Thermal Arc 400 GMS - User Manual

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Notes, Cautions and Warnings3
Important Safety Precautions4
Publications7
Note, Attention Et Avertissement8
Precautions de Securite Importantes9
Documents de Reference12
Declaration of Conformity13
Statement of Warranty14
Table of Contents15
General18
Description18
- Functional Block Diagrams20
Transporting Methods22
Electrical Input Connections22
Specifications25
Duty Cycle26
Operator Controls27
Routine Maintenance31
Basic Troubleshooting32
Common Welding Operation Faults32
Specific Problems32
Advanced Troubleshooting38
System-Level Fault Isolation38
- Opening the Enclosure39
- Initial Setup Conditions40
- Fault Isolation Tests40
Subsystem Test and Replacement Procedures46
- Preparation46
Main Circuit Breaker (MCB)47
- Main Circuit Breaker (MCB) Replacement Procedure47
Main Circuit Board (PCB1) Test and Replacement Procedures49
- Main Circuit Board (PCB1) Test Procedures49
- Gate Drive Enable Signal Test50
- Lift Start Test51
- Gas Control Test51
- High Frequency Test51
- Main Circuit Board (PCB1) Replacement Procedure52
Front Panel Circuit Board (PCB6) Test and Replacement Procedures57
- Front Panel Circuit Board (PCB6) Test Procedure57
- Test Point Voltages57
- PROCESS SELECTOR Switch Test59
- Gas Control Test59
- Front Panel Circuit Board (PCB6) Replacement Procedure59
Current Transformer (CT1)61
- Current Transformer Test Procedure61
- Current Transformer Replacement Procedure61
Power Control Assembly Test and Replacement Procedures62
- Power Control Assembly (PCA) Test Procedures62
- PCA Input Diode Bridge (D1) Test Procedure63
- Input Diode Bridge (D1) Replacement Procedure64
- PCA IGBT Inverter Power off Test Procedure65
- Power off Test Procedure66
- IGBT Inverters (Q1 and Q2) Replacement Procedure67
- PCA Output Diodes (D2 and D3) Test Procedure68
- Output Diodes (D2 and D3) Replacement Procedure69
- PCA Thermal Sensor (TH1) Test Procedure70
- Thermal Sensor (TH1) Replacement71
- Auxiliary Transformer (T3) Test Procedure72
- Power off Test72
- Power on Test74
- Auxiliary Transformer (T3) Replacement74
- Main Transformer Assembly (T1 and T2) Test Procedure75
- Fan Assembly Replacement Procedure80
- HF Unit Test and Replacement Procedures81
  - HF Unit Test Procedure81
  - HF Unit Replacement Procedure81
- HF Coupling Coil Test and Replacement Procedures83
  - HF Coupling Coil Test Procedure83
  - HF Coupling Coil Replacement Procedure83
- Gas Solenoid Valve Replacement Procedure85
Sequence Timing Diagrams86
- S Models86
  - Lift TIG Mode86
- GMS Models86
- GTS Models87
Parts Lists90
- Complete Systems90
  - 400Gms94
  - 400Gts97
Appendix A - Interconnection Diagrams112
- 230/460V Interconnection Diagram113
- 400S - 380V Interconnection Diagram115
- 400Gms 230/460V Interconnection Diagram119
- 400Gms 380V Interconnection Diagram121
- 400Gms 460/575V Interconnection Diagram123
- 400Gts 230/460V Interconnection Diagram125
- 400Gts 380V Interconnection Diagram127
- 400Gts 460/575V Interconnection Diagram129
Appendix B - Diode Testing Basics132
Appendix C - Remote Receptacle Pinout134

Questions and Answers

C
Christopher TaylorAug 6, 2025
What to do if speed is too slow or too fast on Thermal Arc Welding System?
- W
  William DennisAug 6, 2025
  Adjust the speed settings appropriately on your Thermal Arc Welding System.
C
Connie SmithAug 20, 2025
What to do if remote is not connected to Thermal Arc Welding System?
- D
  Dominic BushAug 20, 2025
  If the remote is not connected to your Thermal Arc Welding System, connect it.