Thermal Arc 400 S Service Manual
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Thermal Arc 400 S Service Manual

Thermal Arc 400 S Service Manual

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  • Page 2 While the information contained in this Service Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Thermal Arc Models 400 S, GMS & GTS CC/TIG Welder Service Manual Number 0-2509 Published by: Thermal Dynamics Corporation Industrial Park No.

  • Page 3: Notes, Cautions And Warnings

    notes, cautIons and WarnIngs Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: An operation, procedure, or background information which requires note additional emphasis or is helpful in efficient operation of the system. A procedure which, if not properly followed, may cause damage to the cautIon equipment.

  • Page 4: Important Safety Precautions

    WarnIng Important safety precautIons operatIon and maIntenance of pLasma arc eQuIpment can Be dangerous and HaZardous to your HeaLtH. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.
  • Page 5 Important safety precautIons (contInued) Electric Shock can injure or kill. The plasma arc process uses and eLectrIc sHocK produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. •...
  • Page 6 Important safety precautIons (contInued) Plasma Arc Rays can injure your eyes and burn your skin. The plasma pLasma arc rays arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

  • Page 7: Publications

    puBLIcatIons Refer to the following standards or their latest revisions for more information: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W.

  • Page 8: Note, Attention Et Avertissement

    note, attentIon et avertIssement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit : oute opération, procédure ou renseignement général sur lequel notet il importe d’insister davantage ou qui contribue à...

  • Page 9: Precautions De Securite Importantes

    avertIssement precautIons de securIte Importantes L’opÉratIon et La maIntenance du matÉrIeL de soudage À L’arc au Jet de pLasma peuvent prÉsenter des rIsQues et des dangers de santÉ. Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité...
  • Page 10 precautIons de securIte Importantes Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet cHoc eLectrIQue de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail. •...
  • Page 11 precautIons de securIte Importantes rayons d’arc Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et de pLasma brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à...

  • Page 12: Documents De Reference

    documents de reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 13: Declaration Of Conformity

    decLaratIon of conformIty Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EU, as recently changed in Directive 93/63/EU) and to the National legislation for the enforcement of this Directive.

  • Page 14: Statement Of Warranty

    Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc repair facility within thirty (30) days of the repair. Authorized Thermal ® repair facilities are authorized distributors and authorized Thermal Arc Service Centers. No ® ®...

  • Page 15: Table Of Contents

    table of contents Notes, Cautions and Warnings ............ii Important Safety Precautions ............iii Publications ...................vi Note, Attention et Avertissement ............ vii Precautions De Securite Importantes ..........viii Documents De Reference ..............xi Declaration of Conformity ..............xii Statement of Warranty ..............xiii 1.0 GENERAL ..................
  • Page 16 5.2.2 Main Circuit Breaker (MCB) ........... 30 Main Circuit Breaker (MCB) Replacement Procedure ..30 5.2.3 Main Circuit Board (PCB1) Test and Replacement Procedures ............32 Main Circuit Board (PCB1) Test Procedures ......32 5.2.3.1 Gate Drive Enable Signal Test ........33 5.2.3.2 Lift Start Test ..............
  • Page 17 Main Transformer (T1 and T2) Assembly Replacement Procedure ............. 59 Output Inductor Test Procedure ..........60 Output Inductor Assembly Replacement Procedure .... 61 5.2.6 Fan Assembly Replacement Procedure ........ 63 5.2.7 HF Unit Test and Replacement Procedures......64 HF Unit Test Procedure ............. 64 HF Unit Replacement Procedure ..........

  • Page 18: General

    1.0 GENERAL 1.1 Description The Thermal Arc Model 400 S, GMS and GTS Series are single or three- ™ phase DC arc welding power sources with Constant Current (CC) output characteristics. The GMS Model also features Constant Voltage (CV) output characteristics and a digital panel meter. All of the other models are available with an optional digital AMPERAGE/VOLTAGE panel meter (standard in European models).
  • Page 19 The 400GTS unit is equipped with a built-in Sloper, Pulser, gas control solenoid, lift arc starter, and a high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW -P), Gas Tungsten Arc Welding-Sloped (GTAW-S), Gas Tungsten Arc Welding-TIG Spot (GTAW-TIG), and Shielded Metal Arc Welding (SMAW) processes.

  • Page 20: Functional Block Diagrams

    Functional Block Diagrams Figures 4a, 4b and 4c illustrate the functional block diagrams of the 400S, 400GMS and 400GTS power supplies. Input Main Current Coupling Input Output Inrush Current IGBT Inverter Output Circuit Capacitor Diode Diodes Suppresor Module Transformers Power Breaker Transformer Coil...
  • Page 21 Input Main Current Coupling Input Output Inrush Current IGBT Inverter Output Capacitor Circuit Diode Diodes Suppresor Module Transformers Power Breaker Transformer Coil (CT-1) Thermal Sensor Control Transformer (-c Config.) Primary Lift Tig Mode Drive Circuit Current Output Short Sensor Sensing Circuit DC Power Voltage Sensor Thermal...

  • Page 22: Transporting Methods

    1.2 Transporting Methods These units are equipped with a handle for carrying purposes. ELECTRIC SHOCK can kill. WARNING • DO NOT TOUCH live electrical parts. • Disconnect input power conductors from de-energized supply line before moving welding power source. FALLING EQUIPMENT can cause serious personal injury and WARNING equipment damage. • Lift unit with handle on top of case. • Use hand cart or similar device of adequate capacity. • If using a fork lift vehicle, place and secure unit on a proper skid before transporting. 1.3 Electrical Input Connections ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present WARNING after removal of input power.
  • Page 23 • Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal. • Do not connect the ground (GREEN) conductor to an input line terminal. Refer to Figure 5 and: Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes. Connect ends of line 1 (BLACK), line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch. 3. Use Table 1 below as a guide to select line fuses for the disconnect switch.
  • Page 24 have charged to full operating voltage (after approximately 5 seconds). Damage or faulty operation will occur if the INPUT SELECT switch on the rear panel of the power supply is not set to match the input voltage. Verify that the primary power and the INPUT SELECT switch agree. Note the available input power. Damage to the PCA will occur if NOTE 460/575VAC is applied with the INPUT SELECT switch in the 208-230V position. 208VAC 50/60Hz three-phase 230VAC 50/60Hz three-phase 460VAC 50/60Hz three-phase GENERAL...

  • Page 25: Specifications

    1.4 Specifications Parameter 400S 400GMS 400GTS Rated Output Amperes Volts Duty Cycle Output Range (Min. - Max.) TIG/STICK Amperes 5-400 5-400 5-400 Volts 10-32 10-36 10-32 Open Circuit Voltage Maximum OCV 64 V 73 V 64 V Input Data 50/60 Hz Dimensions/Weight Width 8.3 in (210 mm)

  • Page 26: Duty Cycle

    1.5 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases.

  • Page 27: Operator Controls

    2.0 OPERATOR CONTROLS Amperage Control - The Amperage Control selects the desired amperage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage output. The scale surrounding the amperage control represents approximate actual amperage values. Process Selector Switch - The Process Selector Switch allows the operator to select the STICK welding (SMAW) process or LIFT TIG (GTAW) process.
  • Page 28 Amperage/Voltage Control - The amperage/voltage control selects the desired amperage or open circuit voltage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage or voltage output. The scale surrounding the control represents approximate actual amperage (innerscale) or voltage (outerscale) values.
  • Page 29 Amperage Control - The Amperage Control selects Process Selector Switch - The Process Selector the desired amperage within the entire range of the Switch allows the operator to select the STICK welding power source. Rotating this control in a welding (SMAW) process, LIFT TIG (GTAW) or clockwise direction increases the amperage output.
  • Page 30 Primary Power Switch - Placing the Primary Power Switch (circuit breaker) located on the rear panel to the ON position energizes the welding power source. Voltage Selector - Manual slide switch selects the proper input voltage range. If this slide switch is not set to the position that matches the input voltage from the electrical source the Smart Logic will inhibit welding power source turn on and the warning indicator will be illuminated.

  • Page 31: Routine Maintenance

    3.0 ROuTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency determined by the usage and the operating environment. Disconnect primary power at the source before opening the enclosure. WARNING Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

  • Page 32: Basic Troubleshooting

    4.0 BASIC TROuBLEShOOTING You should always attempt to isolate and fix a problem using this section first. This section on basic troubleshooting will help you isolate faults and problems that are easily remedied without requiring that the power supply be opened, or requiring specialized test equipment and procedures. If the problem or fault cannot be corrected by following the recommendations in this section, then proceed to Section 5.0 on Advanced Troubleshooting, page 21. 4.1 Common Welding Operation Faults The following are some of the more common operating faults that occur during welding operations:...
  • Page 33 A. No Weld Output; Unit is Completely Inoperative 1. Line disconnect switch is in OFF position a. Place line disconnect switch in ON position. 2. Line fuse(s) open a. Check and replace line fuse(s). 3. Improper electrical input connections a. See Section 1.3 Electrical Input Requirements, page 5, for proper input connections.
  • Page 34 D. Wandering Arc, Poor Control of Arc Direction 1. Wrong size tungsten electrode, typically larger than recommended a. Use proper size electrode for amperage selected (see Operating Manual 0-2508 S Model; 0-2510 GMS Model; 0-2512 GTS Model) 2. Improperly prepared tungsten electrode a. Prepare tungsten properly 3. Gas flow rate too high a. Reduce flow rate. 4. Drafts blowing shielding gas away from tungsten electrode a. Shield weld zone from drafts and check condition of tungsten electrode.
  • Page 35 3. Poor ground connection to power supply a. Verify ground by trying to strike arc within one inch (2.54 cm) of ground clamp. G. Green AC POWER Indicator OFF; Fan Not Operating 1. Input line disconnect switch in OFF position a. Place input line disconnect switch to ON position.
  • Page 36 a. GMS Model Only – Set OUTPUT CONTACTOR selector to ON position and AMPERAGE/VOLTAGE selector to PANEL position. If amperage and voltage can be adjusted with front panel controls, repair or replace remote control device. b. S and GTS Models Only – Connect a jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure. If amperage and voltage can be adjusted with front panel controls, repair or replace remote control device. 3. Faulty OUTPUT CONTACTOR selector a. Refer to section 5.2.3, page 40, Front Panel Test Point Voltages.
  • Page 37 4. Faulty Current Transformer (CT1) a. Check continuity and signals to current transformer CT. Refer to section 5.1.3.2, page 24, step 12, measuring between pins 3 and 4, and section 5.2.4, page 44. N. No 115VAC or 24VAC at 14-Pin Connector (GMS Model only) 1.

  • Page 38: Advanced Troubleshooting

    5.0 ADVANCED TROuBLEShOOTING If you are here, all of the troubleshooting suggestions in Section 4 - Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective.

  • Page 39: Opening The Enclosure

    5.1.1 Opening the Enclosure Figure 10. Opening the enclosure (shown in GMS model)

  • Page 40: Initial Setup Conditions

    To open the enclosure: 1. Turn off the MAIN CIRCUIT BREAKER on the rear of the power supply. Wait at least two minutes to allow the input capacitors to discharge. Remove the two screws on the top and three screws from bottom of the unit. Remove the two screws from the middle of the case on both sides of the unit.

  • Page 41: Power Supply Voltage Test

    maximum 460 and the minimum 208-230V input power, and correctly configure the internal power circuits for proper operation under both input power conditions. 1. Disconnect primary power at the source. Make sure the MAIN CIRCUIT BREAKER (MCB) is in the OFF position. 2. Set the INPUT SELECTOR switch on the rear panel to the low voltage (208-230VAC) range position. 3. Using an Ohmmeter, at CN13 on the Main Circuit Board between pins 1 (BLUE) and 3 (GREEN) should measure a short, and an open between CN13 pins 2 (GRAY) and 3 (GREEN). 4. Set the INPUT SELECTOR switch to the high voltage (460VAC or 575VAC if so equipped) range. NOTE: Applicable to units with the last letter of the serial number ending in “A”-”D” not “E” or “F”. 5. Using an Ohmmeter, at CN13 on the Main Circuit Board between pins 1 (BLUE) and 3 (GREEN) should measure an open, and a short between CN13 pins 2 (GRAY) and 3 (GREEN). 6. Replace the INPUT SELECTOR switch if these readings are not obtained. 5.1.3.2 Power Supply Voltage Test 1. Connect the power supply to a source of either 208-230VAC or 460VAC.
  • Page 42 CN9 (PCB6) CN8 (PCB6) Pin 1 CN7 (PCB6) CN23 CN22 CN10 CN13 CN21 Figure 11. Power Supply Voltage Connector Locations 8. On the ribbon cable, measure for the following voltages between pins: Pins 2 (-) and 1 (+) +12VDC Pins 2 (-) and 5 (+) -12VDC Pins 2 (-) and 3 (+) +5VDC Pins 2 (-) and 4 (+) +5VDC...

  • Page 43: Output Load Test

    5.1.3.3 Output Load Test This test verifies that the output current (amperage) controls are functioning properly. A clamp-type amperage meter or equivalent meter capable of reading approximately 400A full-scale will be needed for this test. Before performing any portion of the procedure below, make certain the CAuTION unit is placed in the initial setup condition as described at the beginning of this section.

  • Page 44: High Frequency (Hf) Start Circuit Test

    indicate Volts DC. S and GTS Models – Connect a jumper between pins 2 and 3 of the REMOTE 8 connector, or if a remote contactor is connected, close it. GMS Model – Set the front panel OUTPUT CONTACTOR switch to the ON position. 5. Place the power supply MCB on the rear of the unit to the ON position. After five (5) seconds, the voltmeter will indicate approximately 6 volts open circuit. Turn off the power supply MCB. To avoid injury or worse, Power Supply MUST be turned OFF before WARNING performing the next step in this procedure. 7. Connect the POSITIVE (+) and NEGATIVE (-) OUTPUT TERMINALS to a piece of metal, separated by approximately three feet. 8. S and GTS Models – Connect a jumper between pins 2 and 3 of the REMOTE 8 connector, or if a remote contactor is connected, close it.

  • Page 45: Auxiliary Transformer (T3) Test

    REMOTE 8 receptacle for contactor closure. If a remote switch is installed, close it. 5. Place the power supply MCB on the rear of the unit to the ON position. After PRE-FLOW of 150 ms, the HF START circuit will turn ON. If the torch is brought to within 1/2” of the work, lead arc transfer will occur. After arc transfer, the HF START circuit will turn OFF. 6. Remove the jumper, or open the remote control switch if installed. The arc turns OFF. Turn off the power supply MCB. This completes the HF START circuit test.

  • Page 46: Subsystem Test And Replacement Procedures

    3. Turn OFF the MAIN CIRCUIT BREAKER. If either or both of these voltages are not present, reset the front panel circuit breakers and perform the Auxiliary Transformer tests, page 55. 5.2 Subsystem Test and Replacement Procedures 5.2.1 Preparation The following initial conditions must be met prior to starting any of the procedures in this section (5.2).

  • Page 47: Main Circuit Breaker (Mcb)

    5.2.2 Main Circuit Breaker (MCB) Main Circuit Breaker (MCB) Replacement Procedure Disconnect primary power at the source before performing this WARNING procedure. Refer to figure 13. Shield Figure 13. MAin CiRCuiT bREAkER (shown in GMS model) To remove the MAIN CIRCUIT BREAKER: Remove the four screws from the rear panel that secure the MAIN CIRCUIT BREAKER assembly to the rear panel.
  • Page 48 Black White Figure 14. MAin CiRCuiT bREAkER connections To replace the MCB, reverse the above steps, replacing the input and output leads in the same matching positions. Refer to figure 14. ADVANCED TROuBLEShOOTING...

  • Page 49: Main Circuit Board (Pcb1) Test And Replacement Procedures

    5.2.3 Main Circuit Board (PCB1) Test and Replacement Procedures Main Circuit Board (PCB1) Test Procedures CN23 CN22 CN21 CN10 CN13 Figure 15. Main circuit board (shown in GMS model) ADVANCED TROuBLEShOOTING...

  • Page 50: Gate Drive Enable Signal Test

    5.2.3.1 Gate Drive Enable Signal Test The gate drive signals are 21.3kHz square wave signals, with an OFF level of -4VDC for 26µs, and the ON level of +11VDC for 21µs. There is a 2.5µs dead time before and after the ON time of each channel before the other goes through its OFF/ON transition. Refer to figure 16. Apply power to the unit and turn the MAIN CIRCUIT BREAKER (MCB) ON. 2. Using an oscilloscope at the CN8 connector on the Main Circuit Board (PCB1), measure the voltage between Q1 signal pairs: Pin 1 and 2 Pin 4 and 5 3. Using an oscilloscope at the CN9 connector on the Main Circuit Board (PCB1), measure the voltage between Q2 signal pairs: Pin 1 and 2 Pin 4 and 5 4. Using a voltmeter, measure the voltage between signal pins 1 and 2 and pins 4 and 5 at connector CN8. The voltage between each pair of pins should be +5VDC.

  • Page 51: Lift Start Test

    5.2.3.2 Lift Start Test 1. Disconnect primary power at the source. Make sure the MAIN CIRCUIT BREAKER is in the OFF position. 2. Measure the continuity between the front panel NEGATIVE (-) OUTPUT TERMINAL to CN5-3 on the Main Circuit Board (PCB1), and from the front panel POSITIVE (+) OUTPUT TERMINAL to CN5-1 on the Main Circuit Board (PCB1). Both should be zero Ohms. Replace wire if continuity is broken. 3. Disconnect connectors CN8 and CN9 on the Main Circuit Board (PCB1). 4. Reapply power to the unit by turning the MAIN CIRCUIT BREAKER to the ON position. Measure the voltage between CN22-5 and CN22-4 for 0VDC. Install a jumper between the (+) and (-) output terminals on the front panel. The voltage between CN22-5 and CN22-4 should increase to +5VDC. If the voltage does not increase in step 4 above, replace the Main Circuit Board (PCB1).

  • Page 52: Main Circuit Board (Pcb1) Replacement Procedure

    5.2.3.5 Main Circuit Board (PCB1) Replacement Procedure Refer to figures 17 through 22. To remove the Main Circuit Board: Retaining Figure 17. Ribbon cable location and release of retaining bar (shown in GMS model) 1. Locate connectors CN7, CN8 and CN9 at the top edge of the Front Panel Circuit Board. Gently pull up on the retainer bar on each side of each connector to release the ribbon cable in the connectors.
  • Page 53 TB12 Figure 18. Location of Tb12 on main circuit board (shown in GMS model) CN10 CN13 Figure 19. Connectors to be removed from main circuit board (shown in GMS model) Remove all connectors from the left front corner of the Main Circuit Board – CN1 , CN2 , CN4, CN5 , CN7, CN10 and CN13.
  • Page 54 Figure 20. Location of Tb1 through Tb6 on main circuit board (shown in GMS model) 8. Remove screws, associated hardware and wire lugs from TB1 through TB6. Straighten the lugged wires that were removed from TB1 and TB2 so they stand vertically. This will allow the wires to pass through the current sensors when the Main Circuit Board is lifted away from the chassis in a later step.
  • Page 55 Front Panel Figure 21. Main circuit board retaining screws (shown on GMS model) Remove the four (4) mounting screws from the corners of the Main Circuit Board. 10. Lift the Main Circuit Board straight up, passing the lugged wires removed from TB1 and TB2 through the current sensors. 11.
  • Page 56 Hold the Main Circuit Board over the chassis, oriented so the three ribbon cables are toward the front panel of the power supply. As you lower the Main Circuit Board onto the chassis, feed the lugged wires that will attach to TB1 and TB2 through the current sensors.

  • Page 57: Front Panel Circuit Board (Pcb6) Test And Replacement Procedures

    5.2.3 Front Panel Circuit Board (PCB6) Test and Replacement Proce- dures Front Panel Circuit Board (PCB6) Test Procedure To gain access to the test points on the Front Panel Circuit Board, it is necessary to remove the front panel of the power supply unit. Figure 23.
  • Page 58 TP0 TP1 TP2 TP3 TP6 TP4 TP5 TP7 TP9 TP8 Figure 24. Front panel voltage test points (shown in GTS model) Measure the voltage between test points TP8 and TP0 to be 12VDC. Measure the voltage between test points TP4 and TP0 to be 5VDC. Measure the voltage between test points TP5 and TP0 to be 5VDC.

  • Page 59: Process Selector Switch Test

    Process selector switch test Using CN8-4 as common, check the voltages on CN8-9 and CN8-10 for the voltage listed below with the PROCESS SELECTOR switch in each position as follows: Switch Position: Voltage at CN8-9 Voltage at CN8-10 STICK 15VDC 0VDC HF TIG 0VDC...
  • Page 60 Figure 25. Front panel circuit board retaining screws Pull the Front Panel Circuit Board back toward the rear of the power supply and then up to free the controls from their respective holes in the front panel. Fold the Front Panel Circuit Board down to expose the component side of the board.

  • Page 61: Current Transformer (Ct1)

    5.2.4 current transformer (ct1) current transformer test Procedure Disconnect connector CN1 from the Main Circuit Board (PCB1). With an Ohmmeter set the Rx10 scale, measure between the pins on the CN1 plug as follows: Pin 4 (YELLOW) and Pin 1 (BROWN) 120KΩ Pin 4 (YELLOW) and Pin 2 (RED) 20KΩ...

  • Page 62: Power Control Assembly Test And Replacement Procedures

    5.2.5 Power control assembly test and replacement Procedures The Power Control Assembly (PCA) consists of input diode, IGBT Inverters, output diodes, heat sinks, main and auxiliary transformers and output inductor. Perform a careful inspection of all components of the PCA first. Failure may be identified by burned insulation or other physical symptoms.

  • Page 63: Pca Input Diode Bridge (D1) Test Procedure

    Pca input diode bridge (d1) test Procedure Refer to figure 29. cn14 Figure 29. Input diode bridge (D1) test points (shown in GMS model) Select the Ohms scale on the digital meter. Check CN14 on Main Circuit Board between pins 1 and 2. The resistance should read 44Ω.

  • Page 64: Input Diode Bridge (D1) Replacement Procedure

    input diode bridge (d1) replacement Procedure Refer to Figure 30. bus bar & Filter cap terminals input diode bridge (d1) Figure 30. Input Diode Bridge (shown in GMS model) To remove the Input Diode Bridge (D1), do the following: Remove the Main Circuit Board (PCB1) per section 5.2.3.5, page 35. Remove the input power and sensing lugged wires from the input terminals R and two RED, S and WHITE, T and BLACk.

  • Page 65: Pca Igbt Inverter Power Off Test Procedure

    Pca igbt inverter Power oFF test Procedure The IGBT Inverter section contains two IGBT transistor/diode assemblies, Q1 and Q2. These can be tested with the power OFF to verify their proper function. If the results of this test do not indicate a fauly IGBT, perform the following test, “IGBT Inverter Power ON”.

  • Page 66: Power Off Test Procedure

    Power oFF test Procedure Set the diode test scale on the digital meter. For Q1, check the diodes between: TB3 and TB1 TB4 and TB1 For Q2, check the diodes between: TB5 and TB2 TB6 and TB2 Select the Ohms scale on the digital meter. Pin 5 Pin 4 Pin 2...

  • Page 67: Igbt Inverters (Q1 And Q2) Replacement Procedure

    igbt inverters (Q1 and Q2) replacement Procedure Refer to Figure 33. step 3 step 2 Figure 33. IGBT Inverters (shown in GMS model; Q1 on right) To remove either of the IGBT Inverters (Q1 or Q2), do the following. Q1 is located on the right side of the unit, Q2 on the left, as you face the front panel of the power supply.

  • Page 68: Pca Output Diodes (D2 And D3) Test Procedure

    Pca output diodes (d2 and d3) test Procedure Disconnect primary power at the source before performing this Warning procedure. Refer to figure 34. Figure 34. Power control assembly - output diodes (D2, D3) (S model shown; output inductor removed) The output section contains two diodes, D2 and D3. Check each diode; the meter should read 0.140mV ±10%.

  • Page 69: Output Diodes (D2 And D3) Replacement Procedure

    output diodes (d2 and d3) replacement Procedure Refer to Figure 35. Figure 35. Output diodes D2 and D3 To remove the Output Diodes (D2 and D3), do the following: Remove the Output Inductor, per procedure on page 61. Remove the nut and associated hardware from the output bus bar that connects between the POSITIVE (+) OUTPUT TERMINAL and the D2-D3 bus bar.

  • Page 70: Pca Thermal Sensor (Th1) Test Procedure

    Pca thermal sensor (th1) test Procedure Disconnect primary power at the source before performing this Warning procedure. Refer to figure 36. cn10 Figure 36. Power control assembly - thermal sensor (shown in GMS model) Select the Ohms scale on the digital meter. Disconnect the connector at CN10 on the Main Circuit Board (PCB1).

  • Page 71: Thermal Sensor (Th1) Replacement

    thermal sensor (th1) replacement Refer to Figure 37. thermal sensor Figure 37. Location of thermal sensor (TH1) To remove the Thermal Sensor (TH1), do the following: Remove the Main Circuit Board per section 5.2.3.5, page 35. Locate the sensor mounted on the main chassis, between the circuit boards (PCB4 and PCB5) that connect to the IGBT Inverters.

  • Page 72: Auxiliary Transformer (T3) Test Procedure

    auxiliary transformer (t3) test Procedure The Auxiliary transformer can be checked with either a power OFF or power ON test. Do the power OFF test first. Locate the auxiliary transformer in the bottom front of the power supply. auxiliary transformers Primary Windings: 0v terminal 230v terminal...
  • Page 73 Select the Ohms scale on the digital meter. Measure the resistance between following pairs of terminals on the auxiliary transformer. If any shorted or open readings are obtained or, if the readings do not match the specified values, replace the transformer.

  • Page 74: Power On Test

    Power on test Dangerous voltage and power levels are present inside this unit. Be sure Warning the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece or any internal components while the unit is activated.

  • Page 75: Main Transformer Assembly (T1 And T2) Test Procedure

    Figure 41. Auxiliary Transformer primaries (left side of unit) Cut the primary leads as close as possible to the wire crimps. Remove the four (4) screws securing the auxiliary Transformer to the Power Control Assembly heat sink. To replace the auxiliary Transformer (T3), reverse the removal steps above, resoldering the secondary leads and replacing the wire crimps on the primary leads.

  • Page 76: Main Transformer (T1 And T2) Assembly Replacement Procedure

    The secondaries of T1 and T2 cannot be isolated. To test the parallel combination of secondaries: 4. Measure the continuity between the connector CN7 pin 3 and CN5 pin Replace the Main Transformer/Inductor Assembly if no continuity is found in any of the windings or if there is evidence of overheating. Main transformer (t1 and t2) assembly replacement Procedure Refer to figures 42 and 43.

  • Page 77: Output Inductor Test Procedure

    Remove bolt and associated hardware from T1/T2 secondary (lead “E”)/D3 anode junction. Remove hardware securing TB2 and T2A lugged leads to T2 transformer primary leads. Repeat for TB1 and T1A lugged leads on transformer T1 primary leads. rear Front auxiliary transformer output inductor...

  • Page 78: Output Inductor Assembly Replacement Procedure

    output inductor assembly replacement Procedure Refer to figures 44, 45 and 46. bolt/negative output terminal cut cable tie Main transformer/output inductor center tap Figure 44. Output inductor assembly removal – initial steps (shown in GMS model) To remove the Output Inductor Assembly: Remove the bolt and hardware from the inside of the NEGATIVE (-) OUTPUT TERMINAL.
  • Page 79 remove bolt remove bolts Figure 45. Output inductor assembly removal – initial steps (shown in GTS model) Cut the cable tie securing the wire harness insulating sleeve to the Output Inductor frame on the right side of the unit. Cut the cable ties securing the wiring harnesses to the large black lugged lead attached to the NEGATIVE (-) OUTPUT TERMINAL.

  • Page 80: Fan Assembly Replacement Procedure

    Remove the three (3) screws that secure the frame of the Output Inductor Assembly to the main chassis frame. Pull the Output Inductor Assembly out of power supply. To replace the Output Inductor Assembly, reverse the removal steps above. 5.2.6 Fan assembly replacement Procedure Refer to figures 47 and 48.

  • Page 81: Hf Unit Test And Replacement Procedures

    output Filter Fan retaining screws Figure 48. Fan housing, retaining screws and output filter network (shown in GMS model with Power Control Assembly removed for clarity) To replace the fan reverse the removal steps above. Be sure to reattach the output filter network components to the fan housing with thermally conductive silicone.
  • Page 82 ac1/ac2 hF unit output Filter network Figure 49. HF Unit replacement To replace the HF Unit: Apply a liberal amount of thermally-conductive grease to the bottom of the new HF Unit. Hold the new HF Unit against the chassis while you replace the two screws that hold the HF Unit onto the chassis.

  • Page 83: Hf Coupling Coil Test And Replacement Procedures

    5.2.8 hF coupling coil test and replacement Procedures hF coupling coil test Procedure Visually inspect coil for overheating or other damage. Check connections of coil wires on HF Unit terminals CC1 and CC2. Verify continuity through the coil. Replace the HF Coupling Coil if damaged on continuity is broken. hF coupling coil replacement Procedure Refer to figure 50.
  • Page 84 To replace the HF Coupling Coil secondary: gray blue From cc1 to cc2 hF unit start Winding Winding Figure 51. HF coupling coil winding onto Output Inductor Assembly Connect one end of the new Coupling Coil wire to the HF Unit terminal closest to the front of the unit.

  • Page 85: Gas Solenoid Valve Replacement Procedure

    5.2.9 gas solenoid valve replacement Procedure Refer to figure 52. compression Wire lugs gas solenoid valve “c”-ring Figure 52. Gas solenoid valve To remove the gas solenoid valve: Remove the YELLOW/VIOLET wires from the lugs on the solenoid valve. Remove the compression nut securing the BLACk gas line to the solenoid valve.

  • Page 86: Sequence Timing Diagrams

    5.3 sequence timing diagrams 5.3.1 s Models lift tig Mode Figure 53 shows the LIFT TIG timing waveforms of the S model power supplies. Output Contactor Short Release Electrode Output Current Figure 53. S Model LIFT TIG mode timing 5.3.2 gMs Models lift tig Mode Figure 54 shows the LIFT TIG timing waveforms of the GMS model power supplies.

  • Page 87: Gts Models

    5.3.3 gts Models hF tig Mode Figure 55 shows the HF TIG timing waveforms of the GTS models with the SLOPE control ON and OFF. (SLOPE OFF) mode (SLOPE ON) mode Output Contactor Shielding Gas Output Current Figure 55. GTS Model HF TIG mode timing lift tig Mode Figure 56 shows the LIFT TIG timing waveforms of the GTS models with the SLOPE control ON and OFF.

  • Page 88: Spot Mode

    sPot Mode Figure 57 shows the SPOT timing waveforms of the GTS models with the SLOPE control OFF and ON. The GTS should be set to operate in the HF TIG mode. use only HF TIG mode (SLOPE OFF) mode (SLOPE ON) mode Output Contactor Shielding Gas...

  • Page 90: Parts Lists

    Address all inquiries to your authorized Thermal Dynamics distributor. If a Thermal Dynamics product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted. Complete systems Complete systems include: Power Supply with primary power cable, two male plugs, and Operating Manual.
  • Page 91 Parts List – 400s DesCriPtion ......iteM ....460 ....e 380 ....575 .... Ce 380 ACRYLIC BOARD ......- ......-....10-5424 ....- ....10-5424 BUS BAR A ........- ....10-5412..10-5412 ..10-5412 ..10-5412 BUS BAR B ........- ....10-5413..10-5413 ..10-5413 ..10-5413 BUS BAR C ........- ....
  • Page 92 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 HEAT SINk ........- ....10-5458..10-5458 ..10-5458 ..10-5458 HOLDER ..........- ....10-5249..10-5249 ..10-5249 ..10-5249 INvERTER; IgBT ......Q1,Q2 ....-..... - ....10-5085 ....- INvERTER;...
  • Page 93 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 REAR FRAME ........- ....10-5466..10-5466 ..10-5466 ..10-5466 REAR PANEL 230/460 FRAME ......- ....10-5394....- .....- ....- 380-415-CE FRAME ......- ......-..... - .....- ....10-5397 460/575 FRAME ......- ......

  • Page 94: 400Gms

    Parts List – 400GMs DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 ACRYLIC BOARD ......- ....10-5424..10-5424 ..10-5424 ..10-5424 BUS BAR A ........- ....10-5412..10-5412 ..10-5412 ..10-5412 BUS BAR B ........- ....10-5413..10-5413 ..10-5413 ..10-5413 BUS BAR C ........- ....
  • Page 95 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 HOLDER ..........- ....10-5249..10-5249 ..10-5249 ..10-5249 INDUCTOR ........FCH ....10-5477..10-5477 ..10-5477 ..10-5477 INvERTER; IgBT ......Q1,Q2 ....-..... - ....10-5085 ....- INvERTER; IgBT ......Q1,Q2 ....-..... - ....10-5086 ....- INvERTER;...
  • Page 96 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 REAR FRAME ........- ....10-5466..10-5466 ..10-5466 ..10-5466 REAR PANEL 230/460 FRAME ......- ....10-5402....- .....- ....- 380-415-CE FRAME .....- ......-..... - .....- ....10-5405 460/575 FRAME ......- ......

  • Page 97: 400Gts

    Parts List – 400Gts DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 ACRYLIC BOARD ......- ......-....10-5424 ....- ....10-5424 BUS BAR A ........- ....10-5412..10-5412 ..10-5412 ..10-5412 BUS BAR B ........- ....10-5413..10-5413 ..10-5413 ..10-5413 BUS BAR C ........- ....
  • Page 98 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 gAS INLET FITTINg ......- ....10-5416..10-5201 ..10-5416 ..10-5201 gAS OUTLET FITTINg .....- ....10-5410....- ....10-5410 ..10-5449 gAS OUTLET FITTINg .....- ......-....10-5423 ....- ....10-5423 gAS vALvE ........SOL1 ....
  • Page 99 DesCriPtion ......iteM ....460 ....e 380 ....575 ..... Ce 380 POTENTIOMETER AMP\HOT\PULSE ......- ....10-5056..10-5056 ..10-5056 ..10-5056 POTENTIOMETER ARC TRIM ..- ....10-5221..10-5221 ..10-5221 ..10-5221 PROTECTION BAR ......- ....10-5443..10-5443 ..10-5443 ..10-5443 Q BUS BAR D ........- ....
  • Page 100 Warning Label Side Label Screws 4 Places/ 2 Per Side Case, Half Screws 5 Places Figure 58. Enclosure Parts List...
  • Page 101 Front Upper Panel 8-Pin Receptacle Front Panel gas Outlet Fitting Output Terminals Figure 59. Front Panel Parts List...
  • Page 102 Main Circuit Breaker Easy Link (Input Select) Switch Input Cable gas Inlet Fitting Figure 60. Rear Panel Parts List...
  • Page 103 Main Circuit Front Panel Main Circuit Board Circuit Board Breaker Auxiliary Main Current Transformer Transformer Transformer (CT1) Figure 61. Left Side Main Circuit Front Panel Main Breaker Circuit Board Circuit Board Heat Sink Figure 62. Right Side Parts List...
  • Page 104 11-Pin Flat Cable 15-Pin Flat Cable Main Circuit Board 12-Pin Flat Cable 2.5A Circuit 10A Circuit Main Circuit Breaker Breaker Breaker Figure 63. Top View Auxiliary Transformer Current Output Main Transformer (CT1) Inductor Transformer Figure 64. Bottom View Parts List...
  • Page 105 knob, Large 3-Position Switch Potentiometer Digital Panel Meter Front Panel Circuit Board Figure 65. Front Circuit Board Easy Link (Input Select) Ferrite Ring Switch Figure 66. Internal Parts List...
  • Page 106 IgBT Inverter Q1 Thermal Sensor (TH1) IgBT Inverter Q2 Figure 67. Internal Parts List...
  • Page 107 Output Inductor Main Transformer (T2) Figure 68. Internal-S Parts List...
  • Page 108 Main Output Transformers Inductor Figure 69. Internal-S Output Main Inductor Transformer (T2) Current Main Transformer Transformer (T1) Figure 70. Internal GMS Parts List...
  • Page 109 Output Inductor Auxiliary Transformer Figure 71. Internal GMS 2.5A Circuit 10A Circit Breaker Breaker Auxiliary Transformer Figure 72. Internal-GMS Parts List...
  • Page 110 Output Inductor Coupling Coil HF Unit gas Outlet Fitting Figure 73. Internal-GTS Compression Wire Lugs gas Solenoid valve “C”-ring Figure 74. Internal-GTS Parts List...

  • Page 112: Appendix A - Interconnection Diagrams

    aPPenDix a – interConneCtion DiaGraMs The following pages contain the interconnection diagrams for all 400S, 400GMS and 400GTS models in current production, to aid in the identification of replacement parts. aPPenDix a interConneCtion DiaGraMs...

  • Page 113: 230/460V Interconnection Diagram

    400s - 230/460V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground PCB1-2 CN20 CN20 Line 3 (Black) Line 2 (White)
  • Page 114 Output Filter Network – 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect Input 1/3 Phase Detect Input Changeover Control...

  • Page 115: 400S - 380V Interconnection Diagram

    400s - 380V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 116 Output Filter Network – 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect Input 1/3 Phase Detect Input Changeover Control...
  • Page 117 400s 460/575V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground PCB1-2 CN20 CN20 Line 3 (Black) Line 2 (White) Line 1 (Red)
  • Page 118 Output Filter Network – 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect Input 1/3 Phase Detect Input Changeover Control...

  • Page 119: 400Gms 230/460V Interconnection Diagram

    400GMs 230/460V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground PCB1-2 CN20 CN20 Line 3 (Black) Line 2 (White) Line 1 (Red)
  • Page 120 Output Filter Network – 14-Pin Receptacle (Front view) Receptacles support industry-standard pinouts; signal names used are for clarity in interconnection diagram only. Refer to Appendix C for receptacle signal connections. 17-Pin Receptacle (Front view) Tripping Relay Control Input Changeover Switch Contactor 24 (Brown) Input Changeover Switch Contactor 115 (Red)

  • Page 121: 400Gms 380V Interconnection Diagram

    400GMs 380V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 122 Output Filter Network – 14-Pin Receptacle (Front view) Receptacles support industry-standard pinouts; signal names used are for clarity in interconnection diagram only. Refer to Appendix C for receptacle signal connections. 17-Pin Receptacle (Front view) Tripping Relay Control Input Changeover Switch Contactor 24 (Brown) Input Changeover Switch Contactor 115 (Red)

  • Page 123: 400Gms 460/575V Interconnection Diagram

    400GMs 460/575V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 124 Output Filter Network – 14-Pin Receptacle (Front view) Receptacles support industry-standard pinouts; signal names used are for clarity in interconnection diagram only. Refer to Appendix C for receptacle signal connections. 17-Pin Receptacle (Front view) Tripping Relay Control Input Changeover Switch Contactor 24 (Brown) Input Changeover Switch Contactor 115 (Red)

  • Page 125: 400Gts 230/460V Interconnection Diagram

    400Gts 230/460V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground PCB1-2 CN20 CN20 Line 3 (Black) Line 2 (White) Line 1 (Red)
  • Page 126 Output Filter Network – (Blue) (gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect...

  • Page 127: 400Gts 380V Interconnection Diagram

    400Gts 380V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 128 Output Filter Network – (Blue) (gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect...

  • Page 129: 400Gts 460/575V Interconnection Diagram

    400Gts 460/575V interconnection Diagram PCB4 PCB5 C21E1 C21E1 IgBT IgBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 130 Output Filter Network – (Blue) (gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front view) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor gate Drive Pre-charge Control PCB Common - 0v Undervoltage Overvoltage Reset Signal +12vDC PCB Common - 0v Input voltage Detect...

  • Page 132: Appendix B - Diode Testing Basics

    aPPenDix B — DioDe testinG BasiCs Testing of diode modules requires a digital Volt/Ohmmeter that has a diode test scale. Locate the diode module to be tested. Remove cables from mounting studs on diodes to isolate them within the module. Set the digital volt/ohm meter to the diode test scale.
  • Page 133 Reverse Bias Diode Not Conducting Cathode Anode Figure 2. Reverse bias diode test aPPenDix B DioDe testinG BasiCs...

  • Page 134: Appendix C - Remote Receptacle Pinout

    aPPenDix C – reMote reCePtaCLe Pinout 24 v 10 v -24 v 1 v/100 Amps 1 v/10 v PCB Common 17 Pin Receptacle Chassis PCB Common Contactor Input Command Output Reference 400GMs Reference Signal 5kOhms PCB Common ground ground 14 Pin Receptacle Contactor 24 vAC, 10 Amp...

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