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Summary of Contents for Thermadyne Thermal Arc 400GMS CC
- Page 1 INVERTER WELDER MODEL 400GMS CC/CV • STICK • TIG - LIFT START • MIG - SHORT ARC - GLOBULAR - SPRAY OPERATING MANUAL July 1, 1997 Manual No. 0-2510...
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Page 2: Table Of Contents
TABLE OF CONTENTS 1.0 GENERAL INFORMATION ............2 1.01 Notes, Cautions and Warnings ..........2 1.02 Important Safety Precautions ............ 3 1.03 Publications ................. 6 1.04 Note, Attention et Avertissement ..........7 1.05 Precautions De Securite Importantes........8 1.06 Documents De Reference ............11 1.07 Declaration of Conformity ............ - Page 3 WARNING Read and understand this entire Operating Manual and your employer’s safety practices before installing, operating, or servicing the equipment. WARNING While the information contained in this Operating Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Thermal Arc Models 400GMS CC/CV Welder Operating Manual Number 0-2510 Published by:...
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Page 4: General Information
1.0 GENERAL INFORMATION 1.01 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 5: Important Safety Precautions
WARNING 1.02 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 6 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. •...
- Page 7 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.
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Page 8: Publications
1.03 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 9: Note, Attention Et Avertissement
1.04 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 : NOTET oute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à... -
Page 10: Precautions De Securite Importantes
AVERTISSEMENT 1.05 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 11 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 12 PRECAUTIONS DE SECURITE IMPORTANTES RAYONS D’ARC DE PLASMA Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et 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...
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Page 13: Documents De Reference
1.06 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 14: Declaration Of Conformity
Thermal Dynamics has been manufacturing products that perform in a safe manner for more than 30 years and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: David Ashworth Vice President & Managing Director Thermadyne Europe Chorley England. MANUAL 0-2510 GENERAL... -
Page 15: Statement Of Warranty
1.08 STATEMENT OF WARRANTY LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommen dations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident,... - Page 16 MANUAL 0-2510...
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Page 17: General
2.0 INTRODUCTION AND DESCRIPTION 2.01 Description ™ The Thermal Arc Model 400GMS is a single or three-phase DC arc welding power source 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 a standard digital AMPERAGE/VOLTAGE panel meter. -
Page 18: Functional Block Diagrams
2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagrams of the 400GMS power supplies. 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... -
Page 19: Transporting Methods
2.03 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING ELECTRIC SHOCK can kill. • 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 equipment WARNING damage. - Page 20 Electrical Code). Ground Conductor Ground Terminal Line Fuse PRIMARY POWER INPUT SELECT SWITCH 208-230V 460V PRIMARY CABLE IEC974 THERMADYNE 5A/10V - 400A/36V Thermal Dynamics 100% WEST LEBANON, NEW HAMPSHIRE USA 03784 230/ MADE IN JAPAN 400/ 300/ 280A 210A 160A 400S...
- Page 21 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT BREAKER is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).
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Page 22: Specifications
2.05 Specifications Parameter 400GMS Rated Output Amperes Volts Duty Cycle Output Range (Min. - Max.) TIG/STICK Amperes 5-400 Volts 10-36 Open Circuit Voltage Maximum OCV 73 V Input Data 50/60 Hz Dimensions/Weight Width 8.3 in (210 mm) Height 16.9 in (430 mm) Length 16.5 in (420 mm) Weight... -
Page 23: Duty Cycle
2.06 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 24: Operator Controls
3.0 OPERATOR CONTROLS 3.01 Front and Rear operator controls 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 25 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.
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Page 26: Setup For Operation
3.02 Setup for Operation The ARC/INDUCTANCE CONTROL may be adjusted while ARC/INDUCTANCE Control welding. Operation of this control depends on the welding mode selected. Arc Control The ARC/INDUCTANCE CONTROL provides a variable for STICK mode selection of short circuit amperage to suit individual welding situations when operating in the STICK welding (SMAW) mode. - Page 27 AMPERAGE/VOLTAGE This switch determines whether the amperage/voltage is adjusted by the front panel AMPERAGE/VOLTAGE control or by a remote control device. If remote control function is not desired, place this switch in PANEL position. For remote amperage/voltage control, place the AMPERAGE/VOLTAGE switch in REMOTE 14 position if remote control connections are made to PANEL the REMOTE 14 receptacle, or to the REMOTE 17 position if remote control...
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Page 28: Shielded Metal Arc Welding (Smaw)
3.02 Setup for Operation Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceding with operation. Install and connect unit according to the installation instructions in section 2.04, page 17 of this manual. Wear dry insulating gloves and clothing. -
Page 29: Gas Tungsten Arc Welding (Gtaw) Lift Start
3.02 Setup for Operation Gas Tungsten Arc Welding (GTAW) Lift Start WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual. 2. - Page 30 In this mode, the unit provides weld output for the Gas Tungsten LIFT START Arc Welding (GTAW) process. When the PROCESS SELECTOR (GTAW without switch is in this position, the HOT START ARC CONTROL will High Frequency) not function. The unit will provide a low open circuit voltage and approximately 15 amps to the tungsten electrode when touched to the work.
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Page 31: Gas Metal Arc Welding (Gmaw)
3.02 Setup for Operation Gas Metal Arc Welding (GMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual. 2. - Page 32 WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill. Shut off gas supply when not in use. 14. Stop welding. Shutting Down 15. Move the PRIMARY POWER switch [18] to the OFF position. 16. Turn off the shielding gas and water supplies if applicable. SETUP FOR OPERATION MANUAL 0-2510...
- Page 33 3.02 Setup for Operation Table 2. Electrode Selection Table Electrode/Diameter Amperage Range DC-Argon Electrode DC-Argon Electrode Negative/Straight Polarity Positive/Reverse Polarity Pure Tungsten (Green Band) 0.010 in. (0.25mm) 1-15 — 0.020 in. (0.51mm) 5-20 — 0.040 in. (1.02mm) 15-80 — 1/16 in. (1.59mm) 70-150 10-20 3/32 in.
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Page 34: Basic Troubleshooting
4.0 BASIC TROUBLESHOOTING Troubleshooting and repairing this unit is a process which should be General undertaken only by those familiar with high voltage, high power electronic equipment. WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had train– ing in power electronics measurement and troubleshooting techniques. - Page 35 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 2.04 Electrical Input Requirements, page 17, for proper input connections.
- Page 36 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 Table 2, page 31). 2. Improperly prepared tungsten electrode a. Prepare tungsten properly 3. Gas flow rate too high a.
- Page 37 3. Line voltage is too high a. Verify that input voltage matches setting on rear panel INPUT SELECTOR switch. I. Low or Maximum Weld Output With No Control 1. Faulty remote control device a. Set OUTPUT CONTACTOR selector to ON position and AMPERAGE/VOLTAGE selector to PANEL position.
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Page 38: Remote 14-Pin Connections
4.03 REMOTE 14-Pin Connections The REMOTE 14-Pin receptacle is used to connect any of the following equipment to the welding power source circuitry: • Remote Contactor Control • Remote Amperage Control • Wire Feeder (one which provides contactor control to welding power source) •... -
Page 39: Remote 17-Pin Connections
4.03 REMOTE 17-Pin Connections The REMOTE 17-Pin receptacle provides a junction point for connecting various remote controls to the welding power source. The functions available from this receptacle are: • Remote MIG synergic and Manual MIG Pulsers • Remote Control •... -
Page 40: Appendix A - Accesories
APPENDIX A – ACCESORIES APPENDIX A MANUAL 0-2510 ACCESSORIES... -
Page 41: Appendix B - Interconnection Diagrams
APPENDIX B – INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 400GMS in current production, to aid in the identification of replacement parts. APPENDIX B MANUAL 0-2510 INTERCONNECTION DIAGRAMS... - Page 42 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 43 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 44 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 45 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 46 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 47 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)
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