THERMACH INC.

THERMAL SPRAY AND MACHINING

AT-400
Electric Arc Spray System

LIMITED WARRANTY
This limited warranty supersedes all previous
Thermach, Inc. warranties and is exclusive with no
other guarantees or warranties expressed or
implied.
LIMITED WARRANTY Subject to the terms and
conditions below, Thermach, Inc., Hortonville,
Wisconsin, warrants to its original retail purchaser
that new Thermach, Inc. equipment sold is free of
defects in material and workmanship at the time it is
shipped by Thermach, Inc.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Thermach,
Inc. will repair or replace any warranted parts or
components that fail due to such defects in material
or workmanship. Thermach, Inc. must be notified in
writing within thirty (30) days of such a defect or
failure, at which time Thermach, Inc. will provide
instructions on the warranty claim procedures to be
followed.
Thermach, Inc. shall honor warranty claims on
warranted equipment listed below in the event of
such a failure within the warranty time periods. All
warranty time periods start on the date that the
equipment was delivered to the original retail
purchaser, and are as follows:
1. Original main power rectifiers in power source
(diodes, SCRs, bridge rectifiers) -- 5 years
parts, 3 years labor

3. Consumable components, such as anodes,

cathodes, nozzles, contactors and relays.
4. Equipment that has been modified by any
party other than Thermach, Inc., or equipment
that has been improperly installed, improperly
operated or misused based upon industry
standards, or equipment which has not had
reasonable and necessary maintenance, or
equipment which has been used for operation
outside the specifications of the equipment.
THERMACH, INC. PRODUCTS ARE INTENDED
FOR PURCHASE AND USE BY COMMERICAL/
INDUSTRIAL USERS AND PERSONS TRAINED
AND EXPERIENCED IN THE USE AND
MAINTENANCE OF THERMAL SPRAY
EQUIPMENT.
In the event of a warranty claim covered by this
warranty, the exclusive remedies shall be, at
Thermach, Inc.s option: (1) repair; or (2)
replacement; or, where authorized in writing by
Thermach, Inc. in appropriate cases, (3) the
reasonable cost of repair or replacement at an
authorized Thermach, Inc. service station; or (4)
payment of or credit for the purchase price (less
reasonable depreciation based upon actual use)
upon return of the goods at customers risk and
expense. Thermach, Inc.s option of repair or
replacement will be F.O.B., factory at Hortonville,
Wisconsin, or F.O.B. at a Thermach, Inc. authorized
service facility as determined by Thermach, Inc.
Therefore, no compensation or reimbursement for
transportation costs of any kind will be allowed.

2. All Power Sources, Parts and Labor -- 3 years

3. All Control Consoles, Spray Guns, Wire
Feeders, Powder Feeders, and Cooling
Systems -- 1 year
4. Replacement/Repair parts, exclusive of labor 60 days

TO THE EXTENT PERMITTED BY LAW, THE

REMEDIES PROVIDED HEREIN ARE THE SOLE
AND EXLUSIVE REMEDIES. IN NO EVENT
SHALL THERMACH, INC. BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS
OF PROFIT), WHETHER BASED ON CONTRACT,
TORT OR ANY OTHER LEGAL THEORY.

5. Batteries -- 6 months
6. All cables and hoses -- 30 days
Thermach, Inc.s Limited Warranty shall not apply to:
1. Any components that may be damaged,
directly or indirectly, from the use of nonThermach gun components and
consumables; e.g. anodes, cathodes,
nozzles, etc.
2. Items furnished by Thermach, Inc., but
manufactured by others, such as engines or
trade accessories. These items are covered
by the manufacturers warranty, if any.

ANY EXPRESS WARRANTY NOT PROVIDED

HERE-IN AND ANY IMPLIED WARRANTY,
GUARANTY OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT TORT OR ANY OTHER
LEGAL THEORY WHICH, BUT PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF
LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR
PARICUALR PURPOSE, WITH RESPECT TO ANY
AND ALL EQUIPMENT FURNISHED BY
THERMACH, INC. IS EXCLUDED AND
DISCLAIMED BY THERMACH, INC.

DECLARATION OF CONFORMITY
Applied Directive(s):

Low Voltage (93/68) and (72/23)

EMC (89/336) and (92/31)

Standard(s):

EN 600204-1
EN 50081-2
EN 50082-2

Equipment:

Twin Wire Arc Spray System

Year of Manufacture:

2014

Brand Name:

Thermach, Inc.

Model:

AT-400

Manufacturer:

Thermach, Inc.
W8921 State Highway 96
Door E
Hortonville, WI 54944
(920) 779-4299
(920) 779-4452

As manufacturer, we declare under our sole responsibility

that the equipment follows the provisions of the Directives
stated above.

Signature:
Full Name:
Position:

David Lewisen
Engineering Manager

Table of Contents
1. SAFETY........................................................................................................................... 1
1.1 SAFETY ISSUES ADDRESSED ............................................................................ 1
1.1.1 General Safety............................................................................................ 2
1.2 SAFETY STANDARDS ........................................................................................... 2
1.3 FIRE PREVENTION AND PROTECTION .............................................................. 4
1.3.1 Flammable Materials .................................................................................. 4
1.4 OPERATING SAFETY ............................................................................................ 4
1.4.1 Using Compressed Air ............................................................................... 4
1.4.2 Proper Connections .................................................................................... 5
1.5 BLASTING EQUIPMENT ........................................................................................ 5
1.6 PART MANIPULATION .......................................................................................... 6
1.7 THERMAL SPRAY EQUIPMENT ........................................................................... 6
1.8 PERSONAL PROTECTION .................................................................................... 6
1.8.1 Protective Clothing ..................................................................................... 7
1.8.2 Eye Protection ............................................................................................ 7
1.8.3 Respiratory Protection ................................................................................ 8
1.8.4 Noise Protection ......................................................................................... 9
1.8.5 Confined Spaces ......................................................................................11
1.9 VENTILATION.......................................................................................................12
1.10 TOXIC MATERIALS ............................................................................................13
1.10.1 Threshold Limit Values ...........................................................................13
1.10.2 Beryllium .................................................................................................14
1.10.3 Cadmium ................................................................................................14
1.10.4 Lead, Lead Alloys, Cobalt, Chromium, and Tellurium ............................14
1.10.5 Tin and Zinc ............................................................................................14
1.10.6 Solvents ..................................................................................................14
1.10.7 Ozone .....................................................................................................15
1.10.8 Safety Standards ....................................................................................15
Notes .............................................................................................................16
2. GENERAL INFORMATION...........................................................................................17
2.1 SPECIFICATIONS ................................................................................................17
2.2 DUTY CYCLE INFORMATION .............................................................................18
2.3 POWER SUPPLY ELECTRICAL SERVICE INSTALLATION ..............................19
2.3.1 AT-400 Power Supply Jumper Link Placement .......................................19
3. INSTALLATION ............................................................................................................21
3.1 AT-400 Hose and Cable Installation .....................................................................23
3.2 AT-400 Arc Power Cables ....................................................................................26
Notes .............................................................................................................27

4. CONTROLS...................................................................................................................27
4.1 ELECTRICAL CONTROLS ...................................................................................27
4.1.1 Power Supply ...........................................................................................27
4.1.2 Wire Feeder, Front Panel .........................................................................27
4.1.3 Side Panel Controls ..................................................................................29
4.1.4 AT-400 Air Controls ..................................................................................30
4.2 WIRE FEEDER to POWER SUPPLY FEEDBACK
AND CONTROL RECEPTACLE .......................................................................31
4.2.1 RC1 Wire Feeder .....................................................................................31
4.3 WIRE FEEDER REMOTE CONTROL RECEPTACLE .........................................32
4.3.1 RC2 Wire Feeder .....................................................................................32
4.4 WIRE FEEDER TRIGGER RECEPTACLE ..........................................................33
4.4.1 RC3 Wire Feeder .....................................................................................33
4.5 GUN HEAD ...........................................................................................................34
4.5.1 AT-400 Gun Head Components ...............................................................34
4.5.1 AT-400 Gun Head Components Parts List...............................................35
4.6 GUN HEAD PREPARATION ................................................................................36
4.6.1 Wire Installation ........................................................................................36
4.6.2 AT-400 Wire Payoff Pack .........................................................................37
4.7 OPERATION .........................................................................................................38
4.7.1 Power Up and Operation ..........................................................................38
4.8 MAINTENANCE ....................................................................................................38
4.8.1 Importance of Maintenance ......................................................................38
4.9 SCHEDULED MAINTENANCE .............................................................................39
4.9.1 Power Supply ...........................................................................................39
4.9.2 Wire Feeder ..............................................................................................40
4.9.3 Gun Head .................................................................................................41
Notes .............................................................................................................42
5. TROUBLESHOOTING ..................................................................................................43
5.1 SHORT CIRCUIT SHUTDOWN............................................................................43
5.1.1 Replacing Fuse ........................................................................................43
5.2 TROUBLESHOOTING CHART ............................................................................44
6. PARTS LIST ..................................................................................................................47
6.1 AT-400 POWER SUPPLY EXPLODED VIEW AND B.O.M................................. 47
6.1.1 AT-400 Front Panel ..................................................................................49
6.1.2 AT-400 Rectifier .......................................................................................51
6.1.3 AT-400 Rear Panel ...................................................................................52
6.2 AT-400 EXPLODED VIEWS .................................................................................53
6.3 AT-400 WIRE FEEDER B.O.M. .........................................................................59
6.4 AT-400 SCHEMATICS and CABLES ...................................................................63

1. SAFETY
1.1 SAFETY ISSUES
ADDRESSED
Any person involved in installing, operating or maintaining this arc
spray system must read and understand this entire manual especially the safety material - before undertaking any operations on
the arc spray equipment. Do not allow untrained or inexperienced
persons to install, operate, or maintain this unit. Contact a Thermach
Factory Representative if you do not fully understand these
instructions.
This chapter identifies some potential hazards and safety issues
associated with thermal spray operations and the associated preparation
and finishing processes. Subjects in this chapter include:
Applicable Safety Standards
Fire Prevention and Protection
Flammable Materials
Operational Safety
Using Compressed Air
Proper Connections
Abrasive Blast Equipment
Part Manipulation
Arc Spray Equipment
Personal Protection
Protective Clothing
Eye Protection
Respiratory Protection
Noise Protection
Confined Spaces
Ventilation
Toxic Materials
Beryllium
Cadmium
Lead, Lead Alloys, Cobalt, Chromium, and Tellurium
Tin and Zinc
Solvents
Threshold Limit Values
When used in this chapter, the words approved or approval indicate
that the process, action or part is acceptable to the jurisdictional authority.

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1.1.1.

GENERAL
SAFETY

Everyone involved with thermal spray operations should be familiar with

safe practices and the safety regulations contained in established
standards. Some pertinent standards are listed in this chapter.
Information presented herein and labeling on the equipment concerns
the design, installation, operation, maintenance, and troubleshooting of
arc spray equipment. All persons involved with the equipment should
read, understand, and follow the instructions to ensure safe and
effective use of this equipment.
When installing, operating, maintaining, or troubleshooting thermal
spray equipment, always ensure personal safety and the safety of
others.
This equipment must be installed, operated, and maintained by
qualified persons following the directions in this manual and all
applicable codes.
Research, understand and comply with all local, state and federal (OSHA)
health standards. Throughout these instructions, you will find safety
information specific to this arc spray system. For easy recognition, those
instructions are highlighted by a warning sign and language that identifies
different levels of hazard.
WARNING statements refer to instances that could include the possibility
of serious personal injury or loss of life.
CAUTION statements refer to procedures or practices that must be
followed to avoid the possibility of minor personal injury or damage to the
equipment.
IMPORTANT indicates processes, procedures or instructions requiring
special emphasis. In many cases, failure to follow the process, procedure
or instruction indicated will cause inefficient or dangerous operation of the
equipment.

1.2

SAFETY
STANDARDS

This safety section contains references to regulations, standards and

recommendations implemented by private or governmental organizations.
Some of those standards are listed here. This is not an exhaustive listing,
but indicates some standards that apply to thermal spray processes. Any
standard or other document referenced in this publication refers to the
latest edition of that document or standard.
To obtain copies of a standard, contact the developing organization or
visit their web site. In addition, the web site www.nssa.org is a valuable
search tool for standards.
The Occupational Safety and Health Administration (OSHA) is the
governmental body tasked with creating federal safety regulations. Refer
to OSHA Standards, Code of Federal Regulations, Title 29, Part 1910.
Occupational Safety and Health Act Standards (29CFR 1910),
available from the U.S. Government Printing Office or www.osha.gov.

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The Resource Conservation and Recovery Act (RCRA) of 1976 a set

of guidelines for dealing with the handling and disposal of toxic wastes. A
database related to the RCRA can be found at www.epa.gov/rcraonline.
Ventilation Control of Grinding, Polishing and Buffing of Metals,
ANSI Z43.1, from the American National Standards Institute:
www.ansi.org.
Safety Requirements for the Design, Care, and Use of Power
Tools, Power Driven Brushing Tools, ANSI B 165.1 1991, available
from the American National Standards Institute: www.ansi.org
Ventilation Guide for Weld Fume, AWS F3.2M/F3.2-2001, available
from the American Welding Society: www.aws.org; or www.nssa.org.
Exhaust Systems Ventilation and Safe Practices for Abrasive
Blasting Operations, ANSI/AIHA Z9.4-1997, available from the
American National Standards Institute: www.ansi.org.
Safety Code for Design, Construction and Ventilation of Spray
Finishing Operations, ANSI/AIHA Z9.3-1994, available from the
American National Standards Institute: www.ansi.org.
Method for Sampling Airborne Particulates Generated by Welding
and Allied Processes, AWS F1.1-1999, available from the American
Welding Society: www.aws.org; or www.nssa.org.
Fire Prevention in Use of Cutting and Welding Processes
(Revision of ANSI/NFPA 51B-1994), ANSI/NFPA 51B-1998, available
from the American National Standards Institute: www.ansi.org.
Recommended Safe Practices for the Preparation of Welding and
Cutting of Containers and Piping (Revision of ANSI/AWS
F4.1-1994), AWS F4.1-1999, available from the American Welding
Society: www.aws.org; or www.nssa.org; or www.ansi.org.
A Sample Strategy Guide for Evaluating Contaminants in the
Welding Environment (revision of ANSI/AWS F1.3-1991), AWS F1.31999, available from the American Welding Society: www.aws.org; or
www.nssa.org; or www.ansi.org.
Safety in Welding, Cutting and Allied Processes (Revision of ANSI
Z49.1-1994), ANSI Z49.1-1999, available from the American National
Standards Institute: www.ansi.org.
Specification for Rubber Welding Hose, published by the Rubber
Manufacturers association and the Compressed Gas Association.
Standard Practices for Occupational and Educational Eye and
Face Protection, ANSI Z87.1-1989 (Revised, 1998), available from the
American National Standards Institute: www.ansi.org.
Standard Practices for Respiratory Protection, ANSI Z88.2-1992,
available from the American National Standards Institute: www.ansi.org.
Standard Practices for Industrial Head Protection with Low
Voltage Hazards, ANSI Z89.1 available from the American National
Standards Institute: www.ansi.org.

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Hand Protection Selection Criteria (new standard), ANSI/ISEA

105-2000, available from the American National Standards Institute:
www.ansi.org.
Safety Requirements for Industrial Hand Protection, ANSI Z89.1,
available from the American National Standards Institute: www.ansi.org
Standard for Safety for Electrical Equipment for Use in Class I, Zone
0, 1, and 2 Hazardous (Classified) Locations (new standard), UL
2279-1997, available from Underwriters Laboratories.

1.3 FIRE
PREVENTION &
PROTECTION

National Electrical Code, ANSI/NFPA 70-1999 (Revision of

ANSI/NFPA 70-1996), updated annually available from the American
National Standards Institute: www.ansi.org.

CAUTION: Finely divided solids, whether airborne or accumulated,

can be explosive. Adequate ventilation in spray booths minimizes
the danger of dust explosions. Use only a dry cartridge-type
collection system to collect spray dust. Good housekeeping in the
work area is critical to avoid metal dust accumulation. Check rafters,
on top of booths or cabinets, ductwork and floor cracks for dust
accumulation.

Thermal spray operations generate high temperatures. NEVER point any

thermal spray equipment at any person or flammable material. The basic
fire prevention precautions for thermal spray are similar to those for
welding and cutting. Information on these precautions is found in:
ANSI/AWS Z49.1, Safety in Welding and Cutting: NFPA 51B, Standard for
Fire Prevention in Use of Cutting and Welding Processes.

1.3.1.

FLAMMABLE
MATERIALS

NEVER store or leave paper, wood, oily rags or cleaning solvents in the
spray room or enclosure.
De-greasing is an important part of thermal spray preparation. Some degreasing solvents and other preparation materials are flammable, thus
requiring special usage, handling and storage precautions in the thermal
spray AND preparation areas. Because of the high heat developed by
thermal spray operations, some of these preparation materials can
vaporize, causing toxicity and flammability risks.

1.4 OPERATING
SAFETY
1.4.1.

COMPRESSED
AIR

For thermal spraying or blasting operations, use compressed air only at

recommended pressures. Keep the air lines free of oil and moisture.
Consult equipment dealer for filter and after-cooler recommendations.
Improper handling and use of compressed gases, including compressed
air, CAN CREATE A SAFETY HAZARD. Consult the equipment
manufacturers instructions or a qualified compressed air system dealer
for more information.

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INJURY HAZARD: Clear the work area of obstructions and be sure it

is well ventilated before opening any compressed air valves.
Unsecured air hoses can whip, striking people and/or objects. If a
foreign gas, such as carbon monoxide, is accidentally drawn into a
compressed air system, injury or death can occur in enclosed,
improperly ventilated areas. ALWAYS stand away from the direction
of force when opening compressed gas valves.
Use pressure-reducing regulators to control the air volume and pressure.
Never use compressed air or other pressurized gas to clean clothing.

1.4.2.

PROPER
CONNECTIONS

Install and use hoses and hose connections according to ANSI/AWS

Z49.1 and the Specification for Rubber Welding Hose. Handle hoses
carefully to avoid damage and use hoses only in applications for which
they are designed. NEVER OVER TIGHTEN connecting nuts on a gas
system as over-tightening can damage the fitting. If a fitting does not seal
without undue force, replace the fitting.
Turn regulator adjustments slowly to prevent surges. Before connecting
hoses, blow out the hoses to remove any dust.
Low pressure can indicate a serious leak. Use soapy water to check hose
connections for leaks. If any connections leak, depressurize the system,
open the connection, clean the sealing surfaces and threads, reassemble, pressurize and test for leaks. If leak persists, shut down the
equipment and correct the condition before restarting.
FIRE or INJURY HAZARD: NEVER USE LEAKING THERMAL SPRAY
EQUIPMENT. Place a Danger - Do Not Operate tag on the defective
equipment.

1.5 BLASTING
EQUIPMENT

Gas flow obstructions can be caused by: defective hoses; collapsed hose
stems or dirt. Obstructions can be indicated by the system requiring
excessive gas supply pressure to obtain proper gas flow. If the required
gas pressure is more than 3 psi (21 kPa) over recommended levels,
check for obstructions.

Abrasive blasting is a common part of thermal spray operations. Always

inspect and maintain abrasive blast equipment according to the
manufacturers instructions. Repair or replace any worn parts as
necessary.
Never exceed the blast tanks recommended air pressure. Keep all hoses
between the blast machine and blasting area as straight as possible.
Sharp bends in hoses cause friction and internal wear, leading to hose
blowouts. If hoses must curve around an object, use long radius curves.
Store blast hoses in cool, dry conditions.
Be sure blast unit controls function properly, requiring continuous
pressure on a spring-loaded activating lever. Releasing the lever should
cause the system to shut off.

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PERSONAL INJURY HAZARD: NEVER point a blast nozzle at a

person.

Most blasting operations require operator respiratory protection. ANSI

Z88.2: Standard Practices for Respiratory Protection provides information
on selecting, operating and maintaining respiratory protection devices.

1.6 PART
MANIPULATION

1.7 THERMAL
SPRAY
EQUIPMENT

Thermal spray and blasting applications often require target part rotation
or manipulation. Part manipulation equipment can create high rotational or
lateral speeds. Solidly affix and check the balance of parts when mounting
them to a manipulation device. Provide operator protection against the
possibility of a rotating part becoming airborne. Never leave operating
equipment unattended.

All operators should thoroughly read and understand the entire thermal
spray system instruction manual and be familiar with its operation before
starting the system. Always maintain the system according to
recommendations.
When spray operations are complete, equipment is shut down or will be
unattended for any length of time, release all pressure from the regulators
and hoses and disconnect/lock out all power sources. Some thermal
spray equipment uses voltages and amperages that can be electrical
hazards. Train all operators in safe equipment operation and familiarize
them with all operating and safety information in the instruction manual
before allowing them to operate the equipment. Always observe standard
safety precautions for electrical equipment and operate in accordance
with ANSI/AWS Z49.1.
Regularly inspect cables, insulation and hoses. Repair or replace faulty
equipment immediately.
Before supplying power to the system, verify that all equipment is in safe
operating condition. All switches, push buttons, lights, plugs and cables
should be intact and meet ANSI/NFPA 70, National Electrical Code
standards. Ground or insulate exposed electrodes and cable connections.

CAUTION: Never adjust, clean or repair any part of the system

without first disconnecting and locking out all power sources. Clean
the system components frequently to prevent dust accumulations,
which could cause fires or electrical short circuits.

1.8 PERSONAL
PROTECTION

OSHA requires employers to provide safe working conditions AND

requires employees to comply with all rules, regulations and orders
applicable to their actions and conduct. While OSHA does not provide
specific rules for thermal spray operations, it has established general rules
for controlling unsafe and unhealthy elements.

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General requirements for protecting thermal spray operators and welders

can be found in: ANSI/AWS Z49.1, Safety in Welding and Cutting; ANSI
Z87.1, Standard Practices for Occupational and Educational Eye and
Face Protection; ANSI Z88.2, Standard Practices for Respiratory
Protection; and ANSI Z89.1, Standard Practices for Industrial Head
Protection with Low Voltage Hazards.

1.8.1. PROTECTIVE
CLOTHING
Thermal spray operators should wear flame resistant clothing and leather
or rubber gauntlet gloves, especially when working in confined areas.
Clothing should be snug around wrists and ankles to protect the skin from
sprayed materials and dust. Loose fitting clothing, open shirt collars and
unbuttoned pocket flaps create the potential for injury. For work in open
areas, ordinary clothing may be sufficient, but fire resistant clothing is
always recommended.
Suggested clothing items include high-top shoes and trousers or overalls
without cuffs. Pant length should be sufficient to cover the tops of the
shoes. If spraying toxic materials, consult material supplier or the Material
Data Safety Sheet (MSDS) for information on protection.
Electric arc and plasma spraying operations generate ultraviolet (UV)
radiation that can cause sunburn-like, first-degree burns, even through
normal clothing. Wear tightly woven clothing or several layers of clothing
that can provide ultraviolet radiation protection. For more intense
(confined or highly reflective space) or long-term exposure, wear leather
capes or aluminized clothing. If using aluminized protective wear, attach
the aluminized material to the outside of the face shield. Failure to do this
can result in reflecting radiation into the face shield, which can cause
burns or eye damage. Wear aluminized gloves and dark, fire retardant
clothing.
Radiation protection for arc or plasma spraying is similar to that for electric
arc welding and is outlined in ANSI/AWS A49.1. Some thermal spray guns
have a shield that protects the operator from direct exposure to the
arc/plasma, allowing the use of lighter eye protection shades. A helmet is
still strongly recommended, especially if exposure to direct radiation is
possible or if the work area or substrates being sprayed are somewhat
reflective.

1.8.2. EYE PROTECTION

Table 1-1.
Recommended Eye
Protection Shade Numbers

Thermal spray and blasting operations REQUIRE eye protection.

Helmets, hand shields, face shields or goggles are possible forms of
protection: see ANSI Z87.1 and Z89.2 for recommended type of
protection for your application. Arc and plasma spray operators MUST use
protection against infrared and ultraviolet radiation as well as flying
particles. In addition, all helpers and adjacent operators must use suitable
eye protection. Eye protection must provide suitable filtration against
ultraviolet, infrared and intense visible light radiation. (See Table 1-1).

Operation

Eye Protection
Shade Required

Plasma and Arc Spraying

Arc Bonding
Fusing Operations

Shades 9-12
Shades 5-6
Shades 4-6

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In thermal spray operations not requiring additional respiratory protection,

operators have the option of wearing only eye-protecting goggles.
(Thermach recommends respiratory protection in thermal spray
operations of any sort - see next section: 1.8.3.) Protective goggles
should have indirect ventilation to avoid fogging and should protect
against flying particles. In prolonged or repeated exposure operations,
use helmets or shields that provide more complete skin protection from
infrared and ultraviolet radiation.
When blasting, face shields or helmets equipped with dust hoods
protecting eyes, face, chin and neck are the best option. Respiratory
protection should be provided as well. See section C.

1.8.3. RESPIRATORY
PROTECTION

Most spray and blasting operations require respiratory protection.

Thermach recommends using respiratory protection in ALL thermal spray
and blasting operations. Base the protection used on the nature, type and
magnitude of the fumes and gases involved, in accordance with ANSI
Z88.2. Use only devices approved for the specific hazard by the U.S.
Bureau of Mines, National Institute of Occupational Safety and Health
(NIOSH), or other recognized authority.
Typical thermal spray and blasting applications and suggested protective
devices include:
Abrasive Blasting in Unconfined Spaces: mechanical filter respirator with
face shield and dust hood OR self-contained breathing apparatus.
Abrasive Blasting in Confined or Enclosed Spaces: continuous flow airline respirator with a full face piece or helmet and dust hood to protect
the head and neck from rebounding abrasive. Measure airflow to assure
4 cfm (11.2 l/min.) at the face piece and 6 cfm (19.6 l/min.) entering the
helmet or hood. For the respirator air source, use fresh air blowers
(preferred) or compressed air (grade D or better compressed air is
considered breathable). When adequate ventilation is not available, an
in-line vortex cooler aids operator comfort.
Always filter respirator air supplies to remove odors, oil or water mist and
rust particles. Use care in positioning the respirator system air intake so
the respirator receives clean, dry air. If there is ANY chance of
contaminants such as carbon monoxide entering the respirator system,
use a separate air purifier.
Thermal Spraying in Unconfined or Well-Ventilated Work Area:
additional respiratory protection may not be absolutely necessary, but
THERMACH, INC. Recommends using respiratory protection in all
thermal spray applications. In cases of short-term, light work with nontoxic materials, approved mechanical filter respirators can protect
against dust and metal fumes.
Thermal Spraying in Confined or Semi-Confined Spaces: use of a
continuous flow air line respirator similar to the system described for
abrasive blasting is sufficient for thermal spray operations involving
most common materials. If the contaminant protected against is defined
as non-toxic, emergency auxiliary air supplies are not required. In this
situation, if the respirator air supply fails, the operator may stop
operations, remove the air supply line and return to breathable air.

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If applying toxic materials, the contaminated air must be considered

immediately harmful. In the event of respirator air supply failure, the
operator MUST NOT remove the respirator while still in the contaminated
space. When spraying toxic materials, the respirator must have an easily
accessible source of emergency auxiliary breathable air or oxygen. The
operator must be able to quickly switch to this source to allow continued
breathing during the escape from the confined space.

1.8.4. NOISE
PROTECTION

Thermal spray processes can generate high noise levels. If noise levels
exceed the limits established by OSHA in paragraph 1910.95
Occupational Noise Exposure of the Occupational Safety and Health
Standards, provide everyone near the thermal spray operation area with
proper ear protection. Limit individual noise exposure according to
standards prescribed under the Occupational Safety and Health Act.

What Is Noise?
Noise is unwanted and objectionable sound. Excess noise affects
productivity, creates stress and nervous conditions, damages hearing,
and slows reaction times. Noise level measurement quantifies sound
pressure - the energy of sound waves reaching the receiving device.
Sound energy is expressed in decibels (dB). Several situation-specific
scales have been developed to compare sound levels. Continuous sound
is measured on the A-weighted dB scale (dBA). The human ear can
withstand, for extremely short time periods, up to 130 dBA without
immediate damage, but even these short exposures can contribute to
long-term hearing loss. Much hearing damage is cumulative: a person
repeatedly exposed to high sound levels, even of short duration, may
experience hearing loss as he or she ages. Table 1-2 demonstrates
typical noise levels of some environments. If you suspect a noise problem,
quantify the noise levels by measurement and take appropriate action.

Table 1-2.
Typical Thermal
Spray Noise Levels

Equipment
Arc Guns
Powder Guns (Normal)

Powder Guns
(High Capacity)
Wire Combustion Guns
1/8 & 3/16 inch
(3.2 & 4.8 mm)
Plasma Gun

Set-Up
Steel - 24 Volts/200 Amps
32 Volts/500 Amps
Acetylene - without Spray Booth
with Spray Booth
with Spray Booth & Air Jet Cooling
Hydrogen - without Spray Booth
with Spray Booth
Acetylene - with Spray Booth
with Spray Booth & Air Jet Cooling
Acetylene
Propane
Propane & Non-Load Hardware
Methylacetylene-Propadiene Gas
Nitrogen - 600 Amps
Nitrogen/Hydrogen - 600 Amps
Argon - 1000 Amps
Argon/Hydrogen - 600 Amps
Argon/Helium - 600 Amps
Argon/Nitrogen - 1000 Amps

Grit blasting Equipment

Exhaust Equipment

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dBA
111
116
89
90
110
100
101
94
111
114
118
125
118
134
133
128
133
127
131
80-85
<90

Even moderate noise can create physiological effects over time, and as
noise intensity increases, the permissible exposure time must decrease.
Table 1-3 shows exposure time limits for various noise levels.

Table 1-3.
Allowed Duration
of Noise Levels

Sound Level
(dBA)

Exposure Duration
(per day)

80
82
85
88
91
94

24 hours
16 hours
8 hours
4 hours
2 hours
1 hour

97
100
103
106
109
112

30 minutes
15 minutes
7.5 minutes
3.75 minutes
1.88 minutes
0.94 minute

115
118
121
124
127
130
133
136
139

28 seconds
14 seconds
7 seconds
3.5 seconds
1.8 seconds
0.9 second
0.4 second
0.2 second
0.1 second

Thermal spray noise can be managed at the source, in transmission, or at

the point of reception. Managing sound levels at any one of these points
can help protect operators, nearby workers and transient passers-by from
thermal spray noise. Since each thermal spray site is unique, treat each
case individually. This manual contains overall recommendations for noise
control.
Engineering or administrative solutions are often the most direct ways to
reduce noise or noise exposure. Engineering solutions include:
redesigning or relocating equipment, altering operating conditions,
acoustically isolating equipment, insulating the work area, and providing
hearing protection for operators and nearby workers. Administrative
solutions to noise include planning and scheduling to reduce exposure.

How to Protect
Workers Hearing

Using mufflers on thermal spray equipment has proven impractical and

ineffective. Placing baffles or open barriers between the gun and nearby
personnel is only mildly effective because noise travels in all directions
and can overwhelm the baffling. Specially designed sound absorbing
materials can provide up to 5 dB of noise reduction to adjacent areas, but
do not solve the problem for the operator.

Equipment Relocation
Move the noise source away from the receiver to reduce the noise level.
Table 1-4 indicates typical dB reduction as distance increases. Note that
tripling the distance reduces noise by approximately 10 dBA.

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Table 1-4.
Decibel Reduction
by Distance

Equipment Isolation

Work Area Insulation

Plan and Schedule to

Reduce Exposure Time

Distance
from Source

Theoretical
dBA Reduction

3 ft. (1 m)

10 ft. (3 m)

10

30 ft. (9 m)

20

90 ft. (27 m)

80

As indicated in Table 1-4, isolating noise by distance can reduce dBA

levels, but this is often impractical. The most practical and effective
solution to noise is locating the equipment in an acoustically insulated
enclosure. Acoustically insulated rooms limit the noise level outside the
room to specified limits.

Lining the work area with sound absorbing materials provides some noise
reduction by blocking the path of sound transmission. Consult noise
control experts for material recommendations.
Engineering methods of noise control attempt to eliminate, reduce or
contain noise. Administrative solutions, such as planning and adjusting
work schedules with the goal of reducing exposure time are best used
where spraying is intermittent.
Actual spray time is generally a small percentage of the total process
(setup, surface preparation, spraying and finishing). If spray time exceeds
allowable noise exposure limits, re-schedule the job over multiple days or
shifts to keep any one individuals exposure within limits. Alternatively,
schedule multiple operators to spray the job, keeping the exposure of any
one operator within limits. To help control noise exposure for personnel
working near the spray area, schedule spray operations outside of regular
plant hours or rotate work crew assignments in that area.

Provide Hearing
Protection

1.8.5. CONFINED
SPACES

If engineering and administrative solutions do not provide sufficient noise

control, OSHA regulations allow use of suitable Personal Protective
Equipment (PPE). PPE solutions can be used in conjunction with
engineering and administrative solutions to achieve noise control goals.

Tanks, boilers, pressure vessels or ship compartments are some

examples of confined spaces requiring special safety precautions.
CAUTION: If the confined space previously contained combustible
materials, follow AWS F3.1, Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and Piping that have
Held Hazardous Substances.
Ventilation is required for work in confined spaces. Ventilation
requirements are discussed later in this section. If workers must enter a
confined space through a small opening, ALWAYS provide means, such
as safety belts and/or lifelines affixed to the worker, for rapid emergency
exit. Be sure the safety equipment will not jam in the exit, preventing

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escape. Be sure at least one rescue-trained attendant is on duty outside

the confined space at all times. The attendant(s) must be capable of
removing the operator from the confined space if an emergency should
occur.
If possible, spray the confined space from outside the entry opening.
Before entering and during operations, monitor the oxygen level inside the
confined space.

1.9 VENTILATION
An operators exposure to contamination during spray operations varies
with several factors, including:
Size (volume) of area where spraying occurs
Number of units operating in that space
The material sprayed and fumes, gases or dusts it can create
Heat from the spray process
Use of volatile solvents in surface preparation
Consider all factors when selecting ventilation systems for operator safety.
If thermal spray operations are only a portion of total work operations, use
localized exhaust systems in the spray areas to keep general work areas
free of contaminants.
Individual respiratory protection devices protect operators from dust and
fumes. Ideally, each person should have his or her own device. If multiple
operators use a protection device, clean and disinfect it before
transferring between employees (see ANSI Z88.2). Grade D or better
compressed air is required in forced air respiratory devices.
If spraying in an enclosed room without proper ventilation and exhaust
systems, provide a means of mechanical ventilation, such as motorized
portable exhaust units with flexible ducting that remove and filter dust
rapidly, improving visibility for operators. Ventilation is NOT a substitute
for respiratory protection devices. Recommendations on protective
devices and filtration systems are found elsewhere in this section.
Machine tools such as lathes, pose special ventilation problems. One
solution is to mount a hood, connected to the exhaust system and dust
collector by flexible ducting, to the carriage. Aim the gun so the sprayed
material enters the face of the hood. This way, the exhaust hood can
move with the spray gun, allowing little space for the dust and fumes to
spread before being pulled into exhaust system. An average lathe hood is
about 2 sq. ft. (0.2 m2) in size. Air entering the hood opening should move
at 200 ft./min. (1 m/s) or more. Design the hood opening to eliminate
turbulence that could force spray dust into the general room atmosphere.
Some permanent installations enclose the entire machine tool, leaving
only access at the front for spraying. In larger enclosures like this, air
should enter at higher rates, approximately 300 ft./min. (1.5 m/s), to
assure good exhaust action. Automatic and production spraying
operations often allow enclosure of the entire mechanism. Consult
Industrial Ventilation published by the American Conference of
Governmental Industrial Hygienists for more information on exhaust and
ventilation system design.

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Finishing operations (especially dry grinding or lapping operations)

performed on thermal sprayed coatings generally require some type of
exhaust equipment as well. Consult ANSI Z43.1.
Exhaust systems for smaller spray cabinets in which small and medium
size parts are coated should have exhaust air velocities of 200 to 400
ft/min. (1 to 2 m/s) at the hood. Direct the spray into the face area of the
hood. The cabinet design should not create air turbulence. Consult
Industrial Ventilation published by the American Conference of
Governmental Industrial Hygienists for more information on small cabinet
exhaust systems.
Proper lighting and ventilation are important in blasting rooms. Minimum
ventilation airflow should be 80 to 100 ft./min. (0.2 to 0.5 m/s). Consult
local regulations for dust collection requirements and equip the blasting
room accordingly. In most cases, exhausting the ventilation system
directly to the atmosphere is forbidden by local, state or federal regulation.
Comply with all such regulation in the design and construction of blasting
rooms. Do not use the blasting room for thermal spray operations: dust
collectors designed for blasting can clog with spray dust, creating a fire or
explosion hazard. Use only closed-type dust collectors designated for use
in thermal spray environments.
Air removed through the ventilation system must be replaced with clean,
breathable air at a rate of at least 10 air changes per minute. Gasoline or
diesel engine-driven ventilators must be arranged so the engine exhaust
cannot enter the ventilating system or the respirator system air intake.

1.10 TOXIC
MATERIALS

Electrically ground all ventilation and dust removal system fans, pipes,
dust arrestors and motors, but NEVER ground to piping containing
flammable gases or oxidizers. When cleaning out booths, pipes, etc., run
the ventilation fans to prevent dust or fume accumulation in the system.
NEVER weld or cut on ventilation or dust collecting system unless it has
been thoroughly cleaned first.

Thermal spray preparation, spraying or finishing operations sometimes

use or generate toxic substances. Disposal of potentially toxic substances
must be done in accordance with the EPA Resource Conservation and
Recovery Act (RCRA).

1.10.1. THRESHOLD
LIMIT VALUES

Finely divided materials (dust, fumes, smoke) can damage the respiratory
system. The protection level required to safeguard spray equipment
operators can vary depending on the material sprayed. Because health
damage from fine or toxic materials may not be immediately apparent,
careful attention to prevention becomes important. Keep floors,
workbenches and booths clean and free of dusty residues. Discard or
carefully clean protective clothing after use, to remove dust.

Threshold Limit Values (TLV) indicate the maximum safe concentrations

of hazardous materials to which workers can be exposed for eight hours
or less per day. TLV recommendations are published annually by the
American Conference of Governmental Industrial Hygienists (ACGIH).
Always consult the most current TLV listing when researching maximum
allowable exposures.

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Regularly scheduled air sampling will verify the ventilation requirements

for spray operations involving toxic materials. When spraying less toxic
materials, use air sampling to verify that dust and fume concentration
does not exceed the TLV recommendation. Provide respiratory protection
and sufficient exhaust ventilation when dust or fume concentration causes
operator discomfort, regardless of the TLV recommendation.

1.10.2. BERYLLIUM

Highly toxic, beryllium, its compounds and alloys containing beryllium

should only be sprayed when adequate exhaust ventilation and air line
respirators are in use. Ventilation system exhaust ducting must be sealed
and must direct the exhaust to a restricted area. Workers in the immediate
area of the spray operation must be protected by local exhaust ventilation
or air line respirators.
Before working with beryllium, seek advice and information from certified
industrial hygienists, the Nuclear Regulatory Commission, insurance
companies, state agencies, and OSHA.

1.10.3. CADMIUM

1.10.4. LEAD, LEAD

ALLOYS, COBALT,
CHROMIUM, &
TELLURIUM

1.10.5. TIN and ZINC

Cadmium is highly toxic and hazardous, requiring use of respiratory

protective equipment. Fume respirators approved by the U.S. Bureau of
Mines, National Institute of Occupational Safety and Health (NIOSH) or
other approving authority should be considered minimum protection.

The fumes and dust from lead, lead alloys, chromium alloys (stainless
steels, nickel chromium, chromium oxide, etc.) and tellurium are toxic and
pose a hazard due to the potential for ingestion, inhalation and absorption
of fumes, dust or vapors. Respiratory protection and adequate ventilation
are minimum protections.

Tin and zinc are usually found in the forms of their oxides and, while not
considered highly toxic, tin and zinc may cause serious illness, including
coughing and headache. Zinc oxide fumes can cause nausea, vomiting,
chills, fever, muscle and joint pain, and serious thirst. This result of zinc
oxide ingestion has been called brass founders ague, brass chills,
zinc fever, or metal fume fever. Repeated, low-level exposure can
create a temporary, short-term immunity to these symptoms.
When spraying tin or zinc, adequate ventilation and proper respirators are
important to preventing these symptoms. Any operators with pulmonary
disease or those who continue suffering symptoms or discomfort, even
with proper ventilation and respirators, should be reassigned to different
operations.

1.10.6. SOLVENTS

Thermal spraying creates heat and radiation that can decompose some
solvent vapors into noxious and toxic gases. To reduce this possibility,
extract the part from the solvent cleaning tank slowly. If vapor degreasing
was used to clean parts, take care to remove ALL solvent residue (vapor,
liquid film or drops of solvent in pockets and crevices) prior to beginning
spray operations.

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1.10.7. OZONE

1.10.8. SAFETY
STANDARDS

Arc and plasma spraying create ultraviolet radiation that generates

airborne ozone. Spraying in confined or enclosed spaces without
adequate ventilation may cause the ozone level in the atmosphere to rise
above the maximum allowable concentration. To determine adequacy of
ventilation, perform regular air quality tests.

OSHA establishes mandatory federal safety regulations. For information

on these regulations, refer to OSHA Standards, Code of Federal
Regulations, Title 29, Part 1910.

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Notes

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2. GENERAL
INFORMATION
2.1 SPECIFICATIONS

Physical
Weight

384 lbs. (174 kg) net

Dimensions

Width: 22.25 in (565 mm)

Length: 35.75 in (908 mm)
Height: 27.25 in (692 mm)

Electrical (60 Hz version)

Input Voltage

200

230

460

575

Input Amps at Rated Output

72

63

32

25

Max Recommended
Standard Fuse or Circuit
Breaker Rating in Amps

110

90

45

40

Minimum Input Conductor

Size in AWG/Kcmil

10

Max Recommended Input

Conductor Length in Feet
(Meters)

163
(50)

142
(43)

366
(112)

379
(115)

10

10

Input Voltage

380

400

440

Input Amps at Rated Output

39

37

33

Max Recommended Standard Fuse or

Circuit Breaker Rating in Amps

60

50

50

Minimum Input Conductor Size in AWG/

250
(76)

277
(84)

335
(102)

10

10

10

Minimum Grounding
Connector Size in
AWG/Kcmil
Electrical (50 Hz version)

Max Recommended Input Conductor

Length in Feet (Meters)
Minimum Grounding Connector Size in
AWG/K

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2.2 DUTY CYCLE

INFORMATION

Thermachs Model AT-400 is designed for production environments. Easy

to use controls make the AT-400 ideal for any Electric Arc Spray coating
application. The AT-400 Power Supply is controlled remotely by the AT400 Wire Feeder and features safety interlocks, preventing operation in
case of circuit failure.

Spray Amperes

600

500
460

400

300
40

50

60

70

80

90

% Duty Cycle
Table 2-1.
Volt-Ampere Curves

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100

2.3 POWER SUPPLY

ELECTRICAL
SERVICE
INSTALLATION
ELECTRIC SHOCK HAZARD:
Do not touch live electrical parts.
Shut down the power supply and disconnect input power
using lockout/tagging procedures before making cable
connections.
Install the AT-400 using a floor plan compliant with local
rules and regulations and in accordance with general safety
instructions described in Section 1.
After positioning system components, connect the power
supply to the wire feeder.
Cable numbers refer to the callout numbers in Fig. 3-4, p.23
Most cable part numbers end with a dash and a number
telling cable length in feet (example: 861000007-25 is a 25foot cable).
Since cable lengths are custom, we do not reference actual
lengths in these instructions, unless the length is not
variable.

2.3.1. AT-400 POWER

SUPPLY JUMPER
LINK PLACEMENT

The AT-400 can be optimized to run on various input voltages, through

use of either four or eight jumper links on the input power side of the unit.
Position jumper links to match the input voltage (see Fig. 3-1, p.21).
1. Check input voltage available at operating site.
2. Check jumper link placement label (see Fig. 3-1, p.21) for the
jumper arrangement required for the input voltage available.
3. Use a 3/8 inch (9.525 mm) socket wrench to loosen the jumper
link nuts, then use a flat blade screwdriver to pop the jumper links
off their posts. Be sure to also remove the flat washers from the
jumper posts.
4. Place the flat washers on the correct jumper posts, then install
jumper links in front of the washers by placing each link above its
proper posts and pressing down until the link snaps into place.
5. Secure the links with the 3/8 inch (9.5 mm) nuts. Tighten jumper
link nuts just until snug. Do not over tighten.

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ELECTRIC SHOCK HAZARD:

The AT-400 uses high voltage input power. Contact with this amount
of voltage can be fatal. Connection to plant electrical service should
be performed by qualified personnel only. Observe all local and
national regulations when connecting power to the AT-400 or any
electrical device.
6. Remove power and lock/tag out power from the electrical service
line disconnect device.
7. Open the power supplys rear access door (see fig 3-1, p.21).
Check the input cable connections at the AT-400s 3-phase input
contactor. Be sure all connections, including the ground
(GND/PE), are making good contact and secure.
8. Bring free end of the AT-400 input cable to the disconnect device.
Attach the ground (GND/PE) wire to the disconnect devices
grounding connection.
9. Attach the remaining wires (L1, L2, L3) to the proper terminals in
the disconnect device (see fig 3-1, p.21).
10. Close the access door. Remove the lock/tag out device and
reapply power to the disconnect device. Move the disconnect
device to the ON position to apply power to the AT-400.

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3. INSTALLATION
Figure 3-1.
AT-400 Input Power
Connection and Jumper
Link Placement

Table 3-1.1
Dimensions and Weights

Dimensions
Height
Width
Depth*

27 in. (692 mm)

22 in. (565 mm)
35 in. (908 mm)

Weight
300 Amp Model
323 lb. (147 kg)
450 Amp Model
384 lb. (174 kg)
650 Amp Model
472 lb. (214 kg)
* 300 Amp Model = 28 in. (718 mm)

If you need to contact THERMACH for additional information or parts for your
arc spray system, always provide the model and serial number for reference.

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Figure 3-2
AT-400 Power Supply
Input Power Connection

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FIG 3-3:
Selecting a Location

3.1

AT-400 HOSE
and CABLE
INSTALLATION

1. Note: All terminals and connectors needed for cable connections

between the Power Supply and AT-400 Wire Feeder are located
underneath the black plastic door on the front of the Power
Supply.
2. Attach cable # 6 (Negative Power Cable) to power supply
NEGATIVE terminal, then to the wire feeders NEGATIVE (black)
connector (see Fig.3-4).
3. Attach cable # 5 (Positive Power Cable) to power supply
POSITIVE HIGH INDUCTANCE terminal and to the wire feeders
POSITIVE (red) connector (see Fig.3-4).
4. Attach cable # 4 (P/N 861000008-XX) Control/Feedback Cable to
the power supply 14 pin remote receptacle. Connect the opposite
end to the wire feeders remote connector labeled RC-1 POWER
SUPPLY (see Fig.3-4).
5. Attach cable # 10 (OPTIONAL Remote Control Cable) to the wire
feeder receptacle labeled RC-2 Remote.

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801000003 - AT-400 Wire Feeder System Cable Interconnections

Figure 3-4. AT-400 Connections

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NOTE: Contact the Factory prior to utilizing RC-2. RC-2 allows remote control of
AT-400 Arc Spray Systems parameters by a Programmable Logic Controller
(PLC) or other logic device.
6. Attach cables # 8 (Coaxial Cable from the front of the wire feeder) to the
AT-400 Gun Head. Secure cable to the gun head using a 3/4" wrench.
Insert opposite end into wire feeder wire drive mechanism. Ensure that
end is fully inserted and item # 7 is just contacting the upper and lower
drive rolls of the wire feed mechanism of the wire feeder.
Prior to installing coaxial cable (Fig. 3-5) ensure that the
Internal Wire Guide Liner of the coaxial cable is properly installed by
using the following procedure.

FIG 3-5:
AT-400 Coax Cable
Assembly

A. Refer to Fig. 3-5 before connecting cable assembly to wire feeder or

gun head. Remove item # 7 from wire feeder end of coax cable
assembly.
B. Ensure that there is at least 4 inches (1.6 mm) of Wire Guide Liner (#
14) protruding from gun head end of coaxial cable. Insert this end into
the rear of the gun. Secure item # 13 of the coaxial cable to the rear
of the gun head using a 3/4 inch wrench.
C. At the feeder end of the coaxial cable push Wire Guide Liner (# 14)
toward the gun head, ensuring that the liner is properly positioned
within the gun head.
D. At the feeder end of the coaxial cable cut off excess wire guide liner
with a sharp tubing cutter. Ensure that 3/4 inch of liner remains and
protrudes from the end of the feeder end of the coaxial cable
connector, item # 1.
E. Reinstall item # 7, Coaxial Cable Wire Guide. If procedures 1 through
4 are performed properly, item # 7 of wire guide will compress Wire
Guide Liner (item # 14). Ensure that item # 7 Coaxial Cable Wire
Guide is fully threaded into the coaxial cable.

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7. Attach the AT-400 Gun Head Handle Cable (# 9) to the wire feeder
connection labeled RC-3 Gun.
8. Attach Atomizing Air Hose (# 7) to the gun head air extension and to the
wire feeder connection labeled AIR.

3.2 AT-400 ARC

POWER CABLE

TABLE 3-6:
Cable Length/Amperage
Table

Cables 86100006-xx (negative) and 86100007-xx (positive) carry arc current

from the power supply to the wire feeder. These cables are comprised of 2/O
cable. This allows the AT-400 Wire Feeder to be located up to 50 feet (15m)
away from the power supply and still maintain 100% duty cycle at 400 amps.
For longer distances, refer to Table 3-6 for correct cable construction and
allowable amperages. Custom length cables are available from the factory.
Total Cable (Copper) Length in Power Circuit from Power Supply to Wire Feeder
100 ft. (30 m)
150
200
250
300
350
400
Arc Spray
or less
(45)
(60)
(75)
(90)
(105) (120)
1060Amperes
60%
100% 10-100%
Duty Cycle
Duty Cycle
100

1/0

1/0

150

1/0

2/0

3/0

3/0

200

1/0

2 /0

3/0

4/0

4/0

250

1/0

2/0

3/0

4/0

2-2/0

2-2/0

300

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

FIG. 3-7:
Power Cable

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Notes

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4. CONTROLS
4.1

ELECTRICAL
CONTROLS

4.1.1. POWER SUPPLY

Figure 4-1.
Power Supply
Control Panel

Power Switch: A two-position rocker switch located on the right side of the
Power Supply Control Panel on the AT-400 Power Supply. Press ORANGE
section to energize power supply control circuitry. Orange section of POWER
Switch illuminates, indicating it is ready to receive command and control inputs
from the AT-400 Wire Feeder.
High Temperature Shutdown Indicator: Located on the Control Panel of the
AT-400 Power Supply. Illuminates when unit has shutdown output due to an
overheat condition. Overheat can be caused by exceeding rated duty cycle (400
Amperes @ 100%) of equipment. Unit will reset shutdown condition
automatically when equipment has cooled sufficiently to resume operation.

4.1.2. WIRE FEEDER:

FRONT PANEL
FIG. 4-2:
Wire Feeder
Control Panel

Power Switch: Located at the lower left of the AT-400 Wire Feeder Control
Panel. Press switch to de-energize/disable control circuitry for BOTH wire
feeder and power supply. To reset, twist red cap of pushbutton to release.
Start Switch: Green button located on the front top faceplate of the AT-400
Wire Feeder. Press switch to reset control power to the wire feeder and power
supply. Power Switch must be reset/released in order to enable control
circuitry/power.

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System Ready Indicator: Green, when lit, indicates control power has
been successfully reset or is on.

CAUTION: Whenever System Ready Indicator is lit, AT-400 Arc Spray

System has been enabled and is waiting for either gun trigger or remote
device command via RC3 to begin spray operation.

Gun On Indicator: Amber, when lit, indicates control power is on AND spray
operation has been commanded via the gun trigger or remote device via RC3.
Purge Air Switch: Blue, domed, momentary contact pushbutton. While
pressed, atomizing air will be turned on. This feature is useful for purging air
pressure from the air supply circuit prior to disconnecting AT-400 Arc Spray
System from the plant air system. Additional uses include blowing debris, dust
off, or cooling objects after spraying.

PERSONAL INJURY HAZARD: Do not use compressed air/gas to blow

debris from operators clothing!

Maintain Air Switch: Blue, domed, maintained contact, pushbutton, item #27.
Similar in description and operation to Purge Air Switch, except switch contact
is maintained: press for on, press again for off. Used for extended periods of air
operation for cooling parts.
Jog Switch: Black, domed, momentary contact pushbutton. While pressed, the
AT-400 Wire Feeder feeds wire at the speed dictated by the Amperage Adjust
control knob.
NOTE: Remote Amperage On/Off Rocker Switch (Figure 4.3, pg. 29) must be
set to OFF (upper portion of rocker switch pressed) in order for Amperage
Adjust knob to function.
Voltage Adjust Knob: Black, three turn, detented. Controls and sets spray
voltage levels of the AT-400 Power Supply. Turning the Voltage Adjust Knob
clockwise increases, turning counter-clockwise decreases the Arc Spray
Voltage Level. Preset Arc Voltage by setting Voltage Adjust and observing
Voltage level indicated on red LED Voltage Display.
NOTE: Remote Voltage On/Off Rocker Switch (Figure 4.3, pg. 29) must be set
to OFF (upper portion of rocker switch pressed) in order for Voltage Adjust knob
to function.
Amperage Adjust Knob: Black, three-turn, detented. Controls and sets spray
amperage levels (wire speed) of the AT-400 Wire Feeder. Turning the
Amperage Adjust Knob clockwise increases, turning counter-clockwise
decreases the Arc Spray Amperage Level. Set Arc Amperage levels by setting
the Amperage Adjust and observing Amperage levels indicated on red LED
Amperage Display.
NOTE: Remote Amperage On/Off Rocker Switch (Figure 4.3, pg. 29)
must be set to OFF (upper portion of rocker switch pressed) in order
for Amperage Adjust knob to function.

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THERMACH INC.

4.1.3. SIDE PANEL

CONTROLS
FIG. 4-3:
Side Panel
Controls

Located on right side of wire feeder. Access may be gained to these

controls and displays by opening the wire drive access door.
Wire Counter: Re-settable LCD meter displays total wire fed in feet/meters
during the spray operation.
Counter Clear: Reset wire counter meter to 0 by pressing the green
switch/button.
Time Counter: Re-settable LCD meter displays elapsed spray times. Timer is
activated automatically whenever spray unit is operating. Meter displays in
minutes.
Timer Clear: Reset time counter meter to 0 by pressing the green
switch/button.
Remote/Local Voltage Control Switch: Allows remote control of arc voltage
when incorporating the AT-400 to automation. Disables voltage control knob on
faceplate. Remote control signals are applied via RC2.
Remote/Local Amperage Control Switch: Allows for remote control of arc
amperage when incorporating the AT-400 to automation. Disables Amperage
control knob on faceplate. Remote control signals are applied via RC2
Preflow Adjust: Operator adjustment to increase or decrease time that air flow
is started prior to arc start. Optimizes arc start for different wire feedstocks.
Adjustable from 0 to 3 seconds.
Burnback Adjust: Operator adjustment to increase or decrease time that arc
power and atomizing air are left on after trigger is released. Optimizes arc shut
off which increases wire tip life. Adjustable from 0 to 3 seconds.
Display Hold Adjust: Holds the last voltage and amperage display values from
0 to 10 seconds after spray operation is complete.

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4.1.4. AT-400 AIR

CONTROLS
FIG. 4-4:
AT-400 Air
Controls

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THERMACH INC.

TABLE 4-5:
AT-400 Air Pressure
Setting vs. Air Flow

PRESSURE

FLOW

PSI

BAR

CFM

L/M

100

6.89

83

2,350

95

6.55

79.25

2,224

90

6.2

75.5

2,138

85

5.86

71.75

2,031

80

5.51

68

1,925

75

5.17

64.25

1,819

70

4.82

60.5

1,713

65

4.48

56.75

1,606

60

4.13

53

1,500

55

3.9

49.25

1,394

50

3.44

45.5

1,288

45

3.1

41.75

1,182

40

2.75

38

1,076

35

2.41

34.25

969

30

2.06

30.5

863

25

1.72

26.75

757

20

1.37

23

651

4.2 FEEDER to
POWER SUPPLY
FEEDBACK/
CONTROL
4.2.1. RC1 WIRE
FEEDER, RC8
POWER SUPPLY
SOCKET
INFORMATION

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THERMACH INC.

A. 24 volts AC. Protected by power supply circuit breaker CB2.

B. To remote ON/OFF.
C. Command reference: 0 - +10 Volts DC.
D. Power supply DC control common.
E. 0 to +10 Volts DC input command signal from wire feeder.
F. Voltage sensing signal from Positive (+) wire drive housing.
G. Circuit common for 24 and 115 Volts AC.
H. Voltage sensing signal from Negative (-) wire drive housing.
I.

115 volts AC, 15 amps, 50/60 Hz, protected by power supply circuit
breaker CB1.

J.

Contact closure to Pin I completes 115 Volts AC contactor control

circuitry.

K. Chassis common.
L. No connection.
M. Arc voltage display, 1 Volt DC = 10 Volts of display.

4.3 WIRE
FEEDER REMOTE
RECEPTACLE
4.3.1. RC2 WIRE
FEEDER SOCKET
INFORMATION

N. Arc amperage display, 1 Volt DC = 100 Amps of display.

1. Vane sensor, 5 Volts DC, 21 pulses/10.5" of wire travel.

2. 5 Volts DC common.
3. Command reference: 0 - +10 Volts DC power supply output when Voltage
Remote Switch in REMOTE position.
4. 0 to +10 Volts DC input command signal from remote source when
Voltage Remote Switch in REMOTE position.
5. Power supply DC control common.
6. Wire drive remote speed control, isolated/floating 0 to 10 Volts DC when
Amperage Remote Switch in REMOTE position.
7. Wire drive remote speed control wiper of potentiometer (10K) when
Amperage Remote Switch in REMOTE position. Limited to 15 feet from
feeder.
8. Wire Drive remote speed control DC common of remote speed control
potentiometer (10K) when Amperage Remote Switch in REMOTE
position. Limited to 15 feet from feeder.

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THERMACH INC.

9. Signal DC common in reference to pin 6.

10. Chassis.
11. Arc voltage, 1 Volt DC = 10 Volts of Arc Voltage display.
12. Arc amperage, 1 Volt DC = 100 Amps of Arc Amperage display.
13. Not Used.
14. Not Used.

4.4 WIRE
FEEDER TRIGGER
RECEPTACLE
4.4.1. RC3 WIRE
FEEDER SOCKET
INFORMATION

1. 24 Volts AC supply.
2. Relay/switch contact to socket 1 starts/stops spray on/off cycle.
3. 115 Volts AC supply.
4. Relay/switch contact to socket 3 starts/stops atomizing air only on/off
cycle.
5. Chassis.

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801000023, AT-400, Rev. Q

THERMACH INC.

4.5

GUN HEAD

4.5.1. AT-400 GUN

HEAD COMPONENTS
FIG. 4-6:
AT-400 Gun Head

PART NUMBER / ORDERING SCHEME

(ITEM 1) Base Gunhead - No Hardware
(ITEM 2) Air Connector - Comes Standard on Every Gunhead
(ITEM 8) Tubing, Heat Shrink, 0.5"
(ITEM 3) Model Name
T AT-400 - Thermach Inc.

861000014
840000241
881000175
Use label

(ITEM 4) Wire Guides

A 14 GA Wire Guide
B 14 GA 85/15 Wire Guide
C 2mm Wire Guide
D 2mm 85/15 Wire Guide
E 11 GA Wire Guide
F 11 GA 85/15 Wire Guide

881000146
840000308
840000282
840000375
840000376
840000243
840000377

(ITEM 5) Wire Guide Retainer

A Standard Retainer - For High Velocity and Open Arc Air Caps Only
B Retainer with Pins - For use with Fan Spray Air Cap Only
( ITEM 6) Air Caps
A High Velocity Air Cap with Arc Shield
B High Velocity Air Cap without Arc Shield
C N/A
D 14 GA Fan Spray Air Cap
E 11 GA Fan Spray Air Cap
F 11 GA Air Cap Corrosion
G Open Arc Air Cap with Shield
H Open Arc Air Cap without Shield

840000312
840000480
845004734
840000222
840000381
840000340
840000941
840000954
840000953

(ITEM 7) Lock Ring - For use with and required for Fanspray Air Caps Only
Blank for no Lock Ring
A Fan Spray Lock Ring with Shield
840000379
B Fan Spray Lock Ring without Shield
840000380

861000081 -

___ ___ ___ ___ ___

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4.5.2. AT-400 GUN

HEAD COMPONENT
PARTS LIST
FIG. 4-7:
AT-400 Air Caps and Wire
Guide Part Numbers

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THERMACH INC.

4.6 GUN HEAD

PREPARATION
4.6.1. WIRE
INSTALLATION

1. Press the two spring loaded stops on the spool retaining ring, and
withdraw the retaining ring off of the wire spool hub.
2. Slide the wire spool onto spool hub so the wire feeds off the bottom of the
spool and into the wire feeder wire liner. Align the spool with pin on the
wire spool hub.
3. Install the spool retaining ring by pressing the two spring-loaded stops
and sliding the ring over the end of the spool hub.
4. Loosen the wire drive roll pressure adjustment knobs and pivot knobs free
of drive roll lever arms.
5. Find end of wire on spool. Cut off twisted end of wire and file off all sharp
ends as this will reduce the chances of the wire damaging the flexible wire
liner of the coaxial cables.
6. Feed wire into the flexible wire liner and through the wire drive
mechanism and into the inlet guide of the coaxial cables for about two
inches.
7. If needed, adjust spool brake tension by turning hex nut on spool hub.
Turning clockwise increases braking; counter-clockwise decreases
braking.
8. Re-engage drive roll tension knobs, turning clockwise to increase drive
roll pressure.
9. Repeat above steps for other spool of wire.
10. Remove air cap, air cap retainer and wire guides from gun head.
11. Press the JOG switch and set the wire drive feed rate with the
AMPERAGE knob.
12. When both wires emerge from the gun head, release the JOG switch and
trim both wires with a wire cutter.
13. Reinstall both wire guides, wire guide retainer and air cap.

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THERMACH INC.

4.6.2. AT-400 WIRE

Pay-Off Pack
FIG. 4-8:
AT-400 Wire
Pay-Off Pack Parts List

Wire is packaged in many forms other than 12-inch diameter spools.

Reels, coils, and barrels are some of the packaging forms. Barrels or
Payoff packs are the most economical. Payoff packs are desirable in production
environments where large amounts of feedstock are to be sprayed.

38
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THERMACH INC.

Wire packaged in this manner allows up to 500 lbs. to be coiled in each barrel.
The most common feedstock for the Payoff pack is Zinc wire. Due to the
malleability of Zinc, the barrel may remain stationary. For other feedstock
materials it is necessary to either turn the barrel or employ reverse twist wire to
eliminate the possibility of the wire knotting when pulled out of the barrel.
Figure 4-8 illustrates typical wire handling equipment needed to convert an AT400 wire feeder from spools to a Payoff pack wire delivery system.

4.7

OPERATION

4.7.1. POWER UP AND

OPERATION

1. With input power OFF and the power supply properly connected to wire
feeder (see AT-400 System operators manual), connect an AT-400
Electric Arc Spray Gun to the feeder. Mount and thread wire.
2. Place the gun in a properly protected and ventilated enclosure and aim
nozzle into the dust collector. Energize the collector.
3. Supply compressed air to the wire feeder according to the AT- 400
operators manual.
4. Supply input power to the AT-400 and press the POWER switch to ON
position. POWER switch should illuminate.
5. Verify that AT-400 gun is pointed in a safe direction and that all personnel
are clear of the spray area.
6. Energize the AT-400 wire feeder.
7. Adjust wire feeder voltage control to desired level.
8. Place properly shaded protection over eyes.
9. Press the gun trigger.
10. Adjust amperage to desired levels and observe the gun spray behavior.
See AT-400 Operators Manual for spray system adjustments,
maintenance and troubleshooting.
11. Release gun trigger or press the red mushroom switch to stop spraying.

4.8 MAINTENANCE
4.8.1. IMPORTANCE
OF MAINTENANCE

Regular Maintenance is critical to assure safe and accurate operation of the AT400. THERMACH recommends developing a maintenance schedule to assure
the correct tasks are performed at the proper times. A suggested schedule
follows in the next three pages.
The table on page 39 is for the AT-400 Power Supply, page 40 is for the AT-400
Wire Feeder, and page 41 is for the AT-400 Gun Head.

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THERMACH INC.

ELECTRIC SHOCK HAZARD: High voltages can burn or kill. DO NOT

TOUCH LIVE ELECTRICAL PARTS.

1. Disconnect and lock out all input power to the AT-400.

2. Remove all screws securing the outer cabinet. Remove the cabinet by
lifting it up and away from the frame.
3. Use clean, dry compressed air or vacuum to clean dirt/dust from the
internal components.

CAUTION: Cleaning with pressurized air creates high noise levels and can
cause small particles to become airborne. Wear proper eye and hearing
protection if using compressed air to clean.

4. Replace the outer cabinet and secure with screws removed in step 2.

4.9 SCHEDULED
MAINTENANCE
4.9.1. POWER SUPPLY

Procedure

When Due

Performed By

Inspect all cables for cuts, cracks or

abrasion (replace as required)

Each Startup

Operator

Inspect and ensure all cooling air

intakes and exhaust vents are clear
and unobstructed.

Each Startup

Operator

Inspect power supply controls for

damaged or inoperative switches.

Each Startup

Operator

Inspect power supply controls for

burned out pilot lights.

Each Startup

Operator

Clean and tighten

connections/terminals

Monthly

Operator

Inspect/clean optional intake air filter, if

so equipped.

Monthly

Operator

Check for damaged or unreadable

safety and informative labeling (replace
as required).

Monthly

Operator

Wipe off excessive dirt/dust.

Monthly

Operator

Remove outer cover and vacuum

dirt/dust from inside of unit.

Semi-annually

Maintenance
Technician

40
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THERMACH INC.

4.9.2. WIRE FEEDER

Procedure

When Due

Performed By

Inspect all cables for cuts, cracks or

abrasion (replace as required)

Each Startup

Operator

Inspect coaxial cable inlet wire guides

for wear.

Each Startup

Operator

Inspect drive rolls for wear or

excessive dirt buildup.

Each Startup

Operator

Inspect drive roll intermediate wire

guides for wear.

Each Startup

Operator

Inspect wire feeder for missing or

broken parts.

Each Startup

Operator

Inspect consumable spray wire for dirt,

oil or other contaminants.

Each Startup

Operator

Inspect wire feeders controls for

burned out pilot lights.

Each Startup

Operator

Inspect wire feeder controls for

damaged or inoperative switches.

Each Startup

Operator

Inspect wire feeders digital meters for

proper operation.

Each Startup

Operator

Inspect and clean wire feeders air filter

bowl.

Monthly

Operator

Inspect for damaged or unreadable

safety and information labeling
(replace as required).

Monthly

Operator

Blow out wire drive assembly area with

compressed air.

Monthly

Operator

Wipe off excessive dirt and/or oil from

outer sheet metal wrapper.

Monthly

Operator

Remove outer sheet metal cover and

vacuum dirt/dust from inside of unit.

Semi-Annually

Maintenance/
Technician

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THERMACH INC.

4.9.3. GUN HEAD

Procedure

When Due

Performed By

Inspect all cables and hoses for cuts,

cracks, or abrasion.

Each Startup

Operator

Inspect coaxial cable inlet wire guides

for wear.

Each Startup

Operator

Inspect atomizing air cap for excessive

wear or overspray build up.

Each Startup

Operator

Inspect wire guide for wear or

overspray build up.

Each Startup

Operator

Inspect wire guide retaining ring for

damage or wear.

Each Startup

Operator

Inspect consumable spray wire for dirt,

oil or other contaminants.

Each Startup

Operator

Each Startup

Operator

Each Startup

Operator

Inspect gun head for excessive

overspray on gun head body.

Each Startup

Operator

Inspect gun handle and trigger

assembly for loose or broken parts.

Each Startup

Operator

Remove aircap, retaining ring and wire

guides. Inspect/clean wire guide
seating pockets.

Each Startup

Operator

Inspect coaxial cable to gun head

attachment points and ensure they are
tight.
Inspect gun head and aircap for
evidence of oil or water in atomizing air
source.

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Notes

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THERMACH INC.

5. TROUBLESHOOTING
5.1

SHORT
CIRCUIT
SHUTDOWN

5.1.1. REPLACING
FUSE

If the wire guide tips on the AT-400 spray gun contact a conductive surface, a
short circuit results. The AT-400 drops output to a safe level. To resume spray
operations, release the gun trigger/stop spray operations, turn the AT-400 OFF
and remove the material causing the short circuit. To resume operations, turn
the AT-400 on and pull gun trigger.

ELECTRIC SHOCK HAZARD: High voltages can burn or kill. DO

NOT TOUCH LIVE ELECTRICAL PARTS. Disconnect and lock/tag out
input power to the power supply before inspecting or maintaining
equipment.
1. Open rear access door.
2. Use a 3/8 in. (9.5 mm) wrench to turn the fuse holder cap counterclockwise.
3. Pull out fuse holder cap and fuse.
4. Replace fuse: insert flat end of new fuse into the fuse holder cap and
place fuse and cap into the fuse holder.
5. Turn the cap clockwise to tighten and snug up with 3/8 in. (9.5 mm)
wrench.
The following chart can help diagnose and remedy problems that may develop
in the AT-400. Use this table and the circuit diagram while performing
troubleshooting procedures. If the problem is not remedied after performing
these procedures, contact THERMACH Service Department at (888) 450-2549.
In cases of equipment malfunction, carefully follow the manufacturers
recommendations.

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THERMACH INC.

5.2

TROUBLESHOOTING CHART
Trouble

Possible Cause

Remedy

No output, unit
completely
inoperative.

Input power disconnected. Fuse F1 of power

supply blown. Line fuse blown/circuit breaker
tripped. Improper input connection. Jumper
links of power supply in wrong position.

Move line disconnect to ON. Replace fuse

F1. Replace line fuse or check circuit
breaker. Check for proper input power
connections. Check jumper positions.

No output, power
switch pilot light on,
fan on.

Exceeded duty cycle, power supply

overheated. Control board PC1 of power
supply malfunction.

Stop spray operations allow unit to cool with

fan running. Contact Thermach Service
Department, have technician replace PC1
board.

Unit provides only

maximum or
minimum output.

Control board PC1 malfunction. Remote/Local

switches in Remote position

Contact Thermach Service Department,

have technician replace PC1 board. Check
switches are in Local position.

Erratic or improper
output.

Improper cable size or type. Loose

connections. Wire guides of gun head worn.
Drive rolls tension not properly set. Line fuse
blown/circuit breaker tripped. Motor speed
board malfunction. Motor tachometer
malfunction. Control board PC1 and/or main
rectifier SCR malfunction. Cable 861000008XX feeder to power supply damaged.

Use only Thermach-supplied cables. Clean

and tighten all weld cables. Replace wire
guides. Increase pressure of drive roll
tension. Replace line fuse/reset breaker.
Have technician check speed board. Have
technician check tachometer output. Have
technician contact Thermach Service
Department. Have technician check
continuity of cable connections.

No 115 VAC output

at power supply
outlet.

Circuit breaker of power supply CB1 tripped.

Reset circuit breaker CB1 of power supply.

Wire feeder will not

spray, power supply
(green) indicator on
but system ready
indicator (amber) off.

Circuit breaker of power supply CB1 tripped.

Circuit breaker of wire feeder CB2 tripped.

Reset circuit breaker CB1 of power supply.

Reset circuit breaker CB2 of wire feeder.

Wire feeder will not

respond when reset
power switch
depressed.

Power supply power off. Circuit breaker of

power supply CB2 tripped. Power ON/OFF
switch of power supply not turned on.

Turn three phase power to supply on. Reset

circuit breaker CB2 of power supply. Turn
power supply ON/OFF switch. ON switch will
light when in the ON position.

Fan not operating.

Note: fan runs only when cooling is

necessary.

Check for and remove anything blocking fan

movement. Thermostatic switch malfunction.
Have factory authorized service agent check
fan motor and thermostatic switches.

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Trouble

Possible Cause

Remedy

Wire feeder feeds

wire but does not arc
when trigger
pressed.

Power supply contactor malfunction.

Atomizing air pressure set too low to activate
protective pressure switch. Protective
pressure switch (PSW1) malfunction.
Atomizing air supply to feeder shut off.

Contact Thermach Service Department.

Increase atomizing air pressure. Check or
replace pressure switch (PSW1). Ensure
that air supply to feeder restored.

Wire feeder does not

feed wire when
either the jog or
trigger switches are
pressed.

Motor speed board malfunction. Speed knob

set to 0 speed command. Wire drive motor
malfunction. Wire drive motor brushes worn.
Motor speed potentiometer malfunction. Drive
roll tension arms disengaged. Wire spool
brake tension nut set too tight. Out of wire.
Amperage Remote/Local switch set to
Remote.

Replace motor speed board. Adjust as

necessary. Replace wire drive motor.
Replace motor brushes. Replace wire speed
(amps) potentiometer. Engage drive roll
arms. Loosen brake tension nut. Re-load
new spools of wire. Set Amperage
Remote/Local switch to
Local.

Voltage and/or
amperage meters
fail to illuminate.

Wire feeder circuit breaker CB2 tripped. Cable

861000008-XX malfunction. Power supply
PC2 malfunction. Power supply PC1
malfunction. Wire feeder circuit breaker CB3
tripped.

Reset circuit breaker CB2. Check continuity

of cable connections. Contact Thermach
Service Department. Reset circuit breaker
CB3.

Gun sprays
erratically, throws
chunks of wire.

Inadequate atomizing air supply to feeder. Air

cap worn. Wire guides in gun head worn. Wire
guide liner in coaxial cables worn/dirty. Wire
guides in gun head dirty. Arc voltage set to
high for amperage. Arc voltage set to low for
amperage. Wire has grit, dust, or dirt on it.
Drive roll tension set incorrectly. Atomizing air
pressure set too low. Coaxial cable inlet wire
guide worn out. Air cap/wire guide retainer not
tight. Coaxial cable wire liner improperly
installed.

Replace air fittings under " I. D. Replace

air cap Replace wire guides. Replace wire
guide liner in coaxial cables. Clean or
replace wire guides. Set arc voltage to
proper levels. Set arc voltage to proper
levels. Store wire properly, replace with
clean wire. Tighten drive rolls until wire does
not slip. Increase atomizing air pressure.
Replace inlet wire guides. Tighten air cap
and retainer. Refer to manual for installation
instruction.

No control of Arc
Voltage.

Power supply PC1 malfunction. Wire feeder

potentiometer malfunction. Voltage
Remote/Local switch in Remote position.

Contact Thermach Service Department.

Replace Potentiometer. Place Remote/Local
switch in Local position.

Time counter display

blank.

Time counter on-board battery discharged.

Replace battery.

Wire counter display

blank.

Wire counter on-board battery discharged.

Replace battery.

Wire counter display

does not increment.

Vane sensor (PE1) malfunction. Wire Counter

malfunction (DSP4). Power supply (PS1)
malfunction.

Replace vane sensor (PE1). Replace wire

counter display (DSP4). Replace power
supply (PS1).

46
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THERMACH INC.

Trouble

Possible Cause

Remedy

Excessive coating
build-up on gun air
cap.

Arc volts too high for amperage selected. Air

pressure set too low. Release coating on air
cap worn off.

Reduce arc voltage. Increase air pressure.

Replace air cap.

High current cables

from power supply to
wire feeder are hot
to the touch.

Cable length excessive for operating

amperage. Cable connections at wire feeder
or power supply not tight or clean.

Shorten cables. Increase cable O.D.

Decrease arc amperage. Refer to chart in
manual for allowable lengths of cable for
given cable diameter.

No atomizing air.

Air regulator turned down. Solenoid valve

malfunction. Plant air supply off.

Adjust air pressure accordingly .Test with

purge switch, replace valve (SV1). Test with
purge switch, turn plant air on.

47
801000023, AT-400, Rev. Q

THERMACH INC.

6. PARTS LIST

6.1 AT-400 POWER SUPPLY EXPLODED VIEW and B.O.M.

48
801000023, AT-400, Rev. Q

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Item

Part Number

Description

Quantity

1
2
3
3
4
5
6
7
8
9
9

10
11
12
13
14
14
14
15
16
17

18
19
20
21
21
22
23
24
25
25

27
30
32

881000106
881000105
164-699
164-903
162-816
162-820
162-830
177-279
604-536
166-364
180-066
164-717
168-829
254-596
173-605
163-906
159-042
159-041
159-043
159-244
601-835
038-887
010-913
601-835
038-618
159-034
FIG 8-5
156-065
180-270
258-661
140-750
881000161
163-359
230-732
230-756
163-535
163-534
230-730
162-817
182-660
218-380
161-294
192-672

PANEL, SIDE
COVER, TOP
BAFFLE, AIR
BAFFLE, AIR
CHANNEL, UPRIGHT
BAR, MTG LIFT EYE
LIFT EYE
GASKET, LIFT EYE
SCREW, .312-18 x 1.75 HEXHD-PLN GR5
STABILIZER
STABILIZER
BUS BAR, STABILIZER
TRANSDUCER, CURRENT 1000A
CONTACTOR, DEF PRP 25A 2P 24VDC
BRACKET, MTG CONTACTOR
CAPACITOR, 50 & 60HZ
TRANSFORMER, CONTROL 50VA 24V 230/460/575 (60HZ)
TRANSFORMER, CONTROL 50VA 24V 200/230/460 (60HZ)
TRANSFORMER, CONTROL 50VA 24V (50HZ)
PRIMARY BOX (CONSISTING OF)
NUT 10-32 BRS
STUD, PRI BD BRS 10-32 X 1.375
WASHER, FLAT .218 ID BRS
NUT 10-32 BRS
LINK, JUMPER TERM BD PRI
HOLDER, FUSE MINTR
PANEL, REAR W/COMPONENTS
FUSE, CRTG, .5A 600V TIME DELAY
CONTACTOR DEF PRP 40A 3P 24VAC (400 AMP UNIT)
CONTACTOR DEF PRP 75A 3P 24V
(600 AMP UNIT)
SWITCH, REED
DECAL, DANGER, ELECTRIC SHOCK
BASE
CAPACITOR ASSEMBLY (CONSISTING OF) (400 AMP UNIT)
CAPACITOR ASSEMBLY (CONSISTING OF) (600 AMP UNIT)
CAPACITOR, ELCTLT 16000uF 60VDC (400 AMP UNIT)
CAPACITOR, ELCTLT 16000uF 70VDC (600 AMP UNIT)
RESISTOR, WW FXD 10W 500 OHM
BUS BAR, CAPACITOR
BUS BAR, MTG CAPACITOR
TRANSFORMER, PWR MAIN 200/230/460 (CONSISTING OF)
BRACKET, MTG RECTIFIER
RECTIFIER, SCR MAIN

2
1
2
2
4
2
1
1
2
1
1
1
1
1
1
3
1
1
1
1
24
24
24
24
8
1
1
1
1
1
1
1
1
1
1
6
6
1
2
4
1
2
1

49
801000023, AT-400, Rev. Q

THERMACH INC.

6.1.1. AT-400 FRONT PANEL

50
801000023, AT-400, Rev. Q

THERMACH INC.

Item

Part Number

1
2
2
2
2

3
4
5
6
7

8
9
10
11
13
14
18
19
20
21

22
25

26
27
28

29
30
32
33
34
35

159-863
208-197
208-772
231-160
231-170
169-240
148-439
152-249
052-964
006-393
093-995
604-176
203-778
143-976
204-143
181-245
128-750
161-303
181-246
236-228
179-563
172-587
160-935
601-835
010-913
038-887
231-149
153-501
148-439
192-174
881000100
881001259
185-626
159-522
159-036
234-081
010-381
005-107
881000101

Description

Quantity

ELECTRONICS BOX
CIRCUIT CARD, CONTROL (60HZ)
CIRCUIT CARD, CONTROL (60HZ)
CIRCUIT CARD, CONTROL (50HZ)
CIRCUIT CARD, CONTROL (50HZ)
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
RELAY, ENCL 24VDC DPDT
RELAY, ENCL 24VAC DPDT
CIRCUIT BREAKER, MAN RESET 1P 15A 250VAC
RECEPTACLE, STR DX GRD 2-3W 15A 125V
CONNECTOR/CAPACITOR, W/LEADS (CONSISTING OF)
CONNECTOR & SOCKETS
PANEL, FRONT
TERMINAL, PWR OUTPUT RED
CAPACITOR, CER DISC 0.1F 500VDC
SPRING, CPRSN 0.600 OD X 0.072 WIRE X 1.500 LG
TERMINAL, PWR OUTPUT BLACK
PLATE, CONTROL LOWER
LABEL, WARNING ELECTRIC SHOCK
COVER, STUD OUTPUT
CLIP, SPRING
NUT, 10-32 BRS
WASHER, FLAT 0.218 ID X 0.460 OD X 0.03 THK BRS
STUD, PRI BD BRS 10-32 X 1.375
CIRCUIT CARD ASSY
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
STAND-OFF
FRONT LEXAN
SWITCH, ROCKER SPDT 15A 125VAC
CONNECTOR, BODY 56 SERIES
LED, YELLOW
LENS, LED CLEAR
SNUBBER, ASSY
CONNECTOR, RECTIFIER
BOLT, CRG STL -20 X .750 GR5 PLD
SHEET METAL, FRONT PANEL, POWER SUPPLY

51
801000023, AT-400, Rev. Q

THERMACH INC.

1
1

1
1
1
1
1
2
1
1
1
1
2
3
3
1
1
1
1
3
2
1
1
1
1
1
4
1
1
1
1
1
1
2
6
1

6.1.2. AT-400 RECTIFIER AND B.O.M.

Item

Part Number

1
2
3
4
5
5
6

048-420
191-989
188-691
188-839
161-668
148-091
166-667
158-720
192-673
192-674

Description

Quantity

CAPACITOR, CER DISC 0.1uF 1000VDC

BAR, MTG RECTIFIER
CLAMP, SPRING THYRISTOR RECTIFIER 5.375
HEAT SINK, RECTIFIER SNOWFLAKE 0.800
THYRISTOR, SCR 300A 300V HOCKEY PUCK
THYRISTOR, SCR 865A 300V HOCKEY PUCK
CLAMP, SPRING THYRISTOR RECTIFIER 5.500
CONNECTOR & SOCKETS
THERMOSTAT, RECTIFIER
THERMOSTAT, RECTIFIER

52
801000023, AT-400, Rev. Q

THERMACH INC.

6
2
3
12
6

3
1
1
1

6.1.3. AT-400 REAR PANEL AND B.O.M.

Item

Part Number

1
2
3
4
5
6
8
9
10

173-283
180-165
162-807
168-343
162-818
179-290
124-274
114-808
237-398

Description

Quantity

CHAMBER, PLENUM 14 IN.

BLADE, FAN 14 IN. 3WG 28DEG 0.375 BORE CCW
PANEL, REAR
HINGE, DOOR PRIMARY
DOOR, ACCESS PRIMARY
LABEL, WARNING ELECTRIC SHOCK
BRACKET, MEG FAN MOTOR
RESISTOR, WW FXD 375W 5OHM
MOTOR, HP 230V 1550RPM 50/60HZ 1.5A

53
801000023, AT-400, Rev. Q

THERMACH INC.

1
1
1
2
1
1
1
1
1

6.2 AT-400 EXPLODED VIEWS

861000000B - AT-400 Wire Feeder Electrical Component Assembly

54
801000023, AT-400, Rev. Q

THERMACH INC.

861000000C - AT-400 Wire Feeder Chassis Assembly

55
801000023, AT-400, Rev. Q

THERMACH INC.

861000000D - AT-400 Wire Feeder Drive Housing Assembly

56
801000023, AT-400, Rev. Q

THERMACH INC.

861000000E - AT-400 Wire Feeder Drive Component Assembly

57
801000023, AT-400, Rev. Q

THERMACH INC.

861000000F - AT-400 Wire Feeder Spool Mount Assembly

58
801000023, AT-400, Rev. Q

THERMACH INC.

861000000G - AT-400 Wire Feeder Sheet Metal Component Assembly

59
801000023, AT-400, Rev. Q

THERMACH INC.

6.3 AT-400 WIRE FEEDER BILL OF MATERIALS

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

QTY
1
1
1
1
1
2

PART NO.
881000046
881000013
881000037
881000043
881000044
881000012

DESCRIPTION
PCB, MOTOR DRIVE, SCR REGEN.
MOTOR, hp, 90 RPM, 95 in/lbs, DUAL SHAFT
TACH, GENERATOR, 7V @ 1000 RPM/WITH ADAPTOR
TIMER, PROGRAMMABLE DISPLAY
COUNTER, PROGRAMMABLE DISPLAY
DIGITAL PANEL METER, 20V, END CASE

1
1
2
1
1
1
1
6
1
1
6
1
1
2
1
1
1
1
1
1
1
1
2
2
18
1
2
2
1
1
1
1
3
19
13
1
1
1
1
1
1
1
1

881001402
881000029
881000030
881000848
881000849
881000031
881000049
886000257
881000017
881000018
881000008
881000032
881000045
881000010
881000025
881000050
881000051
881000052
881000053
881000028
881000026
881000027
881000054
881000055
881000387
881000388
881000058
881000059
881000060
881000061
881000062
881000116
881000174
881000065
881000119
881000067
881000110
881000111
881000112
881000085
881000086
881000087
881000088

POWER SUPPLY, 5VDC, 3A

SWITCH, PRESSURE, LOW PRESSURE, PRESET
TIMER, DOB, 120VAC, EXT. ADJ. .1-10 SEC
POTENTIOMETER, 25k OHM, 2W
POTENTIOMETER, 100K OHM, 2W
TIMER, DOM, 120VAC, EXT. ADJ., .05-3.0 SEC
POTENTIOMETER, 300D, 3.0M, 1/4W, W/ 8" LEADS P1004-12X
JUMPER, TERMINAL, 2 WAY
POTENTIOMETER, 3 TURN, 10K, 1/4W, WW
POTENTIOMETER, 3 TURN, 1K, 1/4W, WW
HINGE, 150 DEGREE DETENT
VALVE, AFOS05 SOLENOID, 120VAC
REGULATOR, FILTER, 150 PSI MAX.
KNOB, POTENT., MULTI-TURN, BLACK, 60 DETENT
SWITCH, E-STOP, TWIST TO RELEASE
CONTACT BLOCK, 2NC
PLATE, MARKING, YELLOW, E-STOP, BLANK
CABLE, ASSEMBLY, INHIBIT
SENSOR, VANE, PHOTO-OPTIC, 5VDC, WITH CABLE
SWITCH, PB, NO, MAINTAINED, BLUE DOME
SWITCH, PB, NO, MOMENTARY, BLUE DOME, PURGE AIR
SWITCH, PB, NC, MOMENTARY, BLACK DOME, WIRE JOG
SWITCH, PB, NO, MOMENTARY, GREEN, SHROUD
SWITCH, ROCKER, DPDT, RED, REMOTE ON/OFF
TERMINAL, 4 CONDUCTER, CENTER BLOCK
TERMINAL, 4 CONDUCTER, FLANGE BLOCK
RELAY, 1P2T, 24VAC, TOP BRACKET
RELAY, 3P2T, 24VAC, TOP BRACKET
RELAY, 4P2T, 24VAC, TOP BRACKET
CONNECTOR, RECP, REV. SEX, SKT, CPC-1, 17-14
CONN, RECP, REV. SEX, SKT, CPC-1, 17-9, VDE
CONN, RECP, REV. SEX, SKT, MIL-C-5015, 20-14
INSTRUMENT KNOB, 0.25 SHAFT x 0.5 OD x 0.625 HT
SOCKET, TYPE III+, CRIMP, 18-14 AWG, TIN, LOOSE
SOCKET, CRIMP 18-14AWG, TIN, LOOSE, MIL-C-5015
SWITCH, PB, SPDT, SCREW TERMINAL, GREEN LENS
PILOT LIGHT, LED, 24VAC, GREEN, .25 CNCTR.
PILOT LIGHT, NEON, 120VAC, GREEN, .25 CNCTR.
PILOT LIGHT, LED, 24VAC, YELLOW, .25 CNCTR.
CAP, SEALING, SHELL SIZE 17
LEXAN, FRONT TOP
LEXAN, FRONT LOWER
LEXAN, LEFT SIDE

60
801000023, AT-400, Rev. Q

THERMACH INC.

ITEM
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
2
2
4
4
4
4
4
4
2
2
2
8

PART NO.
881000089
881000090
881000038
881000039
881000040
881000041
881000042
881000003
881000091
881000092
881001188
881000094
881000095
881000113
840000237
881000068
881000069
881000114
881000071
881000132
881000072
881000024
881000073
881000074
881000015
881000011
840000316
881000006
881000076
881000007

DESCRIPTION
RECEPTICLE, INSULATED, MALE, BLACK
RECEPTICLE, INSULATED, MALE, RED
SHEET METAL, WRAPPER, BASE
SHEET METAL, WRAPPER, TOP COVER
SHEET METAL, WRAPPER, LEFT DOOR
SHEET METAL, WRAPPER, RIGHT DOOR
SHEET METAL WRAPPER, ELECTRICAL TRAY
SHEET METAL, MOTOR MOUNT
SHEET METAL, SKID
SHEET METAL, SPOOL STAND
CIRCUIT BREAKER, 1.5 AMP
CIRCUIT BREAKER, 2 AMP
CIRCUIT BREAKER, 5 AMP
BUS BAR, 400A, AT-400 WIRE FEEDER
SPACER, VANE SENSOR, AT-400 WIRE FEEDER
LEVER, MTG. PRESSURE GAUGE, TWO TAB
LEVER, MTG. PRESSURE GAUGE, ONE TAB
GAUGE, 2", 1/4" CBM, DUAL SCALE 0-160 PSI
PIN, COTTER HAIR, 0.042 x 0.750
PIN, HINGE
KNOB, ADJUSTABLE WIRE TENSION
SPRING, COMPRESSION, 0.770 OD x 0.100 WIRE x 0.715
WASHER, CUPPED, 0.328 ID x 0.812 OD x 0.125 LIP
FASTNER, PINNED
PIN, SPRING, CS 0.187 x 1.00
KNOB, WING, PLASTIC, 5/16-18
ADAPTOR, WIRE DRIVE TO REAR LINER
GEAR, SPUR, PINION, 20T
KEY, STL., 0.1215/0.1230 x 0.750
GEAR, SPUR, QUICK CHANGE DRIVE ROLL, 20T

2
8
8
2
2
1
2
2
2
4
4
2
2
1
1
1
4
1
2

881000077
881000004
881000005
881000109
881000020
881000083
881000035
881000023
881000036
881000034
881000033
881000009
881000001
840000002
840000003
840000242
840000310
881000177
845000352

BUSHING, 2.5", SNAP IN, NYLON, BLACK

BUSHING, INSULATOR, DRIVE HOUSING BOLTS
ROLL, DRIVE U GROOVE, 14 GA
INSULATOR, HOUSING, FIBER, 0.125"
RING, RETAINING, WIRE SPOOL
NUT, STL., HEX HD, 5/8-11
WASHER, FLAT, STL, SAE 0.640ID X 1.00 OD
SPRING, COMPRESSION, 0.970 OD x 0.120 WIRE x 1.25
WASHER, FLAT, STL, KEYED, 1.50 DIA X 0.125 THK
WASHER, FIBER, 0.656 ID x 1.50 OD x 0.125 THK
WASHER, BRAKE, STL.
HUB, WIRE SPOOL
HOUSING, WIRE DRIVE
SHAFT EXTENSION, WITH VANES
SHAFT EXTENSION
MANIFOLD, AIR DISTRIBUTION
SPACER, FEEDER TO SKID
SNUBBER, 220 OHM
INTERMEDIATE WIRE GUIDE

61
801000023, AT-400, Rev. Q

THERMACH INC.

ITEM
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150

QTY
1
1
1
2
1
1
1
2
1
3
1

PART NO.
881000137
881000144
881000145
881000136
881000138
881000147
886000119
881000140
881000141
881000142
881000130

DESCRIPTION
NIPPLE, 1/2" MPT, HEX, BRASS
PLUG, 1/8" MPT, HEX SOCKET, BRASS
COUPLING, REDUCER, 1/2" FPT - 1/4" FPT
FITTING, 1/2" MPT - 1/2" TUBE, STRAIGHT
FITTING, 3/8" MPT - 1/2" TUBE, ELBOW, 45 DEG.
FITTING, 1/2" MPT - 3/8" FPT
NUT, 1/2" CONDUIT
FITTING, 1/8" MPT - 1/8" TUBE, STRAIGHT, BRASS
FITTING, 1/4" FPT - 1/8" TUBE, STRAIGHT, BRASS
FITTING, 1/8" MPT - 1/8" TUBE, ELBOW, 90 DEG.
FITTING, BULKHEAD, 1/2"-20 - 1/2" MPT

3
A/R
A/R
2
2
29"
8
2
16
4

840000314
886000102
886000103
881000126
840000374
881000152
886000050
886000051
886000052
886000191

WASHER, BRASS, 1.24 OD X 0.845 ID X 0.093 THK

TUBING, 1/2", NYLON, NATURAL
TUBING, 1/8", NYLON, NATURAL
BUSHING, SHUTTER PASS THROUGH
NUT, HEX, BRASS, 1/8-27 FNPT OVERSIZE
TUBING, 3/4" INSULATOR
SCREW, SKT HD CAP, -20 x 1.25, ZINC PLATE
SCREW, SKT HD CAP, -20 X 3/8, ZINC PLATE
SCREW, BTN HD CAP, -20 X 3/8, BLK
SCREW, HEX HD, 5/16-18 X 2.0, GRD 5, ZINC

886000055

SCREW, HEX HD, -20 X .50, GRD 5, ZINC

14

886000057

SCREW, HEX HD, -20 X .75, GRD 5, ZINC

4
28
1
2
2'
2
8
1
8
21
36
2
18
1
2
16
48
40
6
2
1
2
2

886000059
886000060
840000359
845001166
880000008
881000151
886000065
880000210
886000067
886000068
886000069
886000070
886000071
881000098
886000125
886000074
886000075
886000076
886000079
886000092
886000008
886000093
886000081

SCREW, SET, 8-32 X .25, HALF DOG POINT

SCREW, MACHINE, PAN HD, 10-32 X 0.50, SLOTTED
SCREW, SPOOL STAND, SLOTTED
GUIDE, WIRE, COAX CABLE
LINER, NYLON, BLACK
ADAPTOR, STRAIGHT, 1/8 NPT TO 1/4 TUBE, PLASTIC
SCREW, BTN HD CAP, 10-32 X 1.00, BLACK
ADAPTOR, BRASS, 1/4 NPT x 9/16-18
NUT, HEX, NYLOCK, 5/16-18, GRADE 2, ZINC
NUT, HEX, NYLOCK, -20, GRADE 2, ZINC
NUT, HEX, NYLOCK, 10-32, ZINC
NUT, HEX, NYLOCK, 8-32, ZINC
NUT, HEX, NYLOCK, 6-32, ZINC
LEXAN, CIRCUIT BREAKER
NUT, HEX, -13, BRASS
WASHER, FLAT, SAE, 5/16
WASHER, FLAT, SAE, 1/4
WASHER, FLAT, SAE, #10
WASHER, FLAT, SAE, #4
WASHER, FLAT, SAE, 3/8"
O'RING, #13 VITON
SCREW, NYLON THUMB, 1/4-20 X 0.50
SCREW, HEX HD, 3/8 X 16 X 1.50, GRADE 5, ZINC

62
801000023, AT-400, Rev. Q

THERMACH INC.

ITEM
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200

QTY
4

PART NO.
886000083

DESCRIPTION
SCREW, HEX HD, -20 X 1.50, GRADE 5, ZINC PLT

10

886000085

SCREW, MACH. PAN HD. 6-32 X .0.50, SLOTTED

2
3
3
20
2
4
1
1
2
16
4
1
1

886000124
886000088
886000089
886000078
886000091
886000123
801000000
801000002
881000124
886000117
881000150
881000180
881000394

WASHER, FLAT, 1/2", BRASS

SCREW, MACH. PAN HD, -20 X 1.25, SLOTTED
SCREW, MACH. PAN HD, 8-32 X 0.75, SLOTTED
WASHER, FLAT SAE, #6
NUT, HEX, NYLOCK, 3/8-16
WASHER, FLAT, 3/8, BRASS
LABEL, ELECTRICAL SCHEMATIC
LABEL, PNUEMATIC SCHEMATIC
DECAL, THERMACH LOGO, 2.00 x 16.00
SCREW, BTN HD CAP, 6-32 X 0.375"
BUMPER, W/ 5/16-18 X 0.625" STUD
LEXAN, RC1 RECEPTICLE
LEXAN, RC2 RECEPTICLE

A/R
2
1
3
3
1

881000182
881000160
881000161
886000095
886000115
881000382

GASKET, CLIP ON STRIP

DECAL, PINCH POINT WARNING
DECAL, CAUTION STATIC EQUIPMENT
WASHER, INTERNAL STAR, #8
NUT, KEPS, 8-32
LABEL, SERIAL NUMBER TAG

4
4
1
A/R
2
2

886000086
886000072
881000389
886000356
886000264
886000785

SCREW, MACH PAN HD, 4-40 x 0.625

NUT, HEX, NYLOCK, #4, ZINC
TERMINAL, END PLATE WITH FIXED FLANGE
TERMINAL MARKER
WASHER, FLAT, 1/2" SAE
LUG, RING, 1/2 INCH STUD, 22-16 AWG

1
2

840000758
886000375

FTG, UNION, 1/8 NPS MALE TO FEMALE, BRASS

WASHER, SPLIT LOCK, 3/8

63
801000023, AT-400, Rev. Q

THERMACH INC.

6.4 AT-400 SCHEMATICS and CABLES

801000000A - AT-400 Wire Feeder Electrical Schematic

64
801000023, AT-400, Rev. Q

THERMACH INC.

801000000B - AT-400 Wire Feeder Electrical Schematic

65
801000023, AT-400, Rev. Q

THERMACH INC.

801000001 - AT-400 Power Supply Electrical Schematic

66
801000023, AT-400, Rev. Q

THERMACH INC.

AT-400 Pneumatic Schematic

67
801000023, AT-400, Rev. Q

THERMACH INC.

861000008 - AT-400 Wire Feeder to Power Supply Control Cable

68
801000023, AT-400, Rev. Q

THERMACH INC.

861000009 - AT-400 Wire Feeder to Remote Control Device Cable (optional)

69
801000023, AT-400, Rev. Q

THERMACH INC.

861000280 - AT-400 Wire Feeder Gun Handle/Trigger/ Assembly

70
801000023, AT-400, Rev. Q

THERMACH INC.

861000023 AT-400 Wire Feeder Remote Trigger Cable (optional)

71
801000023, AT-400, Rev. Q

THERMACH INC.

861000003 - AT-400 Wire Feeder to Gun Head Coaxial Cable

72
801000023, AT-400, Rev. Q

THERMACH INC.

861000007 - AT-400 Wire Feeder to Power Supply Negative Power Cable

73
801000023, AT-400, Rev. Q

THERMACH INC.

861000006 - AT-400 Wire Feeder to Power Supply Positive Power Cable

74
801000023, AT-400, Rev. Q

THERMACH INC.

801000023 Rev. Q
THERMACH, INC.
801000023,
AT-400, Rev. Q
P.O. Box 1995
Appleton, WI 54912-1995

Copyright 2014, Thermach, Inc.

75

Phone: (920) 779-4299

THERMACH
INC.
Fax: (920) 779-4452
www.thermach.com