOR BOARD PC1 TESTING PROCE-
DURES (Diagram 8-2 And Figure 8-1)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
Figure 8-1. Regulator Board PC1 Component Locations And Information
Spectrum 1500
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
A. Power Supply Inputs/Outputs
An input voltage of 36 volts ac should be present be-
tween pins 24 and 25 of plug PLG2. Input voltages of 18
volts ac should be present between pin 24 and chassis
ground (pins 16 and 23) and pin 25 and chassis ground
(plug PLG2).
Input voltages of 32 volts ac should be present between
pin 18 and each of pins 19, 20, and 21 of plug PLG2.
Output voltages of –15 volts dc should be present be-
tween pin 2 and chassis ground and +15 volts dc should
be present between pin 1 and chassis ground (plug
PLG1).
B. Control Line Inputs/Outputs
An input voltage of 0 to -6.2 volts dc should be present
between pin 29 and chassis ground (plug PLG2). This
voltage will remain at 0 volts dc until reed switch RS1
senses output amperage.
An input voltage of 0 to +2 volts dc should be present
between pin 28 and chassis ground (plug PLG2). At
maximum output of 80 load amps at 120 volts dc, this
voltage should be +1.92 (+0.1/-0.05) volts dc.
When the torch switch is pressed, +24 volts dc will be
applied between pin 13 and chassis ground (plug
PLG2). This will be a pulsing signal until reed switch
RS1 senses output amperage.
Plug PLG2
Pins 1 thru 29
SN-126 963-C
TM-205 Page 27
 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS IMPORTANT: For DC, the values are based on a good quality
can cause serious injury. digital multimeter DMM or equivalent reading average (not RMS)
• Do not touch live electrical parts. values. For AC, the values are RMS readings. The voltages
• Shut down power source and place line disconnect shown are with respect to chassis ground unless otherwise indi-
cated and the tolerances are ±10% unless otherwise specified.
switch in the off position before making or changing meter
lead connections and before disconnecting or connecting
any machine leads.
• Disconnect HF input receptacle RC5 from Timer/Control
Board PC2 BEFORE troubleshooting, maintaining, or
servicing power source (see Section 8-2).
• Have only qualified persons familiar with and following
standard safety practices perform troubleshooting proce-
dures.
• Follow standard ESD precautions to prevent damaging
static-sensitive parts during testing.

30 to 33 volts ac
(±0.5 volts) input

0 volts dc with RS1 open;

0 to –6 volts dc with RS1 closed

+1.92 volts dc (±0.1

volts)
at maximum output of
80 load amps at
120 volts dc

Pulsing 24 volts dc
before cutting;
steady 24 volts dc
during cutting

18 volts ac
input

18 volts ac input

36 volts ac input

–15 volts dc output

+15 volts dc output

Diagram 8-2. Troubleshooting Circuit Diagram For Regulator Board PC1

TM-205 Page 28 Spectrum 1500
 See Chart 8-2
for SCR waveform

SCR 1A Gate

SCR 1A Cathode

SCR 1B Gate

SCR 1B Cathode

SCR 2A Gate

SCR 2A Cathode

SCR 2A Gate

SCR 2B Cathode

SCR 3A Gate

SCR 3A Cathode

SCR 3B Gate

SCR 3B Cathode

SC-126 851-A

Spectrum 1500 TM-205 Page 29

C. Main Rectifier SR1 Control Leads
The leads attached to pins 1, 4, 5, 8, 9, and 12 output to
the main rectifier SR1 SCR gates. The gate pulses that
fire the SCR’s can be checked by connecting an oscillo-
scope probe to these pins and comparing the wave-
forms with the one on Chart 8-2C.
If correct output voltages or signals are not found at
these check points when the proper input conditions are
met, replace Regulator Board PC1.
8-6. TIMER/CONTROL BOARD PC2 TESTING
PROCEDURES (Chart 8-1, Diagram 8-3 And
Figure 8-2)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
TM-205 Page 30
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
A. Power Supply Inputs/Outputs
An input voltage of 18 volts ac should be present be-
tween pins A and K of receptacle RC2.
An input voltage of 24 volts ac should be present be-
tween pin N of receptacle RC2 and chassis ground (pins
E, M, N, P, R, and S of receptacle RC1, pin C of recep-
tacle RC2, and pins A and B of receptacle RC5).
An input voltage of 115 volts ac should be present be-
tween pin D of receptacle RC2 and chassis ground. Af-
ter being switched and fused, this 115 volts ac outputs at
pin L of receptacle RC1 (referenced to chassis ground).
An input voltage of +15 volts dc is applied to pin S of re-
ceptacle RC2 and outputs at pin R of receptacle RC2
(both referenced to chassis ground). An input voltage of
-15 volts dc is applied to pin G of RC2 and outputs at pin
H of RC2 (both referenced to chassis ground). Both reg-
ulated inputs are for the command ramp generator.
An output voltage of +10 volts dc should be present be-
tween pin A of receptacle RC3 and chassis ground.
An output voltage of 24 volts dc should be present be-
tween pin F of receptacle RC2 and chassis ground when
shield cup is attached to torch head. Pin D should be at 0
volts dc when the shield cup is removed.
An input voltage of 18 volts ac should be present be-
tween pins E and J of receptacle RC2. This 18 volts ac is
rectified and regulated to 24 volts dc for use as the sens-
ing supply voltage. This 24 volts dc output voltage
should be present at the following points (referenced to
chassis ground) whenever the POWER switch is in the
ON position: pins D and E of receptacle RC3, pins B, C,
E, G, F, and L of receptacle RC4, and pin C of receptacle
RC5.
An input voltage of 24 volts ac should be present be-
tween pin P of receptacle RC2 and chassis ground
whenever the unit has input power applied. This 24 volts
ac should be present between pin K of receptacle RC1
and chassis ground to purge the coolant lines when
POWER switch S1 is turned off.
An output voltage of 24 volts ac should be present be-
tween pin J of receptacle RC1 and chassis ground when
coolant circulation is requested.
An output voltage of +24 volts dc should be present be-
tween pins C and E (switched ground) of receptacle
RC5 to power torch warning alarm Y1 when activated by
the torch tip interlock.
B. Control Line Inputs/Outputs
An input voltage of 0 to +10 volts dc is applied between
pin B of receptacle RC3 and chassis ground to track
THICKNESS OUTPUT CONTROL R1 position. This 0
to +10 volts dc is converted to 0 to -6 volts dc and is out-
Spectrum 1500
put between pin C of RC3 and chassis ground. This 0 to
-6 volts dc will remain at 0 volts dc until reed switch RS1
senses output amperage. This 0 volts dc will ramp down
within 150 ms to the value requested by R1.
When TEST/GOUGE/RUN switch S4 is placed in TEST
position, 24 volts dc should be present between pin K of
receptacle RC4 and chassis ground.
When the torch switch is pressed, 24 volts dc should be
present between pin A of receptacle RC4 and chassis
ground.
When RS1 senses output amperage, an input voltage
of 24 volts dc is applied between pin M of RC4 and
chassis ground.
Pins C and D of receptacle RC1 connect to normally-
open relay contacts that track the opening and closing of
RS1.
An output voltage of pulsing 24 volts dc to solid-state
relay CR4 to turn the high-frequency voltage on and off
should be present between pin F of receptacle RC5 and
chassis ground during arc initiation.
C. Interlocks
An input voltage of +24 volts dc should be present at
pins D, H, N, and P of receptacle RC4 (all referenced to
chassis ground) when interlock conditions are met. If
Receptacle RC1
Receptacle RC4
Receptacle RC5
Figure 8-2. Timer/Control Board PC2 Component Locations And Information
Spectrum 1500
+24 volts dc is not found at these input check points, the
unit will not function, the corresponding trouble light will
illuminate, and possibly the torch warning alarm will
sound.
When all the interlock conditions are met, 0 volts dc
should be present between pin K of receptacle RC3 and
chassis ground.
D. Relay And Solenoid Drivers
An output voltage of pulsing +24 volts dc should be pres-
ent between pin B of receptacle RC1 and chassis
ground during arc initiation.
An output voltage of +24 volts dc should be present be-
tween pin G of receptacle RC1 and chassis ground
when high-frequency output is requested.
An output voltage of 24 volts ac should be present be-
tween pin A of receptacle RC1 and chassis ground when
low airflow is requested.
With output amperage present (reed switch RS1 acti-
vated) or with TEST/GOUGE/RUN switch S4 in the
TEST position, 24 volts ac should be present between
pin H of receptacle RC1 and chassis ground.
If all input voltage checkpoints are correct, and the cor-
rect output voltage or signal is not found at these check-
points, replace Timer/Control Board PC2.
Receptacle RC3
Fuse F4; 115 volts ac
output circuit
Fuse F2; 24 volts ac
from control transformer T2
Fuse F3; 24 volts ac
from control transformer T2
Fuse F1; 18 volts ac
from control transformer T2
Receptacle RC2 Fuse F5; 18 volts ac
from main transformer T1
SC-129 567-B
TM-205 Page 31
 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
can cause serious injury.
• Do not touch live electrical parts.
• Shut down power source and place line disconnect switch
in the off position before making or changing meter lead
connections and before disconnecting or connecting any
machine leads.
• Disconnect HF input receptacle RC5 from Timer/Control
Board PC2 BEFORE troubleshooting, maintaining, or ser-
vicing power source (see Section 8-2).
• Have only qualified persons familiar with and following stan-
dard safety practices perform troubleshooting procedures.
• Follow standard ESD precautions to prevent damaging stat-
ic-sensitive parts during testing.

+24 volts dc
when torch
trigger
is pressed

+24 volts dc
when shield
cup is
installed

+24 volts dc input

when N.O. air
pressure switch
is closed

+24 volts dc +24 volts dc +24 volts dc * +24 volts dc

from main input when when N.O. water when TEST/RUN
rectifier reed switch pressure switch S4 is in
thermostat RS1 closes switch S3 TEST position:
TP2 is closed 0 volts dc when
S4 is in RUN
position

Diagram 8-3. Troubleshooting Circuit Diagram For Timer/Control Board PC2

TM-205 Page 32 Spectrum 1500
 IMPORTANT: For DC, the values are based on a good quality
digital multimeter DMM or equivalent reading average (not
RMS) values. For AC, the values are RMS readings. The volt-
ages shown are with respect to chassis ground unless other-
wise indicated and the tolerances are ± 10% unless otherwise
specified.

*IMPORTANT: For units effective with Serial No. KA880069, a

GOUGE position was added to the TEST/RUN switch.

24 volts ac for AS1

or when TEST/RUN
switch S4 is in
TEST position

24 volts ac for GS1

or when TEST/RUN
switch S4 is in
TEST position

No HF if interlock
conditions not met

+24 volts dc
output during HF

Pulsing +24 volts dc

before cutting

IMPORTANT: This is a portion of the PC2 circuit disgram;

see Diagram 10-6 for entire PC2 circuit diagram.

SD-129 569-A

Spectrum 1500 TM-205 Page 33

8-7. RELAY BOARD PC3 TESTING INFORMA-
TION (Diagram 8-4 And Figure 8-3)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
Friction Terminal A
Receptacle RC1
Figure 8-3. Relay Board PC3 Component Locations And Information
TM-205 Page 34
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
A. Power Supply Inputs/Outputs
An input voltage of 18 volts ac should be present be-
tween pins A and B of receptacle RC1.
An input voltage of 115 volts ac should be present be-
tween pin M of receptacle RC1 and chassis ground (pin
G of receptacle RC1). This 115 volts ac should also be
present between pin P of RC1 and chassis ground dur-
ing pilot arc time.
Input voltages of +24 volts dc should be present be-
tween each of pins K and H of receptacle RC1 and chas-
sis ground.
B. Control Lines Circuit
An output voltage of +24 volts dc should be present be-
tween friction terminals A (–) and B (+) unless a torch tip
to electrode short exists.
An input voltage of +24 volts dc should be present be-
tween pin E of receptacle RC1 and chassis ground when
high-frequency is requested.
If all input voltage check points are correct, and the cor-
rect output voltage is not found at these output check
points, replace Relay Board PC3.
Friction Terminal B
Fuse F1: Torch Tip
Sensing Circuit
Ref. SA-128 922-A
Spectrum 1500
Spectrum 1500

WARNING: ELECTRIC SHOCK can kill; IMPORTANT: For DC, the values are based on a good quality digital
MOVING PARTS can cause serious injury. multimeter (DMM) or equivalent reading average (not RMS) values. For
AC, values are RMS readings. The voltages shown are with respect to
Do not touch live electrical parts. chassis ground unless otherwise indicated and the tolerances are ± 10%
• •
Shut down power source and place line disconnect unless otherwise indicated.
switch in the OFF position before making or changing meter
lead connections and before disconnecting or connecting
any machine leads.

Disconnect HF input receptacle RC5 from

•

Timer/Control Board PC2 BEFORE troubleshooting,

or servicing power source (see Section 8-2).
Have only qualified persons familiar with and
•

following standard safety practices perform Connected to the Pins A and B are used for Connected to the output side
troubleshooting procedures. (–) side of rectifier SR1 sensing a short between of main machine relay CR1
the tip and electrode
Follow standard ESD precautions to prevent damaging
•

static-sensitive parts during testing. Provides voltage

isolation during HF

Drop-out delay circuit

+24 volts dc input Not

when HF is Connected
requested

+24 volts dc output to

Timer/Control Board PC2

Not +24 volts dc output to

Connected shield cup circuit
Relay CR1 and CR2 contacts
open to remove HF sensing leads before
HF starts when relay CR3 energizes. HF
will damage sensing circuit. Connected in series
with shield cup
TM-205 Page 35

interlock circuit
CR4 energizes if a short is present between the
tip and electrode. This will remove the +24 volts
dc signal to the torch tip interlock (PC2) which
will lock out machine functions. SB-128 923

Diagram 8-4. Troubleshooting Circuit Diagram For Relay Board PC3

8-8. TROUBLE LIGHT BOARD PC4 (Diagram 8-5
And Figure 8-4)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
Not Used
Gas/Air
Trouble Light
Torch Tip
Trouble Light
Temperature
Trouble Light
Coolant
Trouble Light
Front View
Figure 8-4. Trouble Light Board PC4 Component Locations And Information
TM-205 Page 36
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
Trouble Light Board PC4 contains 5 common anode
LED’s (trouble lights). An input voltage of +24 volts dc
should be present between pins 1, 3, 4, 5 , and 6 of edge
connector CN1 and chassis ground. LED’s are illumi-
nated when the appropriate LED cathode is grounded
through a limit resistor.
+24 volts dc from
Timer/Control Board PC2
Rear View Ref. SA-125 057
Spectrum 1500
 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
can cause serious injury.
• Do not touch live electrical parts.
• Shut down power source and place line disconnect
switch in the off position before making or changing meter
lead connections and before disconnecting or connecting IMPORTANT: For DC, the values are based on a good quality digital
any machine leads. multimeter (DMM) or equivalent reading average (not RMS) values.
For AC, values are RMS readings. The voltages shown are with respect
• Disconnect HF input receptacle RC5 from Timer/Control to chassis ground unless otherwise indicated and the tolerances are
Board PC2 BEFORE troubleshooting, maintaining, or ± 10% unless otherwise indicated.
servicing power source (see Section 8-2).
• Have only qualified persons familiar with and following
standard safety practices perform troubleshooting proce-
dures.
• Follow standard ESD precautions to prevent damaging
static-sensitive parts during testing.

+24 volts dc input from

Timer/Control Board PC2

Not used

Gas/Air Trouble Light

Torch Tip Trouble Light

Temperature Trouble Light

Coolant Trouble Light SA-135 750

Diagram 8-5. Troubleshooting Circuit Diagram For Trouble Light Board PC4

8-9. FILTER BOARD PC5 TESTING PROCE- CAUTION: ELECTROSTATIC DISCHARGE

DURES (Diagram 8-6 And Figure 8-5)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
Spectrum 1500
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
TM-205 Page 37
The trigger circuit from the torch enters PC5 at pins A
and E of receptacle RC1. When the POWER switch is
ON, +24 volts dc will be detected at pin E of RC1 and pin
A of RC2. When the torch switch is pressed, +24 volts dc
will be detected at pin A of RC1 and pin B of RC2 (all ref-
erenced to pin D of RC2, chassis ground).
The shield cup circuit enters PC5 at pins D and H of
RC1. When the POWER switch is ON, +24 volts dc will
be detected at pin D of RC1 and pin C of RC2. When the
shield cup is installed, +24 volts dc will be detected at pin
H of RC1 and pin F of RC2 (all referenced to pin D of
RC2, chassis ground).
If input and output signals do not match, replace Filter
Board PC5.

WARNING: ELECTRIC SHOCK can kill; MOVING PARTS

can cause serious injury.
• Do not touch live electrical parts.
• Shut down power source and place line disconnect
switch in the off position before making or changing meter
lead connections and before disconnecting or connecting
any machine leads.
• Disconnect HF input receptacle RC5 from Timer/Control IMPORTANT: For DC, the values are based on a good quality digital
Board PC2 BEFORE troubleshooting, maintaining, or multimeter (DMM) or equivalent reading average (not RMS) values.
servicing power source (see Section 8-2). For AC, values are RMS readings. The voltages shown are with respect
• Have only qualified persons familiar with and following
to chassis ground unless otherwise indicated and the tolerances are
± 10% unless otherwise indicated.
standard safety practices perform troubleshooting proce-
dures.
• Follow standard ESD precautions to prevent damaging
static-sensitive parts during testing.

+24 volts dc
when shield
cup is installed.
Same as
RC1-H
+24 volts dc
when POWER Same as
switch in ON. RC1-D

+24 volts dc Same as

When torch RC1-A
switch is pressed

+24 volts dc Same as

when POWER RC1-E
switch in ON.
Not used

Chassis
ground
SA-127 793

Diagram 8-6. Troubleshooting Circuit Diagram For Filter Board PC5

Receptacle RC2/Plug PLG13

Receptacle RC1/Plug PLG12

SA-127 791-A

Figure 8-5. Filter Board PC5 Component Locations And Information

TM-205 Page 38 Spectrum 1500
8-10. HALL DEVICE HD1 TESTING PROCEDURES
(Diagram 8-7 And Figure 8-6)
WARNING: ELECTRIC SHOCK CAN KILL
• Do not touch live electrical parts.
• Shut down power source, and place line dis-
connect switch in the off position before in-
specting, maintaining, or servicing.
• Shut down power source, and place line dis-
connect switch in the off position before mak-
ing or changing meter lead connections.
• Disconnect HF input receptacle RC5 from
Timer/Control Board PC2 BEFORE maintain-
ing or servicing power source (see Section
8-2).
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be ener-
gized. Only qualified persons familiar with and
following standard safety practices are to per-
form this testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
Pins A-D, F
Figure 8-6. Hall Device HD1 Component Location And Information
Spectrum 1500
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks should go through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion is not the
problem.
A. Power Supply Inputs
Input voltages of +15 volts dc should be present be-
tween pin C and chassis ground (pins A and F) and -15
volts dc should be present between pin B and chassis
ground.
B. Output Amperage Feedback Circuit
A positive feedback voltage that is proportional to output
amperage should be present between pin D and chassis
ground. With a maximum output load of 80 amperes at
120 volts dc, this voltage should be +1.92 (+0.1/-0.05)
volts dc.
SA-134 827
TM-205 Page 39
 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
can cause serious injury.
• Do not touch live electrical parts.
• Shut down power source and place line disconnect
switch in the off position before making or changing meter
lead connections and before disconnecting or connecting
any machine leads. IMPORTANT: For DC, the values are based on a good quality digital
• Disconnect HF input receptacle RC5 from Timer/Control multimeter (DMM) or equivalent reading average (not RMS) values.
For AC, values are RMS readings. The voltages shown are with respect
Board PC2 BEFORE troubleshooting, maintaining, or to chassis ground unless otherwise indicated and the tolerances are
servicing power source (see Section 8-2). ± 10% unless otherwise indicated.
• Have only qualified persons familiar with and following
standard safety practices perform troubleshooting proce-
dures.
• Follow standard ESD precautions to prevent damaging
static-sensitive parts during testing. +15 volts dc input

Positive feedback voltage

proportional to
output amperage

Chassis ground

–15 volts dc input

SA-110 758-A

Diagram 8-7. Troubleshooting Circuit Diagram For Hall Device HD1

TM-205 Page 40 Spectrum 1500

 SECTION 9 – MAINTENANCE
9-1. ROUTINE MAINTENANCE (Table 9-1)
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of pre-
cautionary labels.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting, maintaining, or ser-
vicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Maintenance to be performed only by qualified
persons.
Table 9-1. Maintenance Schedule
Frequency* Maintenance
Before cutting or Check coolant level (see Section
as required. 5-5). Check gas/air pressure (see
Step 6, Section 6-1). Inspect
shield cup, tip, and electrode (see
Section 9-2).
Every week. Check shield cup detector circuit
(see Section 9-8B).
Every month. Units in heavy service environ-
ments: Check labels, cables,
leads, and torch; clean internal
parts.
Every 3 months. Check cables, leads, and torch
(see Section 9-1D).
Every 6 months. Check all labels (see IMPOR-
TANT block, Section 9-1). Clean
internal parts (see Section 9-1D).
*Frequency of service is based on units operated 40
hours per week. Increase frequency of maintenance if
usage exceeds 40 hours per week.
A. Fan Motors
This power source is equipped with an exhaust fan and
relies on forced draft for adequate cooling. The fan mo-
tor is manufactured with lifetime sealed bearings and re-
quires no maintenance.
Spectrum 1500
B. Coolant Pump Motor
This power source is equipped with a coolant pump mo-
tor. The coolant pump motor is manufactured with life-
time sealed bearings and requires no maintenance.
C. Torch Cables And Leads
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 before
proceeding.
Every three months inspect cables, leads, and torch for
breaks in insulation. Repair or replace cables, leads,
and torch if insulation breaks are present. Clean and
tighten connections at each inspection.
D. Internal Cleaning
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 before
proceeding.
Every six months vacuum dust and dirt from the inside of
the power source. Remove the outer enclosure, and use
a vacuum suction for the cleaning operation. If dusty or
dirty conditions are present, clean the unit once a
month.
9-2. SHIELD CUP, TIP, AND ELECTRODE INSPEC-
TION AND REPLACEMENT (Figures 9-1 And
9-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting, maintaining, or ser-
vicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
CAUTION: TIP AND ELECTRODE WEAR BE-
YOND RECOMMENDED VALUES or OPERA-
TION WITHOUT TIP OR ELECTRODE can
damage torch.
• Inspect shield cup, tip, and electrode before
each use, hourly during operation, or when-
ever cutting speed has been significantly re-
duced.
• Do not operate torch without a tip or electrode
in place.
TM-205 Page 41
 • Be sure to use only genuine replacement 9-3. TORCH AND WORK CABLE INSPECTION
parts. AND CONNECTIONS (Figures 4-3 And 9-2)
• A good practice is to replace both the tip and WARNING: ELECTRIC SHOCK can kill.
electrode at the same time. • Do not touch live electrical parts.
To inspect and replace torch parts, proceed as follows: • Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
1. Shut down power source, and wait approximately dures before inspecting, maintaining, or ser-
30 seconds for coolant to return to coolant tank. vicing.
Warning alarm will sound if shield cup is removed Lockout/tagging procedures consist of padlock-
before coolant returns to coolant tank. ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
2. Remove shield cup and tip. red-tagging circuit breaker or other disconnect-
3. Inspect shield cup. If shield cup is cracked or bro- ing device.
ken, obtain new shield cup. MOVING PARTS can cause serious injury.
4. Using a clean, dry cloth, wipe off contact surface
• Keep away from moving parts.
on shield cup (see Figure 9-1). HOT SURFACES can cause severe burns.
5. Inspect hole in tip (see Figure 9-1). If hole in tip is • Allow cooling period before servicing.
deformed or 50 percent oversize, replace tip. If it should become necessary to replace the torch or
work cable, proceed as follows:
6. Inspect end of electrode (see Figure 9-1). If ero-
A. Removal Of Torch And Work Cable
sion depth of electrode exceeds 0.059 in. (1.0
mm), remove and replace electrode using sup- 1. Shut down power source.
plied wrench. 2. Remove left side panel.
7. Insert tip into shield cup, and reinstall and secure 3. Disconnect Torch (–)/Coolant Out cable from
shield cup and tip. TORCH output connector.
8. Resume operation. 4. Disconnect Pilot (+)/Coolant In cable from PILOT
ARC output connector.
Contact Surface
5. Disconnect Gas/Air In hose from GAS/AIR output
connector.
Shield Cup 6. Disconnect shield cup detector leads 1 and 2
from terminal strip 1T.
Oversized Or 7. Disconnect torch switch leads 3 and 4 from termi-
Proper Out Of Round
Hole Size Hole nal strip 1T, and remove torch cable and leads
from unit.
New Worn 8. Disconnect Work (+) cable from WORK (+) output
Tip Tip terminal, and remove cable from unit.
B. Reinstallation Of Torch And Work Cable
New Electrode
1. Route new torch cable and leads through access
hole in front panel, and connect torch cable and
leads as follows:
a. Connect Torch (–)/Coolant Out cable to
0.059 in. (1.5 mm) TORCH output connector.
b. Connect Pilot (+)/Coolant In cable to PILOT
Worn Electrode ARC output connector.
Maximum c. Connect Gas/Air In hose to GAS/AIR output
Erosion connector.
Depth
d. Connect shield cup detector lead 1 to terminal 1
on 1T.
Worn Electrode e. Connect shield cup detector lead 2 to terminal 2
on 1T.
f. Connect torch switch lead 3 to terminal 3 on 1T.
g. Connect torch switch lead 4 to terminal 4 on 1T.
2. Route new Work (+) cable through access hole in
.059 in. (1.5 mm) S-0099-A
front panel, and connect to WORK (+) output ter-
Figure 9-1. Shield Cup, Tip, And Electrode minal.
Inspection 3. Reinstall and secure left side panel onto unit.
TM-205 Page 42 Spectrum 1500
 Electrode Wrench

Shield Cup

Torch Body

Tip

Electrode

Torch Switch

Torch (-)/Coolant Out Connector

Torch Handle Gas/Air Input Connector

Pilot (+)/Coolant
In Connector

Shield Cup Detector

Leads 1 And 2
Torch Switch
Leads 3 And 4

SB-127 449

Figure 9-2. Torch Parts And Connections

9-4. SHIELD CUP DETECTOR PIN INSPECTION 1.
AND REPLACEMENT (Figure 9-3)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts. 2.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce- 3.
dures before inspecting, maintaining, or ser-
vicing.
4.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and 5.
red-tagging circuit breaker or other disconnect-
ing device.
HOT SURFACES can cause severe burns. 6.
• Allow cooling period before servicing.
7.
Each time the shield cup is removed from the torch,
check that the shield cup detector pins move freely. If 8.
there is dirt around the pins, clean pins with electrical
contact cleaner, and recheck for free movement. If it be-
comes necessary to replace the pins or pin assemblies,
proceed as follows: 9.
Spectrum 1500
Shut down power source, and wait approximately
30 seconds for coolant to return to coolant tank.
Warning alarm will sound if shield cup is removed
before coolant returns to coolant tank.
Remove shield cup and tip.
Remove screws from each half of torch handle,
and set handle aside (see Figure 9-3).
Remove screws from torch body cover, and set
cover aside (see Figure 9-3).
Slide pin assembly(ies) out of torch head (see
Figure 9-3).
Clean pins and pin assemblies with electrical
contact cleaner, and recheck for free movement.
If pins do not have free movement, replace entire
pin assembly.
Reassemble torch in reverse order. Be sure that
leads are not pinched inside torch handle during
reassembly (see Figure 9-3).
Resume operation.
TM-205 Page 43
 HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.

CAUTION: FAILURE TO PROPERLY MAIN-

TAIN THE COOLANT SYSTEM can cause
damage to the coolant system and torch.
• After a break-in period of approximately 100
hours of operation, circulate and flush deion-
ized or distilled water through entire system,
service coolant filters, and replace coolant.
• Circulate and flush deionized or distilled wa-
ter through entire system, and replace cool-
ant every twelve months after break-in period.
• Service coolant filters after every 200 hours of
operation after break-in period.

If coolant system is properly maintained, cooling prob-

lems should not occur. If a problem is suspected, service
coolant filters as described below, and circulate and
flush deionized or distilled water through entire system.
This power source is equipped with a coolant drain plug
for draining the coolant system (see Figure 4-4). Use
proper coolant according to Section 4-5.
To service coolant filters, refer to Figure 9-4 and proceed
as follows:
1. Remove left side panel, and locate coolant tank.
2. Remove cap and drain coolant tank by removing
coolant drain plug located on rear panel (see Fig-
ure 4-4).
3. Service coolant return filter as follows:
a. Remove large brass nut securing return filter
assembly to coolant tank, and remove assem-
bly from tank.
b. Unthread brass nut located at end of return filter
assembly, and remove brass sleeve enclosing
filter material.
c. Clean or replace foam filter material as needed.
d. Reassemble return filter assembly in reverse
order, and reinstall in coolant tank. Be sure rub-
Figure 9-3. Shield Cup Detector Pins And Pin ber packing is seated properly to prevent leaks.
Assemblies
4. Service coolant supply filter screen as follows:
9-5. CLEANING THE COOLANT SYSTEM, a. Locate delivery filter screen assembly on hose
CHANGING COOLANT, AND SERVICING connected to coolant pump motor M1.
COOLANT FILTERS (Figures 4-4 And 9-4)
b. Remove delivery filter screen assembly from
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts. coolant tank.

• Shut down power source, and disconnect in- c. Clean filter screen.
put power employing lockout/tagging proce- d. Reinstall filter screen assembly in reverse or-
dures before inspecting, maintaining, or ser-
vicing. der. Be sure rubber packing is seated properly
to prevent leaks.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re- 5. Be sure coolant drain plug is closed, and refill
moving fuses from fuse box, or shutting off and coolant tank. Replace cap.
red-tagging circuit breaker or other disconnect-
ing device. 6. Reinstall left side panel.
TM-205 Page 44 Spectrum 1500
 Retaining Sleeve
Nut
Cap

Return
Filter
Assembly
Brass Nut

Rubber Packing

Coolant Tank

Rubber
Packing

Supply filter screen assembly Delivery

(attaches to hose connected Filter
to coolant pump motor M1) Screen

Brass
Nut
SB-129 916

Figure 9-4. Location Of Coolant Filters And Components

9-6. SPARK GAP (Figure 9-5) 1. Shut down power source.

WARNING: ELECTRIC SHOCK can kill. 2. Remove right side panel from unit.
• Do not touch live electrical parts. 3. Loosen screw A.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce- 4. Place feeler gauge of 0.030 in. (0.762 mm) thick-
dures before inspecting, maintaining, or ser- ness between point C.
vicing.
5. Apply slight pressure against point B so feeler
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re- gauge is held firmly in gap.
moving fuses from fuse box, or shutting off and 6. Tighten screw A.
red-tagging circuit breaker or other disconnect-
ing device. 7. Reinstall right side panel onto unit.
MOVING PARTS can cause serious injury.
8. Resume operation.
• Keep away from moving parts.
C
HOT SURFACES can cause severe burns. 0.030 in. A
• Allow cooling period before servicing. (0.762 mm)

This unit is provided with a spark gap assembly located B

behind the right side panel. The spark gap was set at the
factory, and readjustment is not recommended. Normal
spark gap setting is 0.030 in. (0.762 mm). If it should be-
S-0201
come necessary to adjust the spark gap, proceed as fol-
lows: Figure 9-5. Spark Gap Adjustment
Spectrum 1500 TM-205 Page 45
9-7. OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down power source, and disconnect in-
put power employing lockout/tagging proce-
dures before inspecting, maintaining, or ser-
vicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Perform work only at a static safe work area.
INCORRECT FUSE can damage unit.
• Use only replacement fuse of same size,
type, and rating (see Parts List).
Main fuse F1 located on the left side of the rear panel
protects control transformer T2 from overload. Should
F1 open, the power source would be completely inop-
erative.
Fuses F1 through F5 located on Timer/Control Board
PC2 protect the circuitry on PC2 from overload. Should
any of these fuses open, the power source would not op-
erate.
To replace main fuse F1 or fuses F1 through F5, correct
the problem, and proceed as follows:
1. Shut down power source.
2. Remove left side panel to replace main fuse F1,
or remove right side panel to replace fuses F1
through F5.
3. Check fuses, and replace if necessary.
4. Reinstall and secure left and/or right side panels
onto unit.
5. Resume operation.
9-8. TROUBLE LIGHTS (Figure 5-1)
A. Gas/Air Trouble Light
To prevent damage to the torch due to insufficient air
pressure, the torch is protected by normally open air
pressure switch S2. When the power source is ener-
gized and the air pressure reaches a preset value, S2
closes. Should air pressure drop below the preset value,
S2 would open, and the power source would be com-
pletely inoperative. The READY light would turn off, and
the GAS/AIR trouble light would come on. Should the
GAS/AIR trouble light come on, check gas/air pressure
(see Step 6, Section 6-1).
TM-205 Page 46
B. Torch Tip Trouble Light
1. Shield Cup Detector Circuit
Should the shield cup be removed or not properly
installed on the torch, the power source would be com-
pletely inoperative. The READY light would turn off, the
TORCH TIP trouble light would come on, and the warn-
ing alarm would sound. Should the TORCH TIP trouble
light come on, turn off power source, and check that
shield cup is clean and properly installed according to
Section 9-2.
Once a week check the shield cup detector circuit for
proper operation by loosening the shield cup and ob-
serving the READY light and TORCH TIP trouble light. If
the READY light turns off, the TORCH TIP trouble light
comes on, and the warning alarm sounds, the detector
circuit is operating properly. If the READY light remains
on or the TORCH TIP trouble light remains off, turn off
power source. Check shield cup detector pins for proper
operation, and replace if necessary (see Section 9-4).
2. Tip Leakage Detector Circuit
To prevent injury from electric shock should the tip and
electrode come in contact with each other, the power
source would be completely inoperative. The READY
light would turn off, the TORCH TIP trouble light would
come on, and the warning alarm would sound. Should
the TORCH TIP trouble light come on, turn off power
source. Check that shield cup is clean and properly
installed, and replace the tip and electrode according to
Section 9-2, if necessary.
C. Temperature Trouble Light
Main transformer T1 is protected by normally closed
thermostat TP1, and main rectifier SR1 is protected by
normally closed thermostat TP2. Should TP1 and/or
TP2 open, thermal shutdown would occur, and the pow-
er source would be completely inoperative. The READY
light would turn off, and the TEMPERATURE trouble
light would come on. The fan motor FM would continue
to run. Should the TEMPERATURE trouble light come
on due to a thermal shutdown, a cooling period of
approximately ten minutes will be required.
D. Water Trouble Light
To prevent damage to the torch due to insufficient cool-
ant pressure, the torch is protected by normally open
pressure switch S3. When the power source is ener-
gized and the pressure reaches a preset value, S3
closes. Should coolant pressure drop below the preset
value, S3 would open, and the power source would be
completely inoperative. The READY light would turn off,
and the WATER trouble light would come on. Should the
WATER trouble light come on, turn off power source,
and check the WATER LEVEL indicator for proper
amount of coolant in system (see Section 5-5). For addi-
tional remedies, see Table 8-1. Troubleshooting. After
correcting problem, reset water sense circuit by press-
ing and releasing torch switch or switching the POWER
switch off/on.
Spectrum 1500
 SECTION 10 – 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 JK628764 thru JK651451 SC-126 462-C D-127 311♦♦

JK651452 thru JK780147 SC-130 440 D-130 433-A♦♦ Added CR4

JK780148 thru KA880068 SC-135 539 D-135 690♦♦ Removed D3, added C1

KA880069 thru KC286938 SC-138 425-A SD-138 376 Added gouge circuit

Circuit Board PC1 JK628764 thru KC286938 SC-126 851-A

Circuit Board PC2 JK628764 thru JK651451 D-125 661-A♦♦

JK651452 thru KC286938 SD-129 569-A

Circuit Board PC3 JK628764 thru JK581592 B-124 519-A♦♦

JK581593 thru KC286938 SB-128 923

Circuit Board PC4 JK628764 thru KA834915 A-129 640♦♦

KA834916 thru KB058479 A-135 750♦♦

KB058480 thru KC286938 SA-143 674

Circuit Board PC5 JK628764 thru KC286938 SA-127 793

Circuit Board HD1 JK628764 thru KC286938 SA-110 758-A

♦♦ Not included in this manual

Spectrum 1500 TM-205 Page 47

TM-205 Page 48
Spectrum 1500

Circuit Diagram No. SC-126 462-C

Diagram 10-1. Circuit Diagram For Spectrum 1500 Effective With Serial No. JK628764 Thru JK651451
Spectrum 1500
TM-205 Page 49

Circuit Diagram No. SC-103 440

Diagram 10-2. Circuit Diagram For Spectrum 1500 Effective With Serial No. JK651452 Thru JK780147
TM-205 Page 50
Spectrum 1500

Circuit Diagram No. SC-135 539

Diagram 10-3. Circuit Diagram For Spectrum 1500 Effective With Serial No. JK780148 Thru KA880068
Spectrum 1500
TM-205 Page 51

Circuit Diagram No. SC-138 425-A

Diagram 10-4. Circuit Diagram For Spectrum 1500 Effective With Serial No. KA880069 Thru KC286938
 Diagram 10-5. Wiring Diagram For Spectrum 1500 Effective With
Serial No. KA880069 Thru KC286938
TM-205 Page 52 Spectrum 1500
 Wiring Diagram No. SD-138 376

Spectrum 1500 TM-205 Page 53

 Diagram 10-6A. Circuit Diagram Portion For Timer/Control Board PC2 Effective With
Serial No. JK651452 Thru KC286938 (Part 1 Of 2)
TM-205 Page 54 Spectrum 1500
 Circuit Diagram No. SD-129 569-A (1 Of 2)

Spectrum 1500 TM-205 Page 55

 Diagram 10-6B. Circuit Diagram Portion For Timer/Control Board PC2 Effective With
Serial No. JK651452 Thru KC286938 (Part 2 Of 2)
TM-205 Page 56 Spectrum 1500
 Circuit Diagram No. SD-129 569-A (2 Of 2)

Spectrum 1500 TM-205 Page 57

TM-205 Page 58
Spectrum 1500

Circuit Diagram No. SC-126 851-A

Diagram 10-7. Circuit Diagram For Regulator Board PC1 Effective With Serial No. JK628764 Thru KC286938
 Circuit Diagram No. SB-128 923

Diagram 10-8. Circuit Diagram For Relay Board PC3 Effective With Serial No. JK581593 Thru KC286938

Circuit Diagram No. SA-143 674

Diagram 10-9. Circuit Diagram For Trouble Light Board PC4 Effective With
Serial No. KB058480 Thru KC286938
Spectrum 1500 TM-205 Page 59
 Circuit Diagram No. SA-127 793

Diagram 10-10. Circuit Diagram For Filter Board PC5 Effective With Serial No. JK628764 Thru KC286938

Circuit Diagram No. SA-110 758-A

Diagram 10-11. Circuit Diagram For Hall Device HD1 Effective With Serial No. JK628764 Thru KC286938
TM-205 Page 60 Spectrum 1500
 July 1996 Form: TM-205
Effective With Serial No. JK628764 Thru
KC286938

SECTION 11 – PARTS LIST

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

Spectrum 1500 TM-205 Page 61

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 11-1. Main Assembly

. . 1 . . . . . . . . . . . . 015 531 . . HOOK, lift (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . 125 351 . . WATER TANK ASSEMBLY, (Prior to KB070482) (Fig 11-7) . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . . 143 156 . . WATER TANK ASSEMBLY, (Eff w/KB070482) (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 11-7) (consisting of) . . . . . . . . . . . . . . . . . . . 1
. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . PACKING, rbr (see Fig 11-7 Item 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . CAP, (see Fig 11-7 Item 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . . . . . . . . . Fig 11-4 . . VALVE AND PRESSURE SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 15 . . . SR1 . . . 135 688 . . RECTIFIER, main (Fig 11-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 16 . . . . . . . . . . . 126 701 . . BRACKET, mtg heat sink RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . . . . . . . . . 126 986 . . HF PANEL, (Fig 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 18 . . . CR1 . . . 605 855 . . CONTACTOR, def prp 40A 3P 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 19 . . . CR3 . . . 124 886 . . CONTACTOR, def prp 60A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 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 . . . . W . . . . 124 886 . . CONTACTOR, def prp 60A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 095 317 . . LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 23 . . . . . . . . . . . 124 960 . . HOSE, water 22 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 24 . . . 2T . . . . 072 253 . . STUD, connection single 10-32 x .500 x 1.250mtg (Eff w/KC285389) . . . . . . . 1
. . . . . . . . . . . . . . . . 010 913 . . WASHER, flat brs .218 ID x .460 OD x .031thk (Eff w/KC285389) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 835 . . NUT, brs hex 10-32 (Eff w/KC285389) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 25 . . . C20 . . . 141 233 . . CAPACITOR, (Eff w/KC285389) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 26 . . . HD1 . . . 134 826 . . CIRCUIT CARD, hall boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27 . . . T2 . . . . 126 982 . . TRANSFORMER, kVA 1/3 24-18-200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27 . . . T2 . . . . 130 534 . . TRANSFORMER, kVA 1/3 24-18-230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 28 . . . TE1 . . . 038 126 . . TERMINAL ASSEMBLY, pri 3ph triple voltage (consisting of) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 835 . . . . NUT, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . 038 887 . . . . STUD, primary board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . 010 913 . . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . 038 618 . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . 038 058 . . . . TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 010 915 . . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . 601 836 . . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . 038 888 . . . . STUD, primary board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. 29 . C21-23 . . 091 141 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. 30 . . . . . . . . . . . Fig 11-3 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 31 . . . CR2 . . . 006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 32 . . . . . . . . . . . 126 707 . . FRAME, center base (Prior to KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 32 . . . . . . . . . . . 132 939 . . FRAME, center base (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 126 981 . . TRANSFORMER, pwr main 200/230/460 (Prior to KA737051) (consisting of) 1
. 34 . . . . . . . . . . . 124 878 . . . . COIL, pri/sec 200/230/460 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 124 877 . . . . COIL, pri/sec 200/230/460 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 133 914 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KA737051 thru KA797306)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 132 377 . . . . COIL, pri/sec 200/230/460 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 132 376 . . . . COIL, pri/sec 200/230/460 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 132 879 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KA797307 and on)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 131 559 . . . . COIL, pri/sec 200/230/460 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 131 558 . . . . COIL, pri/sec 200/230/460 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 130 535 . . TRANSFORMER, pwr main 230/460/575 (Prior to KA737051) (consisting of) 1
. 34 . . . . . . . . . . . 130 328 . . . . COIL, pri/sec 230/460/575 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 130 327 . . . . COIL, pri/sec 230/460/575 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Spectrum 1500 TM-205 Page 63
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-1. Main Assembly (Continued)

. 33 . . . T1 . . . . 133 915 . . TRANSFORMER, pwr main 230/460/575 (Eff w/KA737051 thru KA797306)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 132 375 . . . . COIL, pri/sec 230/460/575 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 132 374 . . . . COIL, pri/sec 230/460/575 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 33 . . . T1 . . . . 136 200 . . TRANSFORMER, pwr main 230/460/575 (Eff w/KA797307 and on)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 34 . . . . . . . . . . . 135 984 . . . . COIL, pri/sec 230/460/575 center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 35 . . . . . . . . . . . 135 983 . . . . COIL, pri/sec 230/460/575 LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 020 520 . . THERMOSTAT, NC open 135C w/insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 36 . . . . . . . . . . . 152 516 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 37 . . . Z1 . . . . 126 489 . . STABILIZER, (Prior to KA797307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 37 . . . Z1 . . . . 135 860 . . STABILIZER, (Eff w/KA797307 thru KA834915) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 37 . . . Z1 . . . . 137 762 . . STABILIZER, (Eff w/KA834916 thru KA873928) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 37 . . . Z1 . . . . 139 709 . . STABILIZER, (Eff w/KA873929 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 38 . . . . . . . . . . . Fig 11-2 . . 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 . . . . . . . . . . . 126 698 . . PANEL, side LH (Prior to KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 42 . . . . . . . . . . . 132 940 . . PANEL, side LH (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 43 . . . . . . . . . . . 126 697 . . PANEL, side RH (Prior to KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 43 . . . . . . . . . . . 132 941 . . PANEL, side RH (Eff w/KA751602) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 44 . . . . . . . . . . . . . . . . . . . . . . See Fig 11-4 Item 20
. 45 . . . M1 . . . . 125 058 . . PUMP, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 46 . . . . . . . . . . . 126 700 . . BRACKET, mtg water/air valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 010 021 . . CLAMP, stl cush .562dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 127 854 . . CLAMP, stl cush 1.312dia x .343mtg hole (Eff w/KB160162) . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 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.
♦Prior to KB070482 these parts were not sold as part of this assembly.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

TM-205 Page 64 Spectrum 1500

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

Figure 11-2. Panel, Front w/Components (Fig 11-1 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 . . . . . . . . . . . . 098 691 . . STAND-OFF, No. 6-32 x .500 lg (Prior to KB058480) . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . . 115 443 . . STAND-OFF, No. 6-32 x .750 lg (Eff w/KB058480) . . . . . . . . . . . . . . . . . . . . . . . 2
. . 6 . . . . PC4 . . . 125 057 . . CIRCUIT CARD, display (Prior to KA834915) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . PC4 . . . 135 748 . . CIRCUIT CARD, display (Eff w/KA834916 thru KB058479) . . . . . . . . . . . . . . . 1
. . 6 . . . . PC4 . . . 143 514 . . CIRCUIT CARD, display (Eff w/KB058480 and on) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG8 . . 134 859 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . S4 . . . . 089 085 . . SWITCH, tgl SPST 20A 125VAC (Prior to KA880069) . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . S4 . . . . 088 409 . . SWITCH, tgl DPDT 15A 125VAC (Eff w/KA880069) . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . R1 . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 2 3 4 5 6

8*

10

20
11 12

19

13

14

18

16
15

*Includes Item 9 17 Ref. ST-129 470-C

Figure 11-2. Panel, Front w/Components

Spectrum 1500 TM-205 Page 65
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 38) (Continued)

. . . . . . . PLG5 . . 115 091 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . PLG3,4 . . 131 052 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG6,11 . 131 056 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . PLG7,13 . 115 093 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PLG2 . . 035 815 . . CONNECTOR, rect amp blade 29skt 2 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 003 168 . . CONNECTOR, rect skt 18ga Amp 531589-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . PLG1 . . 048 281 . . RECEPTACLE w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 048 280 . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 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 . . . PC2 . . . 125 658 . . CIRCUIT CARD, timer/control (Prior to JK651452) (consisting of) . . . . . . . . . . 1
. 12 . . . PC2 . . . 129 568 . . CIRCUIT CARD, timer/control (Eff w/JK651452) (consisting of) . . . . . . . . . . . . 1
. . . . . . . . F1 . . . . 012 658 . . . . FUSE, mintr gl slo-blo 2A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . F2-4 . . . 085 875 . . . . FUSE, mintr cer slo-blo 5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . F5 . . . . 012 654 . . . . FUSE, mintr gl 2A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 13 . . . PC1 . . . 136 688 . . CIRCUIT CARD, regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . PC3 . . . 124 448 . . CIRCUIT CARD, relay (Prior to JK581593) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 14 . . . PC3 . . . 128 920 . . CIRCUIT CARD, relay (Eff w/JK581593) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG12 . . 115 092 . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 15 . . . PC5 . . . 127 790 . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 16 . . . . . . . . . . . 126 368 . . STAND-OFF SUPPORT, PC card No. 6 screw w/post . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . . . . . . . . . 126 696 . . PANEL, front (Prior to KA880069) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 17 . . . . . . . . . . . 138 377 . . PANEL, front (Eff w/KA880069) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 18 . . . . . . . . . . . 004 214 . . BUSHING, snap-in nyl 1.625 ID x 2.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CR4 . . . 004 960 . . RELAY, solid state 3-32VDC 10A 240VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 19 . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 20 . . . . . . . . . . . 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 66 Spectrum 1500

 Item Dia. Part
No. Mkgs. No.
. . 1 . . . R2,3 . . . 126 736 ..
. . 2 . . . . F1 . . . *604 259 ..
. . 3 . . . . . . . . . . . . 070 404 ..
. . 4 . . . . . . . . . . . . 032 611 ..
. . 5 . . . . . . . . . . . . 126 695 ..
. . 6 . . . . . . . . . . . . 168 252 ..
. . 7 . . . . . . . . . . . . 125 044 ..
. . 7 . . . . . . . . . . . . 168 253 ..
. . 8 . . . . . . . . . . . . 125 145 ..
. . 8 . . . . . . . . . . . . 153 277 ..
. . 9 . . . . . . . . . . . . 127 115 ..
. 10 . . . . . . . . . . . 125 042 ..
. 10 . . . . . . . . . . . 153 276 . .
. 11 . . . . . . . . . . . 044 426 . .
. 12 . . . . . . . . . . . 030 170 . .
. 13 . . . . . . . . . . . 605 288 . .
. 14 . . . . . . . . . . . 602 956 . .
. 15 . . . . . . . . . . . 602 958 . .
. 16 . . . . . . . . . . . . . . . . . . . . . .
. 17 . . . . . . . . . . . . . . . . . . . . . .
. 18 . . . R4 . . . . 126 841 . .
. 19 . . . FM . . . 116 190 . .
. 20 . . . . . . . . . . . 131 361 . .
. . . . . . . . . . . . . . . . 045 852 . .
. . . . . . . . . . . . . . . . 059 712 . .
1
20
19
18
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Spectrum 1500
Description Quantity
Figure 11-3. Panel, Rear w/Components (Fig 11-1 Item 30)
RESISTOR, WW fxd 375W 20-161 ohm dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FUSE, crtg 3A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HOLDER, fuse crtg 30A 600V 1P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BLADE, fan 14 in 3wg 23deg .375 bore CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NUT, .187-12knrl (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRACKET, mtg air filter/regulator (Prior to KC183768) . . . . . . . . . . . . . . . . . . . . 1
BRACKET, mtg air filter/regulator (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . 1
GAUGE, air 0-160PSI 1/8NPT (Prior to KC183768) . . . . . . . . . . . . . . . . . . . . . . 1
GAUGE, air 0-160PSI 1/4NPT (Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . 1
HOSE, air 28 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REGULATOR/FILTER, 150 PSIG in 0-125 PSIG out 1/4NPT
(Prior to KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REGULATOR/FILTER, 150PSIG in 0-125PSIG out 1/4NPT
(Eff w/KC183768) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR, clamp cable .690/1.070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FITTING, pipe galv plug sqhd .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FITTING, pipe brs adapter bhd 1/4NPT x .937 lg . . . . . . . . . . . . . . . . . . . . . . . . . 1
FITTING, brs barbed M 1/4tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
See Fig 11-1 Item No. 22
See Fig 11-1 Item No. 21
RESISTOR, w/mtg hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MOTOR, 1/12hp 230V 1550RPM 50/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CLIP, component .687dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
CLIP, component .437dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4
3 5
2
6
11 10
13 12
14
15
16
17
ST-129 471-A
Figure 11-3. Panel, Rear w/Components
TM-205 Page 67
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-4. Valve And Pressure Switch Assembly (Fig 11-1 Item 14)

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

. 2 ............................ See Fig 11-1 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 . . AS1, GS1,2,
WS1 . . . . . . 109 930 . . VALVE, 24VAC 2 way 1/4 IPS 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. 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 . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (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 . . . . . . . . . . . . . . . . . . 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 11-3 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 11-4. Valve And Pressure Switch Assembly

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

TM-205 Page 68 Spectrum 1500

 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 11-5. HF Panel (Fig 11-1 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 11-1 Item No. 22
... 8 .......................... See Fig 11-4 Item No.12
. . . 9 . . . . PILOT . . . . 125 053 . . TERMINAL, pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . See Fig 11-4 Item No. 8
. . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . See Fig 11-1 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
. . . . . . . . . . . . . . . . . . . . . 126 277 . . STRIP, mtg HF coil (Prior to JK595850) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . T4 . . . . . 126 274 . . COIL, HF coupling (Prior to JK595850) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . T4 . . . . . 128 833 . . COIL, HF coupling (Eff w/JK595850) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . C2,3,16 . . . 096 761 . . CAPACITOR, mica .002uf 10000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 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 11-5. 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 69
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-6. Rectifier, Main (Fig 11-1 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 . . . . D3,4 . . . . . 126 213 .. DIODE BLOCK, rect 85A 1000V (Prior to KA780148) . . . . . . . . . 2
... 5 . . . . . D4 . . . . . . 126 213 .. DIODE BLOCK, rect 85A 1000V (Eff w/KA780148) . . . . . . . . . . . 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 . . . . C7-12 . . . . 127 082 .. CAPACITOR, (Prior to KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 8 . . . C1,7-12 . . . . 127 082 .. CAPACITOR, (Eff w/KA780148) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 7
... 9 . . . . VR1 . . . . . 105 779 .. VARISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
4

1 2

6 5

SB-129 611-B

Figure 11-6. Rectifier, Main

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

TM-205 Page 70 Spectrum 1500

 Item Part
No. No. Description Quantity

Figure 11-7. Water Tank Assembly (Fig 11-1 Items 6 & 11)

... 1 .......... 125 207 . . CAP, tank water screw-on (Prior to KB070482) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 1 .......... 165 748 . . CAP, tank water screw-on (Eff w/KB070482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 125 463 . . SPONGE (Prior to KB070482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .......... 125 462 . . PACKING, rbr (Prior to KB070482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 .......... 165 749 . . PACKING, rbr (Eff w/KB070482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 11-7. Water Tank Assembly

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

Spectrum 1500 TM-205 Page 71