Thermal Arc LM-200 ARCMASTER Service Manual

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LM-200

ARCMASTER

INVERTER ARC WELDER

Service Manual

Version No: 1 Issue Date: May 22, 2006 Manual No.: 0-4943B Operating Features:

208V230V460

SMAW

1/3

PHASE

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc® product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 800-752-7621, or visit us on the web at www.thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc® product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc® is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use.

Service Manual Number 0-4943B for: ArcMaster LM-200 Inverter Welding Power Supply Part No. 10-3092

Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: May 22, 2006

Record the following information for Warranty purposes:

Where Purchased: _______________________________

Purchase Date: _______________________________

Equipment Serial #: _______________________________

CONTENTS

SYMBOL LEGE N D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

STATEMENT OF WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

1 SYMBO L LE GEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2 STATEMENT OF WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

1 GENERAL INFORMATION

1 Notes, Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2 Important Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

3 Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

4 Note, Attention et Avertissement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

5 Precautions De Securite Importantes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1– 3

6 Docume n t s D e Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

2 INTRODUCTION AND DESCRIPTION

1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –1

2 Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

4 Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

4.1 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

4. 2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

5 Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

5.1 Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 2

5.2 Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

7 Duty Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

3 OPERATO R CONTROLS

1 LM-200 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

Weld4 Parameter Descriptions for LM-200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

3 Weld Process selection fo r the L M- 2 0 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

4 Weld Par a meter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

4.1 WELD (V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

4. 2 INDUCTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –3

4.3 HOT START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

4.4 WELD (A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

4.5 ARC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

4.6 Weld Parameter s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

4. 7 Power Source Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

4 SEQUENCE OF OPERATION

1 Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 –1

2 LIFT TIG We l d i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

3 MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

5 ROUTINE MAINTENANCE 6 BASIC TROUBLE SHOOTING

1 Solving MIG Problems Beyond the Welding Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

1. 1 Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

1. 2 Inconsistent Wire Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

2 MIG Weld i n g Pro b l e ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

3 TIG Weldi n g Pr o blems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

4 Stick We l d in g Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

5 Power So u rc e Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7

7 VOLTAGE REDUCTION DEVICE (VRD)

1 VRD Spe ci fi c a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

2 VRD Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

3 Switchi n g VR D O n /Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

8 POWER SOURCE ERROR CODES 9 ADVANCED TROUBLESHOOTING

1 System- L e vel Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –1

1.1 Opening the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

1.2 Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4

1.2.1 E01 "Over-Temperature at th e p rimary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –4

1.2.2 E02 "Over-Temperature at the secondary side". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

1.2.3 E03 "

1.2.4 E11 "High Input Voltage Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

1.2.5 E12 "Low Input Voltage Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

1.2.6 E14 "Low Input Voltage Warning". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

1.2.7 E81 "Abnormal Input Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

1.2.8 E82 "Rated voltage selection circuit abnormality". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

1.2.9 E83 "Abnormal mains supply voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6

1.2.10 E85 "Pre-Charge Error". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 7

1.2.11 E94 "Thermistor Fail u re". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7

1.2.12 E99 "Initial Power Receiving" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7

1.3 Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8

1.3.1 "Cooling Fan Failure"

(Fan is not ro ta ting). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8

1.3.2 "Wire feeding failure or inconsistent wire delivery" (Wire feeder does not work) . . . . . . . . . . . . . . . . . . . . . . . . . 9–8

1.3.3 "No weld output" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9

1.3.4 "Operating Panel Failure" (LED's do not light properly or weld settings cannot be establish.) . . . . . . . . . . . . . . 9–10

1.4 Fault Isolation Te s t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –10

1.4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10

1.4.2 Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11

1.4.3 Power Supply Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12

1.4.4 Verification of the Cooling Fan, FAN1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 3

1.4.5 Verification of the primary Diode (D1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13

1.4.6 Verification of the secondary Diode (D2-7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14

1.4.7 Verification of the primary IGBT (Q1-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 4

1.4.8 Verification of No-load Voltage (No OCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15

1.4.9 Output Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 6

2 Subsystem Test and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17

2.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17

2.2 Test and Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17

2.3 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21

2.3.1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –21

2.3.2 Notes of disassembly and assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21

2.4 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–22

2.4.1 PCB1 (WK-5493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 2

2.4.2 PCB2 (WK-5597) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 3

2.4.3 PCB3 (WK-5548), PCB7 (WK-5689) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–24

2.4.4 PCB4 (WK-4819) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 6

2.4.5 PCB5 (WK-5696) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 6

2.4.6 PCB6 (WK-5688) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 7

2.4.7 PCB8 (WK-5479) and PCB9 (WK-5479) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–27

2.4.8 PCB10 (WK-5479), PCB11 (WK-5479) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28

2.4.9 PCB12 (WK-5527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 2 8

2.4.10 PCB13 (WK-5528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–29

2.4.11 PCB14 (WK-5594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–30

2.4.12 PCB15 (WK-5606) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–31

2.4.13 PCB16 (WK-4917) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–32

2.4.14 PCB17 (WK-5699) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–33

2.4.15 PCB18 (WK-5499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–33

2.4.16 Inductor (FCH1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34

2.4.17 Thermistor (TH1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–35

2.4.18 Thermistor (TH2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36

2.4.19 Cooling Fan (FAN1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36

Primary Over-Current Failure

" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

CONTENTS

2.4.20 Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–37

2.4.21 Switch (S2 and S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –38

2.4.22 Current Sensor (HCT1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39

2.4.23 Diode (D1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39

2.4.24 Diode (D2, D4, D5, and D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 4 0

2.4.25 Current Transformer (CT2 and CT3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–41

2.4.26 Reactor (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –41

2.4.27 Molded Case Circuit Breaker (MCB1 and MCB2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–42

2.4.28 Resistor (R2 and R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–43

2.4.29 Transformer (T1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –44

2.4.30 14-Pin Receptacle (CON1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 4 6

2.4.31 19-Pin Receptacle (CON2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 4 7

APPENDIX 1 SPARE PARTS LIST

1 Equipm e n t Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

2 How To Use T h i s Pa r t s Li st. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 –1

APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 4 DIODE TESTING BASIC

ARCMASTER LM 200

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

SAFETY IN WELDING AND CUTTING. This publication and other

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor level.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

May 22, 2006

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

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ARCMASTER LM 200

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

Eye protection filter shade selector for welding or cutting

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen C utting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

1-2

(goggles or helmet), from AWS A6.2-73.

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

May 22, 2006

WARNING

ARCMASTER LM 200

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

May 22, 2006

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

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ARCMASTER LM 200

1.02 Principal Safety Standards

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec.

25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1-4

May 22, 2006

ARCMASTER LM 200

1.03 Precautions de Securite en Soudage à l’Arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.04 Dangers Relatifs au Soudage à l’Arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen

de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

May 22, 2006

1-5

ARCMASTER LM 200

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

1-6

May 22, 2006

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

ARCMASTER LM 200

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

May 22, 2006

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1-7

ARCMASTER LM 200

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

1.05 Principales Normes de Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

1-8

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

May 22, 2006

SYMBOL LEGEND

SEC

Amperage

Voltage

Hertz (frequency)

Seconds

Percent

DC (Direct Current)

AC (Alternating Current)

STICK (Shielded Metal Arc SMAW)

Pulse Current Function

Spot Time (GT A W)

Remote Control (Panel/Remote)

Remote Function

Arc Control (SMAW)

Gas Post-Flow

Standard Function

Slope Function

Slope W/Repeat Function

Spot Function

Impulse Starting (High Frequency GTAW)

Touch Start (Lift Start TIG circuit GTAW)

VRD

Gas Pre-Flow

Voltage Reduction Device Circuit

Negative

Positive

Gas Input

Gas Output

2 INTRODUCTION AND DESCRI PTION

Description

INTRODUCTION AND DESCRIPTION

The Thermal Arc™ LM- 200 is a single & thre e-phase DC arc weld ing power source with Cons tant Current (CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage, lift arc starter for use with Gas Tungsten Arc Welding (GTAW), Arc Control and Hot Start for Shielded Metal Arc Welding (SMAW), I nductance Con trol for Gas Metal Arc We lding (GM AW) processes . The power s ource is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.

OCV

18V

(V)

160A

200A 220A(A)

STICK Process

OCV

10V

(V)

200A25A (A)

LIFT-TIG Process

Figure 2-1: Model LM-200 volt-ampere curve

OCV

36V 10V

(V)

200A 220A(A)

MIG Process

NOTE

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the LM-200-power supply.

Input

Power

Main

Circuit

Switch

Filter

Down

Transformers

AC115V,AC24V

(T3)

Over Current Protect

14PIN

Receptacle

(CON1) 19PIN

Receptacle

(CON2)

Input

Diode

Capacitor

DC Power Primary Voltage Sensor

To each control circuit

+/-15VDC +18VDC +24VDC +5VDC

IGBT

Inverter

Themal

Detector

Trouble

Sensing

Circuit

Drive

Circuit

Main

Transformers

(T1)

Thermal

Sensor

Circuit

Primary

Circuit

Sensor

Current

Adjustment

Circuit

Figure2-2: LM-200 Model functional block diagram

Output

Diodes

Themal

Detector

Stick Mode

VRD

Sensing

Circuit

Sequence

Control

Reference

Adjustment &

Mode select Switch

Panel Circuit Boad

Inductor

Output

Lift Tig Mode

Output Short

Sensing

Circuit

Fan Control

14PIN-19PIN Select Switch

(S3)

Circuit

Hall Current Transformer

(HCT1)

Fan

2 – 1

LM-200 2 INTRODUCTION AND DESCRIPT ION

Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case. Use handcart or si milar dev ice of ad equate ca pac-

ity. If using a fork lift vehicle, pl ace and secure un it on

a proper skid before transporting.

4.2 Location

Be sure to locate the welder according to the following guidelines:

 In areas, free from moisture and dust.  Ambient temperature between 0 degrees C to

40 degrees C.

 In areas, free from oil, steam and corrosive

gases.

 In areas, no t subjected to abnormal vibration or

shock.

 In areas, not exposed to direct sunlight or rain.  Place at a distan ce of 12" (304.79mm) or more

from walls or similar that could restrict natural airflow for cooling.

WARNING

Thermal Arc advises that this equipment be electrically connected by a qualified electrician.

Electrical Input Connections

Installation Recommendations

4.1 Environment

The LM-200 is designed for us e in hazar do us envi ronments.

Examples of env ironments with increa sed hazardous environments are -

a. In locations in which freedom of movement is

restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;

b. In locations which are fully or partially limited

by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or

c. In wet or damp hot locations where humidity or

perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with ha zardou s envi ronme nts do no t include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect

input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

5.1 Electrical Input Requirements

Operate the welding power source from a single or three-phase 50/60 Hz, AC power su pply. The input voltage must match one of the el ectrical in put voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.

The line disconnect switch provides a safe and convenient mean s to co mpl ete ly r em ov e a ll e lec trical power from the welding power supply whenever necessary to inspect or service the unit.

2 – 2

LM-200 2 INTRODUCTION AND DESCRIPTION

NOTE

These units are equipped with a three-conductor with earth power cable that is connected at the welding power source end for single or three-phase electrical input power.

Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal.

Do not connect the grou nd (GREEN) conductor to an input line terminal.

Refer to Figure 2-3 and:

1. Connect end of ground (GREE N) cond uctor to a suitable ground. Use a grou nding met hod that complies with all appl icab le elect rical co des.

2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch.

3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.

NOTE

For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors. Insolate the RED Conductor, it is not used for Single-phase operation.

Input Voltage Fuse Size

208 VAC 60 Amps 230 VAC 50 Amps 460 VAC 30 Amps

Table 2-1: Electrical Input Connections

NOTE

Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

5.2 Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is turned on, the inrush circu it provides a pre-charging of the input capacitors. SCR's in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

NOTE

Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.

The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment:

Minimum

Primary

Model

LM-200

Table2-2: Primary Current Circuit sizes to achieve max-

Supply

Lead Size

8/4 AWG minimum

(Factory

Fitted)

8/3 AWG minimum

imum current

Primary

Current Circuit Size (Vin/Amps)

208/39 230/35 - 460/18 - 208/29 -

3φ

230/27 - 460/14 - 208/45 - 230/41 - 460/21 - 208/51 230/44 - 208/37 -

1φ

230/33 - 208/57 - 230/51 - -

Current & Duty Cycle

MIG TIG STICK

200A@

60%

200A@

60%

200A@

60%

200A@

60%

200A@

60%

Figure 2-3: Electrical input connections

2 – 3

Specifications

LM-200 2 INTRODUCTION AND DESCRIPT ION

Duty Cycle

Parameter LM-200

Rated Output

Amperes Volts Duty Cycle

TIG

Duty Cycle

Output Current Range

Output Voltag e Range

Open Circuit Voltage 65V Dimensions

Width Height Length Weight

Output@Rated Load

Output Amperes Output Volts Duty Cycle KVA KW

Output@No Load

KVA KW

Input Volts Single Phase

208V 230V

Input Volts Three Phase

208V 230V 460V

STICK

MIG TIG

STICK MIG 5–28V

200A / 18V@60%

150A / 16V@100%

200A / 28V@60%

150A / 26V@100%

200A / 24V@60%

150A / 22V@100%

16.89” (420mm)

17.72” (450mm)

Amperage Dr aw

@Rated Load

200

60%

5–200A

8.27” (210mm)

59.5lb. 27.0kg

200A

28V

60%

9.3

7.0

0.5

0.13

57 51

45 41 21

The duty cycle of a welding power source is the percentage of a ten (10) minut e period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decreas e, the duty cycle in crease s. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.

WARNING

Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION

Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

No Load

2.4

1.8

1.4

1.1

0.7

Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or an y product without prior notice. Such updates o r chang es do no t entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

2 – 4

3 OPERATOR CONTROLS

LM-200 Controls

OPERATOR CONTROLS

1. Control Knob This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob in previews the actual w elding voltage while welding.

2. Remote Control Socket The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Socket

A 24VAC auxiliary high side.

Input to energize solid state contactor (Contact

closure between pin A and pin B). 5k ohm (maximum) connection to 5k ohm

remote control potentiometer. Zero ohm (minimum) connection to 5k ohm

remote control potentiometer. Wiper arm connection to 5k ohm remote contro l

potentiometer.

F Current feedback Ifb = 100Amps/Volt

24/115 VAC circuit common, also connected to

chassis.

H Voltage Feedback Vfb = 10 Arc Volts/Volt

I 115 VAC auxiliary high side.

115 VAC input to energize solid state contactor

(Contact closure between pin I and pin J).

K Chassis ground.

L,M,N Not used

Function

Figure3-1: LM-200 Power Source

3. Positive Terminal Welding current flows from the Power Sour ce via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

4. Negative Terminal Welding current flows from the Power Sour ce via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal and /or melting of the housing (case).

3 – 1

LM-200 3 OPERATOR CONTROLS

5. Remote Control Socket The 19 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Socket

A Contactor circuit (+15 Volts).

Contactor circuit in , (c los ure be tw een pi n A and

Pin B will energize output.). Scaled output vo ltage si gnal: Vfb = 10 Arc Volts/

Volt D 24 VAC auxiliary power high side. E 115 VAC auxiliary power high side. G Chassis ground. H Remote control maximum.

J Remote control wiper (0 - 10 Volts).

K Remote Control minimum.

J Remote control wiper (0 - 10 Volts).

L Control circuit common.

M Arc Establish = +12 Volts N Control C ircuit common.

P 24 VAC auxiliary power high side.

R 24/115 VAC neutral.

SN/C TN/C

U Scaled output signal: Ifb = 100 Amps/Volt

VN/C

Function

the Smart Logic will inhibit the welding power source from turning on and a warning indication will be displayed

WARNING

Do not alter the position of the Voltage Input Select Switch when the ON/OFF Switch is in the ON position and the unit is powered up.

9. 14/19 Pin Remote Control Select Switch User selectable switc h. Position this switch for the remote control device socket to be utilized. The unselected Remote Control Socket is disabled at this time and cannot be utilized. Do not alter the position of this switch while one of the Remote Control Sockets is being utilized.

10. 24VAC Remote Device C/B Push to reset. Controls the 24VAC power source for the wire feeders controlled through the Remote Control Sockets.

11. 115VAC Remote Device C/B Push to reset. Controls the 115VAC power source for the wire feeders controlled through the Remote Control Sockets.

Weld4 Parameter Descriptions for LM-200

6. ON/OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components maybe at 500V potential with respect to earth.

7. Input Cable The input cable connects the Primary supply voltage to the equipment.

8. Voltage Input Select Switch (Smart Logic Switch) User selectable switch. A manual slide switch selects the proper input voltage range. If this slide switch is not set to the position that matches the input line voltage,

Figure3-2: LM-200 Front Panel with Parameter Description

3 – 2

LM-200 3 OPERATOR CONTROLS

Parameter Description

This parameter provides a suitable short circuit current in STICK welding to improv e electrode sticking

ARC CONTROL

HOT START

DC (A)

DC (V)

Contactor ON/OFF

and arc stability. This parameter operates in STICK

weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the (WELD) current.

Weld Current (Amperage)- when lit parameter knob sets the STICK and TIG WELD current.

Weld Voltage (Volt) - when lit parameter knob sets the MIG voltage.

Contactor operation in Stick Mode.

Selects in operation Panel board or Remote.

Weld Process selection for the LM-200

Weld Mode

Weld

Parameter WELD (V) INDUCTA

NCE HOT

START

WELD (A)

ARC CONTROL

Table3-2: Weld Process selection verses Weld Mode

STICK MIG

898

988

989

988

Weld Parameter Descrip-

LIFT

TIG

Weld voltage MIG Mode.

Inductance control in MIG Mode.

Start current in amps is added to the WELD (A).

WELD (A) current for STICK or LIFT TIG.

Adjusts percentage increase in welding current and is proportional to arc length (arc voltage).

Description

Operation

PANEL /REMOVE

This parameter, similar to the ARC CONTROL in STICK mode, allows

INDUCTANCE

SAVE LOAD

SAUVEGARDER CHARGER

Table3-1: Weld Parameter Descriptions for LM-200

for the adjustment of the dynamic property of the arc. As the inductance is increased the output voltage may need to be adjusted to achieve the desired weld characteristics.

The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the LM-200 memory.

tions

4.1 WELD (V)

This parameter sets the MIG weld arc voltage in

MIG mode.

4.2 INDUCTANCE

This parameter sets the INDUCTANCE when MIG

welding. It controls the dynamic properties of the

arc in dip transfer welding mode. When this param-

eter is set to 0%, i e minimum inductance, the arc

has a fast response with a resultin g crisp ar c nois e

and coarse spatter. W hen this param eter is set to

100%, ie maximum induct ance, the arc has a slow

response with a resulting soft arc and fine spatter.

NOTE

As the INDUCTANCE is increased, the WELD (V)

may need to be adjusted to achieve the desired

weld characteristic.

3 – 3

LM-200 3 OPERATOR CONTROLS

4.3 HOT START

This parameter operates in STICK mode and improves the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD current.

e.g. HOT START cu rrent = 150 amps when W eld Current = 100 amps & HOT START = 50A

4.4 WELD (A)

This parameter sets the STICK & Lift TIG weld current.

4.5 ARC CONTROL

This parameter operates in ST ICK mode only and is used to adjust percentage increase in welding current and is prop ortional to arc length (arc vol tage). This control provides an adjustable amount of arc control (or dig). This feature can be particularly beneficial in providing the operator with the ability to compensate for variability in joint fit up in ce rtain situations with particular electrodes, eg cellulose and hydrogen control led electrodes . In all welding processes, the amount of penetration obtained is dependent on the welding current; ie the greater the penetration, the greater the current.

Arc Force

Position

Minimum

(0)

Medium

(20%)

Maximum

(100%)

Current Increase when Arc Voltage is less than 18V

32A

160A

Effect on Welding Performance

Soft arc, Low spatter, Low penetration

Normal arc, Improv e d fusion characteristi cs, Normal penetration

Hard arc, Deep penetration

i) Root runs

During root runs the weld pool forms a "keyhole" shape. If too much weld current is used, the hole blows out and the wel d col lap se s. If too l ittle weld current is used, the hole closes up and penetration is lost. The size of the hole also determines the arc length; ie as the hole gets bigger, the arc gets longer.

If arc force is used, the increase in the arc length causes the weld current to dec rease unti l the hole starts to c lose up but if the hole clo ses up to much then the arc length dec re ases whic h causes the weld current to increase. Too little or too much arc force makes this process unstable. The operator must adjust the arc force until a happy medium is reached.

ii) Vertical up welding

When welding v ertical up with arc force on, the operator can control the amount of current by changing arc len gth, ie voltage. Weld me tal is deposited by "digging" the electrode into the side of the base metal joint and then increasing the arc length with a fl ic k ing motion, to allow the weld pool to freeze, before digging the electrode into the other side of the base metal joint.

Without arc force, increasing the arc length does not decrease the weld current sufficiently and the operator h as to manually d ecrease the cu rrent via a remote current control to freeze the weld pool. Thi s welding current reduction a lso reduces the penetration.

The arc force allows the wel d pool to freeze duri ng

the "flick" phase w ithout decreasin g the amount of

weld current availabl e during the "dig" phase thus

maximizing penetration.

Table3-3: Weld Parameter Descriptions

In general, having the ARC CONTROL set at 100% (maximum) allows greater penetration control to be achieved. With the ARC CONTROL set at 0% (minimum) the Power Source has a constant current characteristic . In other words, varying the ar c length does not signifi cantly effect the we lding cur rent. When the ARC CONTROL set to 100%, it is possible to control th e welding current by varying the arc length. This is very useful for controlling penetration on root runs and side wall wash on vertical up fillet welds.

3 – 4

LM-200 3 OPERATOR CONTROLS

4.6 Weld Parameters

Weld Mode

Weld

Parameter

WELD (V) MIG

INDUCTA NCE

HOT START

WELD (A) TIG or STICK

ARC CONTROL

Parameter

Range

10.0 to

28.0V DC

0 to 100%

0 to 70A 20A 1A

1 to 200A

0 to 100%

Factory

Increme

Setting

17.0V 0.1V

10% 1%

Table3-4: Weld Parameters

ntal Unit

80A 1A

STICK

898

988

989

988

4.7 Power Source Features

Feature Description

New Digital Control

Touch Panel Switches

Front Control Cover

Digital Meter Volt & Ammeter

Intelligent Fan Control

ON/OFF switch

Voltage Reduction Device (VRD)

 All welding parameters are adjust-

able

 Touch switches eliminate mechani-

cal damage

 Protects front panel controls

 Displays selected weld parameter

value

 Displays average weld current

when welding

 Displays average weld current for

20 seconds after weld has been completed

 A selected weld parameter value

can be adjusted at any time even while welding

 The intelligent cooling system is

designed to reduce dust and foreign material build-up, while providing optimum cooling.

 Fan speed reduces approximately

30 seconds afte r machin e is turned on

 Fan speed increase s wh en int erna l

components reaches operating temperature

 Mains ON/OFF switch located on

rear panel

 VRD fully complies to IEC 60974-1  VRD light is ON and operational

when in STICK mode.

MIG

LIFT

TIG

Feature Description

Control Knob  For the selected weld parameter,

rotating the knob clockwise increases the parameter

 Rotating the knob counter clock-

wise decre ases the parameter

 A selected weld parameter value

can be adjusted at any time even while welding

 Pushing the knob in sets the

selected parameter then displays the next parameter

Self Diagnosis Using Error Codes

Save/Load function

 An error code is displayed on the

Digital Meter when a problem occurs with Mains supply voltage or internal component problems.

 A total number of 5 programs can

be saved into the LM-200 memory

SA VE the Curren t W el d P arame ters into Memory

 Press the SAVE button  Select a memory location by rotat-

ing the control knob, 1 to 5 is displayed on the meter

 After selecting the desired memory

location (ie. 1 to 5), press the parameter button and the machine give a beep to confirm the weld parameters from the control panel are saved.

LOAD (retrieve) a Program to Control Panel

 Press the LOAD button  Select a memory location by rotat-

ing the control knob, 1 to 5 is dis-

played on the meter After selecting the desired memory location (ie. 1 to 5), press the parameter button and the machine give a beep to confirm the weld parameters are loaded onto the control panel

3 – 5

LM-200 3 OPERATOR CONTROLS

PAGE LEFT INTENTIONALLY BLANK

3 – 6

4 SEQUENCE OF OPERATION

NOTE: Parameter Buttons are used to select the parameters to be set. The LED's s how which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the fro nt of the manual for Symbol descriptions.

Figure 4-1: LM-200 Front Panel

1. Contactor function - Pressing this buttons enables Contactor functions.

2. Remote functions - Pressing this buttons enables remote current functions.

3. Digital LED displays - Welding amperage, Voltage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen.

4. Save/Load Buttons -By using the Save & Load buttons the operator can easily save up to 5 welding parameter programs.

5. Control knob - Allows the operator to adjust the output amperage/voltage within the entire range of the power source, also used to set each parameter value.

6. Process Button - This button selects between STICK, Lift TIG, and MIG modes. MIG modes include MS for mild steel and SS for stainless steel.

7. Parameter Button. - This button select between HOT START, WELD CURRENT, and ARC CONTROL while in STICK and Lift TIG modes and selects between WELD VOLTAGE and INDUCTANCE CONTROL while in MIG mode. This button is also used in conjunction with the Save/Load buttons to save and load welding programs.

SEQUENCE OF OPERATION

Stick Welding

 Connect work lead to negative terminal.  Connect electrode lead to positive terminal.  Switch machine on.  Set weld current.  Set Contactor.  Connect remote control device if required.

Use the Scroll Buttons to m ove to th e pa ra met er to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

 Set HOT START .  Set ARC CONTROL.  Set WELD current .

Commence welding.

LIFT TIG Welding

 Connect work lead to positive terminal.  Connect TIG torch to negative terminal.  Switch machine on.  Set weld current.  Connect remote control device if required.

Use the Scroll Buttons to m ove to th e pa ra met er to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

Commence welding.

MIG Welding

 Connect work lead to negative terminal.  Connect electrode lead to positive terminal.  Switch machine on.  Set weld voltage.  Set Inductance.  Connect Wire feeder.  Set wire feed speed (IPM).

Use the Scroll Buttons to m ove to th e pa ra met er to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter. Commence welding.

4 – 1

5 ROUTINE MAINTENANCE

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

ROUTINE MAINTENANCE

WARNING

Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, op en the enclo sure ( pleas e refer to the 'Opening the Enclosure' section in the LM200 Service Manual P/N 430429-519) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

5 – 1

6 B ASIC TR OUBLE SHOOTING

BASIC TROUBLE SHOOTING

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source m ust be returned to an Accredited Thermal Arc Service Agent for repair.

The basic level of troubleshooting is that which can be performed without spe cial equipment or knowledge.

Solving MIG Problems Beyond the Welding Terminals

The general approach to fix Gas Metal Arc Welding (GMAW) problems is to star t at the wire s pool then work through to the M IG to rch. There are two main areas where problems occur with GMAW:

1.1 Porosity

When there is a gas problem the result is usual ly porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of es caping during solidification of the molten metal.

Contaminants range from no gas around the wel ding arc to dirt on the work pi ece surface. Porosity can be reduced by checking the following points:

1. Gas cylinder contents and flow meter. ...

Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 25 cubic feet per hour.

2. Gas leaks. ...

Check for gas leaks betwe en the regulator/ cylinder connection an d in the gas hose to the Wire Feeder3. Interna l gas hose in the Wire Feeder.

3. Internal gas hose in the Wire Feeder. ...

Ensure the hose from the solenoid valve to the MIG torch adapter has not fractured and that it is connected to the MIG torch adapter.

4. Welding in a windy environment. ...

Shield the weld area from the wind or increase the gas flow.

Welding dirty, oily, painted, oxidized or greasy plate.

...

Clean contaminates off the plate.

6. Distance between t he MIG torch nozz le and the

work piece.

...

Keep the distance between the MIG torch nozzle and the work piece to a minimum.

7. Maintain the MIG torch in good working order. ...

Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle. Do not restrict gas flow by allowing spatter to build up inside the MIG torch nozzle. Check that the MIG torch O-rings are not damaged.

WARNING

Disengage the drive roll when testing for gas flow by ear.

1.2 Inconsistent Wire Feed

Checking the following points can reduce wirefeeding problems:

1. Wire spo ol brake is too tight . ...

Feed roller driven by motor in the cabinet will slip.

2. Wire spool brake is too loose. ...

Wire spool can unwind and tangle.

3. Worn or incorrect feed roller size. ...

Use 'U' groove drive feed roller matched to the aluminium wire size you are welding.

Use 'V' groove drive feed rolle r matched to the steel wire size you are welding.

Use 'knurled V' groove drive feed roller matched to the flux cored wire size you are welding.

4. Misalignment of inlet/outlet guides. ...

Wire will rub against the m isaligned guides and reduces wire feedability.

6 – 1

LM-200 6 BASIC TROUBLE SHOOTING

5. Liner blocked with wire debris. ...

Wire debris is produced by the wire pass ing through the feed roller, if excessive pressure is applied to the pressure roller adjuster.

Wire debris can also be produced by the wire passing through an incorr ect feed ro ller

7. Poor work lead contact to work piece.

groove shape or size. Wire debris is fed into the liner where it

accumulates thus reducing wire feedability.

6. Incorrect or worn contact tip. ...

The contact tip tran sfers the w eld current to

8. Bent liner.

the electrode wire. If the hole in the contac t tip is to large th en arcing may occur inside the contact tip resulti ng i n the ele ctro de wi re jamming in the contact tip.

MIG Welding Problems

Description Possible Cause Remedy

1 Undercut. A Welding arc voltage too high.

B Incorrect torch angle. C Excessive heat input.

2 Lack of penetration. A Welding current too low.

B Joint preparation too narrow or gap too

tight.

C Shielding gas incorrect.

3 Lack of fusion. 4 Excessiv e spa tter. A Voltage too hig h.

5 Irregular weld shape. A Incorrect voltage and current settings.

Voltage too low. Increase WELD (V) control.

B V o lta ge too low .

Convex , voltage too low. Concave,

voltage too high. B Wire is wandering. C Incorrect shielding gas. D Insufficient or excessiv e hea t input.

When using soft ele ctrode wi re such as aluminium it may become ja mmed in the contact tip due to expansion of the wire when heated. A contact tip designed for s oft electrode wires should be used.

...

If the work lead has a poor electr ic al co ntact to the work pie ce then the c onnection point will heat up and result in a reduction of power at the arc.

...

This will cause fricti on b etwee n the wire and the liner thus reducing wire feedability

A Reduce WELD (V) contr ol or increase th e

wire feed speed. B Adjust angle. C Increase the torch travel speed and/or

reduce welding current by reducing the

WELD (V) control or reducing the wire

feed speed. A Increase welding current by increasing

wire feed speed and increasing WELD

(V) control. B Increase joint angle or gap. C Change to a gas which gives higher

penetration.

A Lower the voltage by redu ci ng the WELD

(V) control or increase wirespeed control. B Raise the voltage by increasing the

WELD (V) control or reduce wirespeed

control. A Adjust voltage and current by adjusting

the WELD (V) control and the wirespeed

control. B Replace contact tip. C Check shielding gas. D Adjust the wirespeed control or the

voltage selection switches.

6 – 2

LM-200 6 BASIC TROUBLE SHOOTING

Description Possible Cause Remedy

6 Weld cracking. A Weld beads too small.

B Weld penetration narrow and deep. C Excessive weld stresses. D Excessive voltage. E Cooling rate too fast.

7 Cold weld puddle. A Faulty rectifier unit.

B Loose welding cab l e con nec tio n. C Low Primary Voltage.

8 Arc does not have a

crisp sound, that short arc exhibits, when the wirefeed speed and voltage are adjusted correctly.

The MIG torch has been connected to the wrong voltage polarity on the front panel.

A Decrease travel speed. B Reduce current an d v oltage and increas e

MIG torch travel speed or select a lower

penetration shielding gas. C Increase weld metal strength or revise

design. D Decrease voltage by reducing the WELD

(V) control. E Slow the cooling rate by preheating part

to be welded or cool slowly. A Have an Accredited Thermal Arc Service

Agent to test then replace the faulty

component. B Check all weldi ng ca b l e con nec tio ns. C Contact supply authority. Connect the MIG torch to the positive (+)

welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description Possible Cause Remedy

1 Excessive beard bui ld-

up or poor penetration or poor fusion at edges of weld.

2 Weld bead too wide

and flat or undercut at edges of weld or excessive burn thr oug h.

3 Weld bead too small or

insufficient penetr at ion or ripples in bead are widely spaced apart.

4 Weld bead too wide or

excessiv e bead build up or excessive penetration in butt joint.

5 Uneven leg length in

fillet joint.

6 Electrode melts when

arc is struck.

Welding current is too low. Increase weld current and/or faulty joint

preparation.

Welding current is too high. Decrease weld current.

Travel speed too fast. Reduce travel speed.

Travel speed too slow. Increase travel speed.

Wrong placement of filler rod. Re-position filler rod.

A Electrode is connected to the '+' terminal. A Connect the electrode to the '(' terminal.

6 – 3

Description Possible Cause Remedy

7 Dirty weld pool. A Electrode contaminated through contact

with work piece or filler rod material.

B Gas contaminated with air.

8 Electrode melts or

oxidizes when an arc is struck.

9 Poor weld finish.

10 Arc flutters during TIG

welding.

11 Welding arc can not be

established.

12 Arc start is not smooth. A Tungsten electrode is too large for the

A No gas flowing to welding region. B Torch is clogged with dust. C Gas hose is cut. D Gas passage contains impurities. E Gas regulator turned off. F Torch valve is turned off. G The electrode is too s ma ll for the welding

current.

Inadequate shielding gas. Increase gas flow or check gas line for gas

A Tungsten electrode is too large for the

welding current.

B Absence of oxides in the weld pool.

A Work clamp is not connected to the work

piece or the work/torch leads are not

connected to the right welding terminals. B Torch lead is disconnected. C Gas flow incorrectly set, cylinder empty

or the torch val ve i s off.

welding current. B The wrong electro de is being used for the

welding job C Gas flow rate is too high. D Incorrect shielding gas is being used. E Poor work clamp connection to work

piece.

LM-200 6 BASIC TROUBLE SHOOTING

A Clean the electrode by grinding off the

contaminates.

B Check gas lines for cuts and loose fitting

or change gas cylinder.

A Check the gas lines for kinks or breaks

and gas cylinder contents. B Clean torch@C Replace gas hose. D Disconnect gas hose from torch then

raise gas pressure and blow out

impurities. E Turn on. F Turn on. G Increase electrode diameter or reduce

the welding current.

flow problems. A Select the right size electrode. Refer to

Basic TIG Welding guide. B Refer Basic TIG Welding Guide for ways

to reduce arc flutter. A Connect the work clamp to the work

piece or connect the work/torch leads to

the right welding terminals. B Connect it to the '(' terminal. C Select the right flow rate, change

cylinders or turn torch valve on. A Select the right size electrode. Refer to

Basic TIG Welding Guide. B Select the right electrode type. Refer to

Basic TIG Welding Guide. C Select the correct rate f o r the w el din g jo b.

Refer to Basic TIG Welding Guide. D Select the right shielding gas. Refer to

Basic TIG Welding Guide. E Improve co nne cti on to w ork piece .

6 – 4

LM-200 6 BASIC TROUBLE SHOOTING

Stick Welding Problems

Description Possible Cause Remedy

1 Gas pock ets or v oid s in

weld metal (Porosity).

2 Crack occ urring in weld

metal soon after solidification commences.

3 A gap is left by failure

of the weld metal to fill the root of the weld.

A Electrodes are damp. B Welding current is too high. C Surface impurities such as oil, grease,

paint, etc. A Rigidity of joint. B Insufficient throat thic knes s. C Cooling rate is too high.

A Welding current is too low. B Electrode too large for joint. C Insufficient gap. D Incorrect sequence.

A Dry electrodes before use. B Reduce wel ding current. C Clea n joint before welding.

A Redesign to relieve weld joint of severe

stresses or use crack resistance electrodes.

B Travel slightly slower to allow greater

build up in throat.

C Preheat plate and cool slowly. A Increas e welding current.

B Use smaller diameter electrode. C Allow wider gap. D Use correct build-up sequence.

Incorrect sequence

Insufficient gap

Description Possible Cause Remedy

4 P ortions of the weld run

do not fuse to the surface of the metal or edge of the joint.

Figure6-1: Example of insuffic ie nt gap or inco rre ct sequ en ce

A Small electrodes used on heavy cold

plate. B Welding current is too low. C Wrong electrode angle. D Travel speed of electrode is too high. E Scale or dirt on joint surface.

A Use larger electrodes and pre-heat the

plate. B Increas e welding current. C Adjust angle so the welding arc is

directed more into the base metal. D Reduce travel speed of electrode. E Clean surface before welding.

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Lack of inter-run Fusion

Lack of side fusion, scale dirt, small electrode, amperage too low

Lack of Root Fusion

Figure6-2: Example of lack of fusion

6 – 5

Example of lack o f fusion

Description Possible Cause Remedy

5 Non-metall ic particles

are trapped in the weld metal (slag inclusion).

A Non-metallic particles may be trapped in

undercut from previous run. B Joint preparation too restricted. C Irregular deposits allow slag to be

trapped. D Lack of penetration with slag trapped

beneath weld bead. E Rust or mill scale is preventing full fusion. F Wrong electrode for position in which

welding is do ne.

LM-200 6 BASIC TROUBLE SHOOTING

A If bad undercut is present, clean slag out

and cover with a run from a smaller diameter electrode.

B Allow for adequate penetration and room

for cleaning out the slag. C If very bad, chip or grind out irre gul arities. D Use smaller electrode with sufficient

current to give adequate p enetrati on. Use

suitable tools to remove all slag from

corners. E Clean joint before welding. F Use electrodes designed for position in

which welding is done, oth erwis e pr ope r

control of slag is difficult.

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

Figure6-3: Examples of slag inclusion

6 – 6

LM-200 6 BASIC TROUBLE SHOOTING

Power Source Problems

Description Possible Cause Remedy

1 The welding arc cannot

be established.

2 Maximum output

welding current can not be achieved with nominal Mains supply voltage.

3 Welding current

reduces when welding.

4 No gas flow when the

torch trigger switch is depressed.

5 Gas flow won't shut off. A Weld Mode (STD, SLOPE, REPEAT or

6 The TIG electrode has

been contaminate d due to the gas flow s hutt ing off before the programmed POSTFLOW time has el apse.

A The Primary supply voltag e has n ot been

switched ON.

B The Welding Power Source switch is

switched OFF. C Loose connections internally. Defective control circuit. Have an Accredited Thermal Arc Service

Poor work lead connection to the work piece. Ensure that the work lead has a positive

A Gas hose is cut. B Gas passage contains impurities. C Gas regulator turned off. D Torch trigger switch lead is disconnected

or switch/cable is faulty.

SPOT) w as changed bef ore POST-FLOW

gas time had finished. B Gas valve is faulty. C Gas valve jammed open. D POST-FLOW control is set to 60 sec.

The Weld Process Mo de (STICK, HF TIG or LIFT TIG) was c hange d bef o re POST-FLOW gas time had finished.

A Switch ON the Primary supply voltage. B Switch ON the Welding Power Source. C Have an Accredited Thermal Arc Service

Agent repair the connection.

Agent inspect then repair the welder.

electrical connection to the work piece.

A Replace gas hose. B Disconnect gas hose from the rear of

Power Source then raise gas pressure

and blow out impurities. C Turn gas regulator on. D Reconnect lead or repair faulty switch/

cable. A Strike an arc to complete the weld cycle.

OR Switch machine off then on to reset

solenoid valve sequence. B Have an Accredited Thermal Arc Service

Agent replace gas valve. C Have an Accredited Thermal Arc Service

Agent repair or replace gas valve. D Reduce POST-FLOW time. Do not change Weld Process Mode before

the POST-FLOW gas time had finished.

6 – 7

LM-200 6 BASIC TROUBLE SHOOTING

PAGE LEFT INTENTIONALLY BLANK

6 – 8

7 VOLTAGE REDUCTION DEVICE (VRD)

VRD Specification

Description

VRD Open Circuit Voltage

VRD Resistanc.

VRD Turn OFF Time

VRD Maintenance

Routine inspection and testing (power source). An inspection of the power source, an insulation

resistance test and an earth resistance test shall be carried out.

a. For transportable equipment, at least once

every 3 months; an.

b. For fixed equipment, at least once every 12

months.

The owners of the equipme nt shall keep a suitable record of the periodic tests.

Pro-Plu.

LM-200

15.3 to

19.8V

148 to 193

ohms

0.2 to 0.3 seconds

Open circuit voltage between welding terminals.

The required resistance between welding terminals to turn ON the welding power.

The time taken to turn OFF the welding power once the welding current has stopped.

Notes

Voltage Reduction Device (VRD)

NOTE

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

Switching VRD On/Off

Switch the machine Off.

a. Remove the clear plastic cover from the control

panel (see Figure 7-1).

 Lift up the cover so it rests on the top of the

unit.

 Place a small flat bladed screw driver between

the cover hinge on the front panel.

 Gently lift the cover hinge out of the front cover

mounting hole.

 Remove the control's clear plastic cover.

Figure7-1: VRD ON/OFF Step A

b. Remove four mounting screws from the control

panel (see Figure 7-2).

c. Access the VRD control by gently prying back

the front panel controls to reveal the VRD on/ off potentiomete r (see Figure 7-2).

In addition to the above tests and specifically in relation to the VRD fitted to this mac hine, the following periodic test s should also be conduc ted by an accredited Thermal Arc service agent.

Description IEC 60974-1 Requirements

VRD Open Circuit Voltage

VRD Turn ON Resistanc

VRD Turn OFF Time

If this equipment is used in a hazardo us locati on or environments with a high ris k of electrocution then the above tests should be carried out prior to entering this location.

Less than 20V; at Vin=230V or 460V

Less than 200 ohms

Less than 0.3 seconds

CAUTION

Do not pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers.

Figure7-2: VRD ON/OFF Step B,C

7 – 1

d. Turning the VRD ON/OFF (see Figure 7-3).

 To turn VRD ON: rote the trim potentiometer

(VR1) on the display PCB fully clockwise. When VRD is turned ON check that it operates as per VRD Specifications on page 5-13.

 To turn VRD OFF: rote the tri m potentiometer

(VR1) on the display PCB fully counter clockwise.

WARNING

The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position.

LM-200 7 Voltage Reduction Device (VRD)

Figure7-3: VRD ON/OFF Step D

7 – 2

8 P O WER SOUR CE ERR OR CODES

Power Sourc e Error Codes

Description Possible Cause Remedy Remarks

1 E01 error code displayed

T emperature s ensor TH1 (protects IGBTs) is greater than 80°C for about 1 second.

2 E02 error code displayed

T emperature s ensor TH2 (protects secondary diodes) is greater than 80°C for about 1 secon d.

3 E03 error code displayed

Primary (input) current too high.

4 E11 error code displayed

Over Primary supply (input) volta ge at primary capacitors is exceeded for one second.

A The Welding Power

Source's duty cycle has

been exceede d. B Fan ceases to oper ate. C Air flow is restricted by

vents being blocked.

A The Welding Power

Source's duty cycle has

been exceede d. B Fan ceases to oper ate. C Air flow is restricted by

vents being blocked.

A Primary current is too

high because weldi ng arc

is too long. B Mains supply voltage is

more than 10% below

nominal voltag.

Primary supply voltage is greater than the nominal voltage plus 10%.

A Let Power Source cool

down then keep within its duty cycle.

B Have an Accredited

Thermal Arc Service Agent investigat e.

C Unblock vents then let

Power Source cool down.

A Let Power Source cool

down then keep within its duty cycle.

B Have an Accredited

Thermal Arc Service Agent investigat e.

C Unblock vents then let

Power Source cool down.

A Reduce length of wel din g

arc.

B Have an Accredited

Thermal Arc Service Agent or a qualified electrician check for low Mains voltage.

Have an Ac cre di ted T hermal Arc Service Agent or a qualified electrician che ck the Primary voltage.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E01 resets when TH1 decreases to 70°C for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E02 resets when TH1 decreases to 70°C for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E03 error.

Weld current ceases. Buzzer sounds constantly. Error code E11 automatically will reset when the voltage reduces.

5 E14 error code displayed

Under mains supply (input) voltage warning primary capacitors is reduced for one second.

6 E12 error code displayed

Under mains supply (input) voltage primary capacitors is reduce d for one second.

7 E81 error code displayed

Wrong Primary supply (input) voltage connected.

8 E82 error code displayed

Link switch plug not connected.

Mains supply voltage is less than the nominal operating voltage less 10%.

Mains supply voltage is down to a dangerously low level.

When 3 phase machine is first turned on with the w rong Primary supply (input) voltage connected.

Link switch plug not connected.

Have an Ac cre di ted T hermal Arc Service Agent or a qualified electrician che ck the Mains voltage.

Have an Ac cre di ted T hermal Arc Service Agent check connector plug on inpu t PCB.

8 – 1

Weld current available. Buzzer sounds intermittently. Error code E14 automatically will reset when the voltage increases.

Weld current ceases. Buzzer sounds constantly. Error code E12 automatically will reset when the voltage increases.

No weld current is available. Buzzer sounds constantly. Switch machine off.

LM-200 8 Power Source Error Codes

Description Possible Cause Remedy Remarks

9 E83 error code displayed

CPU checks mains supply (inp ut) voltage when the on/off swit ch on rear panel of mac hine is turned ON.

10 E93 error code displa yed

Memory chip (EEPROM) on control PCB can not read/write weld parameter.

11 E94 error code displa yed

T emperature s ensor TH1 for IGBTs or sensor TH2 for secon dary diodes are open circuit.

12 E99 error code displa yed

Mains supply (input) voltage has been turned off but control circuit has power from the primary capacitors.

The Primary supply (input ) voltage fluctuates and is not stable.

Memory chip (EEPROM) error.

The Welding Powe r Source's temperature sensors have malfunctioned.

A Main on/off switch on

machine has bee n turned

off. B Mains supply (input)

voltage has been turned

off.

Have an Ac cre di ted T hermal Arc Service Agent check connector plug on input PC B and the Mains volta ge.

Have an Ac cre di ted T hermal Arc Service Agent check the control PCB.

Have an Ac cre di ted T hermal Arc Service Agent check or replace the temperature sensors.

A Turn on/off switch on. B Have an Accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses.

No weld current is available. Buzzer sounds constantly. Switch machine off then on to reset E83 error.

Weld current ceases. Buzzer sounds constantly. Switch machine off.

Weld current ceases. Buzzer sounds constantly. Must switch ma chine of f then on to reset E99 error.

8 – 2

9 AD VANCED TROUBLESHOOTING

If you are here, all of the troubles hooting suggestions in Section 7-Basic Troubleshooting have either failed to reso lve the faulty ope ration or ha ve indicated that one or more of the subsystems within the power s upply are d efective . This se ction provides the informa tion needed to take live measurements on the various subsystems within the power supply, and re place those subsystems that prove faulty.

ADVANCED TROUBLESHOOTING

CAUTION

Troubleshooting and repairing this unit is a process, which should be undertaken only by those familiar with high voltage/high power electronic equipment.

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have training in power electronics, measurement and troubleshooting techniques.

Under no circumstances are field repairs to be attempted on printed circui t boards or othe r subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty. If a subassembly is found to be defective by executing any of the procedures in this Service Manual, th e subassembly should be replaced with a new one. The faulty subassembly should then be returned to Thermal Arc through established procedures.

WARNING

Disconnect primary power at the source before disassembling the power supply. Frequently review the "Important Safety Precautions" in section 1.02. Be sure the operator is equipped with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body comes into contact with the work piece or any internal components while the unit is activated.

System-Level Fault Isolation

If none of the sugg estions prov ided in Sec tion 7 have solved t he problem or corrected the faulty ope ration, the next step is to isolate one or more of the internal subassemblies that may be defective.

CAUTION

Perform all steps in each procedure, in sequence. Skipping portions of procedures, or performing steps out of sequence can result in damage to the unit, and possible injury, or worse, to the operator.

1.1 Opening the Enclosure

1) Confirm that the switch of power supply and the switch on switchboard (distribution panel) are all OFF.

9 – 1

LM-200 9 ADVANCED TROUBLESHOOTING

CAUTION

2) Remove all screws and nuts on the side covers.

3) Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW.

NOTE

DO NOT remove the screws completely.

9 – 2

LM-200 9 ADVANCED TROUBLESHOOTING

4) Pull the front panel slightly forward and pull the rear panel slightly backward. The interlocking hooks of the side case covers can now be disengaged from the front and rear panels.

5) Remove the side covers.

6) Remove protection cover sheet by removing the plastic tabs.

NOTE

When you re-assemble the parts, conduct the above process backwards.

9 – 3

LM-200 9 ADVANCED TROUBLESHOOTING

1.2 Verification and Remedy to the Indicated Error Codes

NOTE

The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair (or maintenance) inside the power supply. As for the removal and installation of the case, refer to section Chapter9.1.1.

NOTE

During the "Verification/Remedy" procedures below, follow the alphabetical sequence (a, b, c...) and proceed with your verification and confirmation.

NOTE

After you confirm and replace all spare parts and components, confirm that there are no damaged harnesses or connectors, uninstalled or loose screws.

1.2.1 E01 "Over-Temperat ure at the primary side"

Cause

Occurs when a n o ve r- te m pe ra t ur e co nd i ti o n of th e primary IGBT is detected.

Verification/Remedy

a) Unit may be in thermal shutdown mode.

 Review the rated duty cycle of the unit per

section Chapter2.6. Exceeding the duty cycle can damage the unit and void the warranty. Refer also to section Chapter2.7 for additional information.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 30cm in the front a nd mo re that 50cm in the rear of the unit f or v entilation purposes.

 Verify and maintain clean, dust free, front and

rear airflow paths. Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended. Extremely dusty environments will require more frequent cleanings.

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify that th ere

are no broken or cracked fan blades and that FAN1 is not producing and abnormal sounds.

 If broken or cracked FAN1 blades, or abnor-

mal sounds are emanating from FAN1, replace FAN1.

 Refer to section 9.2 .4.19 for the replacement

of FAN1.

 Refer to section 9.1.4.4 for addition FAN1

tests.

 Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive. Follow the instruction in section 9.1.4.4.

d) Replace PCB3 (WK-5548).

 Refer to section 9.2 .4. 3 for the replaceme nt

of PCB3.

9 – 4

LM-200 9 ADVANCED TROUBLESHOOTING

1.2.2 E02 "Over-Temperature at the secondary side"

Cause

Occurs when an over-temperature condition of the secondary IGBT and diode are detected.

Verification/Remedy

a) Unit may be in thermal shutdown mode.

 Review the rated duty cycle of the unit per

section Chapter2.6. Exceeding the duty cycle can damage the unit and void the warranty. Refer also to section Chapter2.7 for additional information.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 30cm in t he front an d more that 50cm in the rear of the unit f or v entilation purposes.

 Verify and maintain clean, dust free, front and

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify th at there

are no broken or cracked fan blades and that FAN1 is not producing and abnormal sounds.

 If broken or cracked FAN1 blades or abnor-

mal sounds are emanating from FAN1, replace FAN1.

 Refer to section 9.2.4. 19 for the replace ment

of FAN1.

 Refer to section 9.1.4.4 for addition FAN1

tests.

 Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive. Follow the instruction in section 9.1.4.4.

d) Replace PCB3 (WK-5548).

 Refer to section 9.2. 4. 3 for the replacement

of PCB3.

1.2.3 E03 "

Cause

Occurs when excessive curren t is detected flowing into the primary side of the main transformer.

Verification/Remedy

a) Confirm the operation of the machine within

the rated specificatio n.

 Refer to the specifi cation data sheet in Se c-

tion Chapter2.6.

b) Verify the secondary diode (D2, D3, D4, D5,

D6, and D7).

 Refer to section 9.1.4.6 for the test and

replacement of D2 and section 9.2. 4.24 for D3, D4, D5, D6 and D7.

c) Replace the Hall CT, HCT1.

Primary Over-Current Failure

NOTE

Pay special attention to installed direction of HCT1. The Hall CT will not function properly if installed in the incorrect direction.

 Refer to secti on 9.2.4. 22 for th e replacement of

HCT1.

1.2.4 E11 "High Input V olta ge Fa ilure "

Cause

Occurs when the input voltage is more than approximately 275VA C (at input vol tage 230V) or 520VAC (at input voltage 460V) (=1/1.41 of the maximum value of the sinusoidal wave).

Verification/Remedy

a) Verify input voltage.

 Follow the instruction in se ction 9.1.4.2.

b) Replace PCB4 (WK-4819).

 If the voltage and curre nt available is deter-

mined to be sufficient, replace PCB4.

 Refer to section 9.2 .4. 4 for the replaceme nt

of PCB4.

9 – 5

LM-200 9 ADVANCED TROUBLESHOOTING

1.2.5 E12 "Low Input Voltage Failure"

Cause

Occurs when the input voltage is less than approximately 150V AC (=1/1.41 of the maximum value of the sinusoidal wave).

Verification/Remedy

a) Verify input voltage.

 Follow the instruction in section 9.1.4.2.

b) Replace PCB4 (WK-4819).

 If the voltage and curr ent available is deter-

mined to be sufficient, replace PCB4.

 Refer to section 9.2. 4. 4 for the replacement

of PCB4.

1.2.6 E14 "Low Input Voltage Warning"

Cause

Occurs when the input voltage is less than approximately 173V AC (=1/1.41 of the maximum value of the sinusoidal wave).

Verification/Remedy

a) Verify input voltage.

 Follow the instruction in section 9.1.4.2.

b) Replace PCB4 (WK-4819).

 If the voltage and curr ent available is deter-

mined to be sufficient, replace PCB4.

 Refer to section 9.2. 4. 4 for the replacement

of PCB4.

 Contact the manufacturer if you find a ny bro-

ken connectors or damaged wiring harnesses.

c) Verify PCB4 (WK-4819) for burned or discol-

ored components or printed circuit board.

 Confir m that the PCB is se curely fastened in

place. (No loose screws).

 Refer to section 9.2 .4. 4 for the replaceme nt

of PCB4.

1.2.8 E82 "Rated voltage se lec t ion cir cuit abnormality"

Cause

Failure detected by the input voltage detection circuit, etc.

Verification/Remedy

a) Verify the wiring harness and connection of

CN4 on PCB4 (WK-4819).

 Confirm a secure connection of CN4 on

PCB4.

 Contact the manufacturer if you find a ny bro-

ken connectors or damaged wiring harnesses.

b) Verify PCB4 (WK-4819) for burned or discol-

ored components or printed circuit board.

 Confir m that the PCB is se curely fastened in

place. (No loose screws).

 Refer to section 9.2 .4. 4 for the replaceme nt

of PCB4.

1.2.7 E81 "Abnormal Input Voltage"

Cause

Failure detected by the input voltage detection circuit, etc.

Verification/Remedy

a) Verify the AC input voltage using a voltmeter.

 Follow the instruction in section 9.1.4.2.

b) Verify the wiring harness and connection of

CN1 on PCB21 (WK-4917) and CN2 on PCB3 (WK-5548).

 Confirm a secure connection of the harness

between CN1 on PCB21 and CN2 on PCB3.

1.2.9 E83 "Abnormal mains supply voltage"

Cause

Failure detected by the input voltage detection circuit, etc.

Verification/Remedy

a) Verify the AC input voltage using a voltmeter.

 Follow the instruction in se ction 9.1.4.2.

b) Verify the wiring harness and connection of

CN1 on PCB21 (WK-4917) and CN2 on PCB3 (WK-5548).

 Confir m a secure connec tion of the harn ess

9 – 6

LM-200 9 ADVANCED TROUBLESHOOTING

between CN1 on PCB21 and CN2 on PCB3.

 Contact the ma nufacturer if you find any bro-

ken connectors or damaged wiring harnesses.

c) Verify PCB4 (WK-4819) for burned or discol-

ored components or printed circuit board.

 Confirm that the PCB is securely fastened in

place. (No loose screws).

 Refer to section 9.2. 4. 4 for the replacement

of PCB4.

1.2.10 E85 "Pre-Charge Error"

Cause

Occurs, after you a pply power, when a failure is detected during the preliminary charging of the capacitors.

Verification/Remedy

a) Verify the AC input voltage and the Capacitor

Bus Voltage on PCB2 (WK-5597).

 Follow the instruction in section 9.1.4.2.

b) Verify the input diode, D1.

 Refer to section 9.1.4.5 for the test and

replacement of D1.

c) Verify the IGBT, Q1-Q24.

 Refer to section 8.02.06.02 for the test and

replacement of Q1, Q2, ..., Q23, and Q24.

d) Replace PCB2 (WK-5597) and PCB4 (WK-

4819).

 If the tests in the ab ove sections (a, b, c) are

within expected results and the unit is still defective, replace PCB2 and PCB4.

 Refer to section 9.2. 4. 2 and 9.2.4. 4 for the

replacement of PCB2 and PCB4.

1.2.11 E94 "Thermistor Failure"

Cause

Occurs when the thermistor for the temperature detection circuitry is open.

Verification/Remedy

 Confir m a secure connec tion of the harn ess

wired between CN8 and CN9 on PCB 6 and TH1 and TH2 and re-install the harnesses with a secure connection.

 Contact the manufacturer if you find a ny bro-

ken connectors or damaged wiring harnesses.

b) Replace thermistors, TH1 and TH2.

 Refer to section 9.2.4.17 and 9.2.4.18 for the

replacement of TH1 and TH2.

c) Replace PCB6 (WK-5688).

 Refer to section 9.2 .4. 6 for the replaceme nt

of PCB6.

1.2.12 E99 "Initial Power Re ce iving"

Cause

Occurs when the initial AC powe r-received signa l has not reached the CPU.

NOTE

This error occurs normally during the power "OFF" sequence of the unit.

Verification/Remedy

a) Verify the wiring harness and connection of

CN1 on PCB21 (WK-4917) and CN2 on PCB3 (WK-5548).

 Confir m a secure connec tion of the harn ess

wired between CN1 on PCB21 an d CN2 on PCB3 and re-install the harness with a secure connection.

 Contact the manufacturer if you find a ny bro-

ken connectors or damaged wiring harness.

b) Verify and replace PCB4 (WK-4819).

 During the installation of PCB4 and PCB3,

confirm that the PC B's are se curely fastened in place. (No loose screws).

 Refer to section 9.2 .4. 4 for the replaceme nt

of PCB4.

c) Replace PCB6 (WK-5688).

 Refer to section 9.2 .4. 6 for the replaceme nt

of PCB6.

a) Verify the wiring harness and connection

between CN8 and CN9 on PCB6 (WK-5688) and thermistors TH1 and TH2.

9 – 7

LM-200 9 ADVANCED TROUBLESHOOTING

1.3 Verification and Remedy to Failures without Indication Codes

Refer to Note 11 on Page 9-4. Refer to Note 12 on Page 9-4. Refer to Note 13 on Page 9-4.

1.3.1 "Cooling Fan Failure" (Fan is not rotating)

Cause

Occurs when the cooling fan is defective, damaged or the driving voltage is incorrect.

Verification/Remedy

a) Verify the cooling fan, FAN1.

 Inspect the condition of the fan blades and all

peripheral par ts. Clea n the fan blades and all peripheral par ts if covered with dust. Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended. Extremely dusty environments

 Verify that there are no wiring harnesses

entangled inside the fan, confirm that the harnesses do not have any brakes in the wire or damaged connecto rs.

 Contact the manufacture if you find any

broken connectors or damaged wiring har nesses.

 Replace the fan if there are any broken,

cracked or missing fan blades.

 Refer to section 9.2. 4. 19 for replacement of

FAN1.

b) Verify the wiring harness between the cooling

fan (FAN1) and CN11 on PCB3 (WK-5548).

 Confirm a secure connection of the harness

to CN11 on PCB3.

 Contact the manufacture if you find any

broken connectors or damaged wiring har nesses.

c) Cooling fan voltage tests and replacement of

the cooling fan (FAN1).

 Follow the instruction in section 9.1.4.4.

will require more frequent cleanings.

1.3.2 "Wire feeding failure or inconsistent wire delivery " ( W ire feeder does not work)

Cause

Power Source: Faulty or damaged 14-pin recepta-

cle and 19-pin receptacle, tripped or damaged the circuit breaker (MCB1 , MCB2 ), blown downtransformer, associated wiring.

Wire Feeder: Feeder gear failure. Refer to the

wire feeder operator manual, supplied by the wire feeder manufacture, for additional infor mation.

Verification/Remedy

a) Confirm wire setting.

 The pressurizing lever is applied when the

pressurizing lever comes off and pressure is applied to the installation wire.

 When the wire is blocked, the wire is con-

nected again.

 When the wire dia meter and the diameter of

the wire feeder are different, the diameter of the wire feeder is matched to the wire dia meter.

b) Verify CON1 of 14-pin receptacle (CON2 of 19-

pin receptacle). *Applies to MIG mode.

 Confir m the wiring har ness and connections

between CON1 of 14-pin receptacle (or CON2 of 19-pin receptacle) and the wire feeder device are secure.

 Confir m the wiring har ness and connections

between CON1 of 14-pin receptacle (or CON2 of 19-pin receptacle) and PCB17 (WK-

5699).

 Contact the manufacture if you find any bro-

ken connectors or damaged wiring harnesses.

 The thing whos e voltage between "I" pin a nd

"G" pin of the CO N1 of 14-pin receptacle is AC115V (AC100~125V) is confirmed.

 When there i s n o voltage between "I" pi n an d

"G" pin in AC115V (AC100~125V ), the connection of the pin of the connector is done over again.

 The thing whose voltage between "E" pin and

"F" pin of the CON2 of 19-pin receptacle is AC115V (AC100~125V) is confirmed.

9 – 8

LM-200 9 ADVANCED TROUBLESHOOTING

 When there is no voltage between "E" pin

and "F" pin in AC115V (AC100~125V), the connection of the pin of the connector is done over again.

 Confirm the pin-out numbers of the 14-pin

receptacle (or 19-pin receptacle) located on the wire feeder equipment. (Refer to Operating Manual.)

 Confirm the wiring and connections on the

14-pin receptacle (or 19-pin receptacle) located on the wire feeder equipment.

c) Verify the circuit breaker used for the wire

feeder equipment power supply, MCB1 and MCB2.

 Confirm whether MCB 1 or MCB2 has trip ped

or not. (When the MCB trips, yellow knob will be exposed.)

NOTE

If the circuit breaker of the wire feeder power supply has tripped, there are other possible failures that must be considered. For example, the capacity of the wire feeder equipment motor is large, or there are some other problems in the wire feeder equipment. Before continuing onto the next section, verify and eliminate the above possible failure conditions. Refer the operating manual supplied by the wire feeder manufacture.

 Press the yellow knob down AFTER the

faults in the wire feeder equipment are resolved.

 If the wire feeder equipment still does not

operate, verify MCB1 and MCB2. Replace them if necessary.

 Refer to section 9.2.4. 27 for the replace ment

of MCB1 and MCB2.

d) Verify the transformer, T1, and replace it if nec-

essary.

 Refer to section 9.2.4. 29 for the replace ment

of T1.

e) Verify the wire feeder equipment, and replace

it if necessary.

 Refer to the operating manual supplied by

the wire feeder manufacture before any work is performed on the wire feeder.

1.3.3 "No weld output"

Cause

Occurs when the 14-pin receptac le (19-pin rec eptacle) or associated circuitry is defective, damaged, or the TIG tor ch ca ble is d efec ti ve and Wire feeder Abnormality.

Verification/Remedy

CAUTION

Read and understand this entire section before proceeding. Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately.

a) Verify the 14-pin receptacle. *Applies to LIFT

TIG and MIG mode.

 Confir m a secure connection betwe en CON1

of the 14-pin receptacle and the wire feeder.

 Confir m a secure connection betwe en CON1

of the 14-pin receptacle and the remote device.

 Confir m a secure connec tion of the harn ess

and the connections between CON1 and PCB17 (WK-5699) are all correct and there are no open circuit.

 Contact the manufacture if you find any bro-

ken connectors or damaged wiring harnesses.

 Confirm the proper pins-outs of the 14-pin

receptacle on the wire feeder side. (Refer to Operating Manual.)

 Confirm the proper pins-outs of the 14-pin

receptacle on the remote device side. (Refer to Operating Manual.)

 Confirm that a wire feeder or there is no open

circuit on the 14-pin rece ptacle at the r emote device side.

b) Verify the condition and connect and connec-

tions of the welding cable, the stick rod holders and the base metal cables. *Applies to STICK and LIFT TIG mode.

 Confirm a secure connection of the welding

cable, stick rod holders, base metal cables and dines connectors and there are no open circuits.

c) Verify the cables connected to wire feeder

equipment including welding and base metal cables. *Applies to MIG mode only.

9 – 9

LM-200 9 ADVANCED TROUBLESHOOTING

 Confirm the connections of the required

cables; control cable for the wire feeder equipment, cable for welding, and a cable for the base metal are all secured.

 Confirm that there are no connection errors

or broken wires of the required ca bles; control cable for the wire feeder equipment, cable for welding, and a cable for the base metal.

d) Verify the no-load voltage (OCV). *Applies to

STICK and MIG mode.

 Refer to section "Verification of No-Load volt-

age (No OCV)" in the section 9.1.4.8 first before continuing this section.

 If performing the "No-Load Voltage Failure"

procedure does not rectify the failure, perform the following tests in the sequence below. Replace any defective components found.

1 ) Diode, D2, D4, D5 and D6. (Refer to the

Section 9.1.4.6)

2 ) Reactor, FCH. Confir m the connection of

FCH and PCB14 (WK-5594) . (Ref er to the Section Appendix 3)

3) PCB8, PCB9, PCB 10, PCB 11 (WK -5479 ). (Refer to the Section 9.1.4.6)

4 ) Hall CT, HCT1. Confirm the con nection of

FCT1 and PCB6 (WK- 5549). ( Refer to the Section 9.2.4.22)

e) Verify the wire feeder equipment, and replace

it if necessary.

 Refer to the operating manual supplied by

the wire feeder manufacture before any work is performed on the wire feeder.

1.3.4 "Operating Panel Failure" (LED's do not light properly or weld settings cannot be establish.)

Cause

Occurs when there is a connecti on failure among PCB3 (WK-5548), PCB6 (WK-5688) and PCB12 (WK-5527) or PCB3, PCB6 and PCB12 are defective.

Verification/Remedy

a) Verify the PCB connecti on betwe en CN21 on

PCB6 (WK-5688) and CN2 on PCB12 (WK-

5527).

 Confir m a secure connec tion of the harn ess

and the connections between CN21 on PCB6 and CN2 on PCB12.

 Contact the manufacture if you find any broken

connectors or damaged wiring harnesses.

b) Verify the connecti on betwe en PCB 5 (WK-

5551) and PCB6 (WK-5688).

 Confirm that all four connectors between

PCB5 and PCB6 are tightly connected.

 Confir m the conditio n of the pins on the c on-

nectors and the connectors themselves, if bent pins or damaged co nnectors are found, replace the suspected PCB.

 Refer to section 9.2. 4. 5 and 9.2.4. 6 for the

replacement and installation of PCB5 and PCB6.

c) Replacement of PCB6 (WK-5688) and PCB12

(WK-5527).

 Refer to section 9.2 .4. 6 for the replaceme nt

and installation o f PCB6 and section 9.2. 4. 9 for PCB12.

1.4 Fault Isola t ion Tests

1.4.1 Preparation

The following initial conditions must be met prior to starting any of the procedures in this section (9.1.4).

1 ) Connect the appropriate inp ut voltage. (Check

the data tag on the rear of the power supply for the proper input voltage.)

NOTE

Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply.

2) Close primary power source wall disconnect switch or circuit breaker.

3 ) Place power supply MAIN CIRC UIT SWITCH

(S1) on rear of unit in the ON position.

WARNING

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

9 – 10

LM-200 9 ADVANCED TROUBLESHOOTING

1.4.2 Verification of the Power Input Circuitry

Refer to Note 9 on page 9-2. Refer to Note 11 on page 9-4.

1 ) Verify the AC i nput voltage using an AC volt-

meter Verify input voltage (Phase-to Phase) using an AC voltmeter. (The c apability of the voltmeter should be more than 600VAC). Measure the point between lines U1 and V1 on the input switch, S1.

Measure the point between lines U1 and W1 on the input switch, S1. Measure the point between lines V1 and W1 on the input switch, S1.

The location of points U1, V1 and W1on switch S1 are indicated in Figure 7-1.

When using a single-phase connection, the voltage can be verified only between U1 and V1.

the points V2 and W2 on the input s witch, S1.

The location of points U2, V2 and W2 on switch S1are indicated in Figure 7-1. When using a single-phase connection, the voltage can be verified only between U2 and V2.

4) If this voltage is out of the operating range, which is ±10% (187~253/414~ 506 VAC) of the rated voltage (208, 230/46 0V), replace S1 following the process in section 9.2.4.20.

5 ) Verify the recti fied output voltage of the input

diode, D1 using a DC vol tmeter. (The cap ability of the voltmeter should be more than 1000VDC.)

Using a DC voltmeter, measure between the points 0 (R2) [+] and 1 (P) [-] on D1.

Points 0 (R2) and 1 (P) are on D1. See Figure 9-2. The measured voltage should be approxi-

mately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the calculated measure ment is not within the corresponding range (260~ 360/58 0~720V DC) f ollowing the process in section 9.2.4.23.

Figure9-1: Check points U1, U2, V1, V2, W1 and W2

2) If the input voltage is out of the operating range of the unit, which is ±10% (187~253/41 4~506 VAC) of the rated voltage (208, 230/460V), verify the available power capacity at the installed site.

If the input voltage is within the operating range, recheck the input voltage while welding, as welding may cause the input voltage to decrease to a valu e below th e operatin g range of the unit.

3 ) Ver ify input voltage after the i nput switch (S1)

using an AC voltme ter. (The capability of the voltmeter should be more than 600VAC.)

 Using an AC voltmeter, measure between

the points U2 and V2 on the input switch, S1.

 Using an AC voltmeter, measure between

the points U2 and W2 on the input switch, S1.

 Using an AC voltmeter, measure between

Figure9-2: The check points 0 (R2) and 1 (P)

6 ) Verify bu s voltage (the voltage of th e electro-

lytic capacitor after rectification) using a DC voltmeter. (The capability of the voltmeter should be more than 1000VDC.)

Using a DC voltmeter, measure between the points TB1 (P) [+] and TB2 (N) [-] on PCB2 (WK-5597). Points T B1(P) and TB2(N) can be found on the parts side of PCB2.

See Figure 7-2. The measured voltage should be approxi-

mately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the

9 – 11

LM-200 9 ADVANCED TROUBLESHOOTING

calculated measurem ent is not within the corresponding range ( 260~3 60/580~ 720VDC) following the process in section 9.2.4.23.

TB1(P) TB4(N)

PCB2

Figure9-3: The check points TB1(P) and TB2(N)

7 ) A fter the replacement of D1, if the above volt-

age is still abnormal, replace PCB1 (WK-

5493).

1.4.3 Power Supply Voltage Test

Connect the power supply to a source of rated input voltage. (Check the data tag on the rear of the power supply for the proper input voltage.)

Refer to Note 15 on page 9-7. Apply power to the u nit and plac e the s witc h of the

power supply to the ON position. On the PCB6 (WK-5549) and PCB3 (WK-5548),

measure the voltages according to the following table. The test point and the reference a re obtainable on the parts side of PCB6 (WK-5549) and PCB3 (WK-5548).

The location of points TP0-3 are indicated in Figure 9-4.

The location of points PIN1-PIN3 of CN18 on

PCB3 are indicated in Figure 9-5.

PCB6

Figure9-4: The check points TP0-3

Test Point

(PCB6;WK-5688)

TP1 TP0 +15VDC TP2 TP0 +5VDC TP3 TP0 –15VDC

Reference

(PCB6;WK-5688)

PCB3

CN18

PIN 1 PIN 3

TP3 TP0 TP1

TP2

ACCEPTABLE

VALUE

Figure9-5: The check points PIN1-PIN3 of CN18 on

PCB3

Test Point

(CN18 on PCB3;

WK-5548)

Reference

(CN18 on PCB3;

WK-5548)

PIN1 PIN3 +24VDC

If any of these voltages are not present or are below a 10% tolerance, replace PCB3 (WK-5548).

9 – 12

ACCEPTABLE

VALUE

LM-200 9 ADVANCED TROUBLESHOOTING

1.4.4 Verification of the Cooling Fan, FAN1, Drive Circuitry

Verify the conditio n of the c oo ling fan, FAN1, using a DC voltmeter. (The capability of the voltmeter should be more than 50VDC.)

Using a DC voltmeter, measure betw een PIN 1[+] and PIN 2[-] of CN11 on PCB3 (WK-5548).

The location of connector CN11 of PCB3 (WK-

5548) is indicated in Figure 9-6.

NOTE

When you measure the above voltage, do not remove the connector. Conduct the measurement while the connector plug and receptacle are still connected.

PCB3

CN11

Fan

Status

Case

Inactive

Case

Inactive DC 18~25V

Voltage

measurement

(PIN1-PIN2 of

CN11onPCB3)

Below

DC 18V

Remedy

Replace PCB3 (WK-5548). (Refer to section 9.2.4.4)

Conduct the "Verific ation of the power inp ut c ircuitry" in section 9.1.4.2.

Replace FAN1. (Refer to section 9.2.4.19)

NOTE

This welding unit has a feature that will slow the rotational speed of the cooling fan during low output current and while in standby. Under these conditions, the voltages in the above table will be inaccurate; therefore, when verifying the voltage, do so during the failure condition.

NOTE

When verifying the voltage, confirm that the AC input voltage remain within the operating range of the unit. (The AC input does not drop below 180VAC).

PIN1 PIN2

Figure 9-6: The location of connector CN11 of PCB3

(WK-5548)

Using the measurement taken above, follow the chart below for possible failure modes.

Fan

Status

Case

Rotating DC 18~25V

Case

2Rotating

V oltage

measurement

(PIN1-P IN 2 of

CN11onPCB3)

Below

DC 18V

Remedy

Fan drive circuit is normal.

Replace PCB3 (WK-

5548). (Refer to section

9.2.4.3)

1.4.5 Verification of th e prim ary Di ode (D1)

CAUTION

Before performing any portion of the procedure below, make certain unit is placed in the initial set up condition as described at the beginning of an above section "Preparation". [Refer to the page 9-9]

1. Verify the characteristic of the primary diode, D1, using a diode tester.

2. Refer bellow Table and Figure 9-7, 9-8 for the checkpoints on D1.

COMPONENT

TESTED

Diode of D1

Thyristor of D1

Table 9-1: Tester checkpoints in the primary diode (D1)

TERMINALS

Positive

lead

3, 4, 5

2 0

Negative

lead

3, 4, 5

1 0

ACCEPTABL

E VALUE

0.3 to 0.5V Open

Open

0.3 to 0.5V Open

Open

9 – 13

LM-200 9 ADVANCED TROUBLESHOOTING

1. Verify the characteristic of the secondary diode, D2, D3, D4, D5, D6 and D7 using a diode tester.

2. Refer bellow Table 9-2 and Figure 9-9 for the checkpoints on D2, D3, D4, D5, D6 and D7.

Figure9-7: Tester checkpoints in the primary diode (D1)

5 4 3

Figure 9-8: The primary diode (D1) interconnection

diagrams

076

D2 D7

TERMINALS

Positive

lead

Anode

Cathode

Anode

Cathode

Negative

lead

Cathode

Anode

Cathode

Anode

Cathode

ACCEPTABL

E VALUE

0.2 to 0.3V Open

Anode

Cathode

COMPONENT

TESTED

Diode 1 of D2, D3, D4, D5, D6 and D7

Diode 2 of D2, D3, D4, D5, D6 and D7

Table 9-2: Tester checkpoints in the secondary diode

(D2, D4, D5)

Figure9-9: Tester checkpoints in the secondary diode

(D2-7)

1.4.7 Verification of the prim ary IGB T (Q1-24)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described at the beginning of an above section "Preparation". [Refer to the page 9-9]

1.4.6 Verification of the secondary Diode (D2-7)

CAUTION

1. Check whether there are any abnormalities on the appearance of PCB8 and PCB9.

2. Verify the characteristic of the primary IGBT (Q1-24), using a diode tester.

3. Refer bellow Table and Figure 9-10 for the checkpoints on PCB8 and PCB9.

9 – 14

LM-200 9 ADVANCED TROUBLESHOOTING

COMPONENT

TESTED

Collector-Emitter of Q1-24 with PCB8 and PCB9

C CE E

TRO_0031

PCB8

TERMINALS

Positive

lead

PCB10

PCB9

Negative

lead

PCB11

ACCEPTABL

E VALUE

Open

0.2 to 0.5V

Open

0.2 to 0.5V

CAUTION

Electric shock hazard. The unit will generate OCV immediately when contactor function is put into the state of on pushing Function button at STICK mode.

3) Verify the no-load voltage using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.)

4) The normal no-load voltage is approximately 65V.

b) Verify the no-load voltage in MIG mode.

1) Confirm a secure connection between CON1 of the 14-pin recept acle (or CON2 of the 19-pin receptacle) and the remote device.

2) Confirm a secure connection of the harness and the con nections betwe en CON1 (or CON2) and PCB17 ( WK-5699) are al l correct and there are no open circuits.

3) Contact the manufacturer if you find any broken connectors or damaged wiring harnesses.

4) Contac tor function is put into the state of on pushing Function button. Refer to 5.0 on page 33.

C CE E

Figure9-10: Tester checkpoints in the primary IGBT

(Q1-24)

1.4.8 Verification of No-load Voltage (No OCV)

a) Verify the no-load voltage in STICK mode.

1) STICK we lding mode, ma rk and then turn potentiometer VR1 on PCB6 (WK-5688) all the way to the right and turn off the electric shock protector fu nction (VoltageReduction-Device, VRD).

2) Contact or function is put into the state of on pushing Function button. Refer to 5.0 on page 33.

CAUTION

Electric shock hazard. The unit will generate OCV immediately when contactor function is put into the state of on pushing Function button at MIG mode.

5) The normal no-load voltage is approximately 65V.

6) Return potentiometer VR1 to the original position.

9 – 15

LM-200 9 ADVANCED TROUBLESHOOTING

1.4.9 Output Load Test

This test verifies that the output current, (amperage) controls are functioning properly. A clamptype amperage meter or equivalent meter capable of reading approximately 200A full-scale will be needed for this test.

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described at the beginning of this section.

1) Connect the POSITIVE (+) and NEGATIVE (–) OUTPUT TERMINALS to a piece of metal, separated by approximately three feet (one meter).

2) Connect the clamp-on amperage meter or equivalent to the output loop between the POSITIVE (+) and NEGATIVE (–) OUTPUT TERMINALS.

3) Place the power supply PRIMARY POWER SWITCH on t he rear of the unit to the ON position.

4) Press the Welding mode selection button to select STICK welding mode. The amperage meter will indicate approximately 5 Amps. Contactor function is put into the state of on pushing Function button.

NOTE

This completes the output load test. If the results of any step differ from those above, then refer to the various test procedures in this section to isolate the problem.

WARNING

At this time, some voltage is applied to the stick electrode holder. Never touch the current conducuting portion of it. Extra care shall be taken to prevent electric shock. Further, to prevent the risk of striking the arc inadvertently, care shall be taken to keep the work piece to be welded away from the said electrode holder.

5 ) Slowly turn the Control Knob clo ckwise to the

maximum of the power supply, then counter clockwise, back to 5 Amps as the control returns to its minimum position. T he amper age meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 200 Amps maximum.

6) Place the power supply MAIN CIRCUIT SWITCH on the rear of the unit to the OFF position.

7 ) Remove the dead short between the OUTPUT

TERMINALS.

9 – 16

LM-200 9 ADVANCED TROUBLESHOOTING

Subsystem Test and Replacement Procedures

2.1 Preparation

This section prov ides specific procedures for verifying the operation and r eplacement of each subsyste m within the power supply.

Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect subsystem for physical damage, overheating, and loose connections.

2.2 Test and Replacement Parts List

2 4

No. DWG No. Parts name Reference page Note

PCB2 Print Circuit Board (WK-5597)

PCB3 Print Circuit Board (WK-5548)

PCB4 Print Circuit Board (WK-4819)

PCB5 Print Circuit Board (WK-5696)

PCB7 Print Circuit Board (WK-5689)

PCB12 Print Circuit Board (WK-5527)

PCB13 Print Circuit Board (WK-5528)

PCB14 Print Circuit Board (WK-5594)

PCB16 Print Circuit Board (WK-4917)

9-23 9-24 9-26 9-26 9-24 9-28 9-29 9-30 9-32

9 – 17

LM-200 9 ADVANCED TROUBLESHOOTING

2 6

No. DWG No. Parts name Reference page Note

PCB1 Print Circuit Board (WK-5493)

PCB6 Print Circuit Board (WK-5688)

PCB8 (Q1-Q6) Print Circuit Board (WK-5479)

PCB9 (Q7-Q12) Print Circuit Board (WK-5479)

PCB10 (Q13-Q18) Print Circuit Board (WK-5479)

PCB11 (Q19-Q24) Print Circuit Board (WK-5479)

PCB15 Print Circuit Board (WK-5606)

PCB17 Print Circuit Board (WK-5699)

PCB18 Print Circuit Board (WK-5499)

9-22 9-27 9-27 9-27 9-28 9-28 9-31 9-33 9-33

9 – 18

LM-200 9 ADVANCED TROUBLESHOOTING

10 11

9 8 3

7 4

No. DWG No. Parts name Reference page Note

CON1 14-PIN Receptacle

CON2 19-PIN Receptacle

D1 Diode

D2 Diode

D4 Diode

D5 Diode

D7 Diode

MCB1 Molded Case Circuit Breaker

MCB2 Molded Case Circuit Breaker

S1 Switch

S2 Switch

S3 Switch

T1 Transformer

9-46 9-47 9-39 9-40 9-40 9-40 9-40 9-42 9-42 9-37 9-38 9-38 9-44

9 – 19

LM-200 9 ADVANCED TROUBLESHOOTING

1 6

2 8

No. DWG No. Parts name Reference page Note

CT2 Current Trans

CT3 Current Trans

FAN1 Cooling Fan

FCH1 Inductor

HCT1 Current Sensor

L1 Reactor

R2 Resistor

R3 Resistor

TH1 Thermistor

TH2 Thermistor

9-41 9-41 9-36 9-34 9-39 9-41 9-43 9-43 9-35 9-36

9 – 20

LM-200 9 ADVANCED TROUBLESHOOTING

2.3 Service Tools

2.3.1 Tools and parts

The tools and parts to be used for maintenance are shown by icons.

Spanner

(5.5, 8, 10, 17mm)

Philips Head Screwdriver

Long Nose Pliers

C-Ring Pliers

Snap Band

Silicon Compound

2.3.2 Notes of disassembly a n d ass embl y

NOTE

When removing the locking type connectors and board supporters, disengage the locking mechanism first and then disconnect them. Locking type connectors and board supporters are indicated in this manual using the following symbols; black star marks for locking connectors and white star marks for locking board supports.

NOTE

During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or repair, please reassemble and tie-wrap all components and wiring in the same manner as before the maintenance or repair.

CAUTION

Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the harness (cable) part.

WARNING

9 – 21

LM-200 9 ADVANCED TROUBLESHOOTING

2.4 Replacement Procedure

2.4.1 PCB1 (WK-5493) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB2 (WK-5597). [Reference page: 9-23]

3) Remove the diode (D1). [Reference page: 9-39]

4) Remove the current transformers (CT2 and CT3). [Reference page: 9-41]

5) Remove two screws and three terminals from PCB1 (WK-5493).

6) Remove the reactor (L1). [Reference page: 9-41]

7) Disconnect one connector and remove four terminals.

purple

orange

Blue

brown

8) Remove 18 screws and remove PCB1 (WK-5493).

9 – 22

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.2 PCB2 (WK-5597) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB6 (WK-5688). [Reference page: 9-27]

3) Remove one screw and three ground terminals. Disconnect 13 connectors.

CN22

CN23

CN21

CN20

CN11

CN9

CN10

CN11

CN7

CN4

CN3

CN2 CN1

4) Loosen two screws. Rotate the resistors (R2 and R3) to expose two screws on PCB3 (WK-5548).

5) Disconnect five connectors.

CN2

CN1

CN15

CN13

CN16

9 – 23

LM-200 9 ADVANCED TROUBLESHOOTING

6) Remove five screws, three terminals, and five connectors from PCB2 (WK-5597).

CN1

CN4

CN5

CN2

CN3

7) Cut off one snap ban d. Rem ove two boar d s up ports and then re move P CB2 (W K-5 597) an d the insul ating sheet.

2.4.3 PCB3 (WK-5548), PCB7 (WK-5689) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB4 (WK-4819). [Reference page: 9-26]

3) Remove PCB6 (WK-5688). [Reference page: 9-27]

4) Remove PCB5 (WK-5696). [Reference page: 9-26]

5) Disconnect 11 connectors from PCB3 (WK-5548).

CN9

CN11

CN1

CN2

CN21

CN20

CN8

CN3

9 – 24

CN7

CN23

CN22

LM-200 9 ADVANCED TROUBLESHOOTING

6) Loosen two screws. Rotate the resistors (R2 and R3) to expose two screws on PCB3 (WK-5548).

7) Remove one screw and three ground terminals. Remove four screws and remove PCB3 and PCB7. Disconnect five connectors from PCB7 (WK-5689).

CN13

CN16

CN15

CN1

CN2

8) Disconnect one co nnec to r an d re move two sc rew s a nd the n remo ve P C B7 (WK- 56 89) fr om P CB3 (W K-

5548). Remove one screw and one ground terminal from PCB7 (WK-5689).

CN20

9 – 25

LM-200 9 ADVANCED TROUBLESHOOTING

9) Disconnect two connectors from PCB3 (WK-5548).

CN18

CN33

2.4.4 PCB4 (WK-4819) 

1) Remove the side cover. [Reference page: 9-1]

2 ) Disc onnect three connector s. Remove two screws and di sconnect three connect ors, and then remove

PCB4 (WK-4819).

CN10

CN7

CN4

CN5

CN4

CN6

2.4.5 PCB5 (WK-5696) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB6 (WK-5688). [Reference page: 9-27]

3) Remove two screws and disconnect three connectors. Remove PCB5 (WK-5696).

CN30

CN31

CN32

9 – 26

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.6 PCB6 (WK-5688) 

1) Remove the side cover. [Reference page: 9-1]

2) Disconnect five connectors.

CN1

CN21

CN8

CN9

CN20

3) Remove three screws and disconnect six connectors, and then remove PCB6 (WK-5688).

CN3

CN27

CN18

CN30

CN31

CN32

2.4.7 PCB8 (WK-5479) and PCB9 (WK-5479) 

1) Remove the side cover. [Reference page: 9-1]

2 ) Remove eight s crews and four component clips. D isconnect four connectors and rem ove six screws,

and then remove PCB8 (WK-5479) and PCB9 (WK-5479).

 When reinstalling, remember to install new silicon rubber sheets.

CN2

9 – 27

CN1

CN2

CN1

Silicone Rubber Sheet

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.8 PCB10 (WK -5479), PCB11 (W K -5 47 9) 

1) Remove the side cover. [Reference page: 9-1]

2 ) Remove eight s crews and four component clips. D isconnect four connectors and rem ove six screws,

and then remove PCB10 (WK-5479) and PCB11 (WK-5479).

 When reinstalling, remember to install new silicon rubber sheets.

CN2

2.4.9 PCB12 (WK- 55 27) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB13 (WK-5528). [Reference page: 9-29]

3) Release three hooks and remove PCB12 (WK-5527).

CN1

CN2

CN1

Silicone Rubber Sheet

 Engage two hooks before reinstalling the unit.

9 – 28

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.10 PCB13 (WK-5528) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove the operation cover.

3) Remove the jog dial cap. Loosen the screw while pressing the jog dial and then remove the jog dial.

1mm

4) Disconnect one connector from PCB12 (WK-5527). Remove four screws and pull out the operation panel and tilt it.

CN1

9 – 29

LM-200 9 ADVANCED TROUBLESHOOTING

5) Disconnect one connector and remove two screws, and then remove PCB13 (WK-5528).

CN1

2.4.11 PCB14 (WK-5594) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699). [Reference page: 9-33]

3) Remove the inductor (FCH1). [Reference page: 9-34]

4) Remove two screws from the front side and detach the bus bar.

5) Remove four screws and open the rear cabinet.

9 – 30

LM-200 9 ADVANCED TROUBLESHOOTING

6) Remove two screws from PCB 1 (WK- 5 477) an d disc onn ect three ter mi na ls. C ut off two snap ban ds and slide the insulating tube. Remove two screws, two nuts, and four terminals.

7 ) Remov e four screws from the bo ttom and disconnect one t erminal. Remove two screws fro m the rear

side and remove PCB14 (WK-5594) by pulling it out. Remove four screws and detach the bus bar.

2.4.12 PCB15 (WK-5606) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699). [Reference page: 9-33]

3 ) Remove the sheet and remove eight screws. Remove two board suppo rts and remove PCB15 ( WK-

5606).

9 – 31

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.13 PCB16 (WK-4917) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove six screws from the switch (S1) and disconnect six terminals.

3) Remove four screws and open the rear board.

4 ) Disconnect the one connect or. Remove the two scr ews and one ground te rminal. Remove the P CB16

(WK-4917).

CN1

9 – 32

LM-200 9 ADVANCED TROUBLESHOOTING

5) Remove the three screws and the bus bar from the PCB16 (WK-4917).

2.4.14 PCB17 (WK-5699) 

1) Remove the side cover. [Reference page: 9-1]

2 ) Disconnect 11 connectors and remove one terminal. Remove four screws and remove PCB17 (WK-

5699).

CN10

CN6 CN9 CN3

CN4 CN2

CN7

CN15

CN1 CN5

CN8

2.4.15 PCB18 (WK-5499) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699). [Reference page: 9-33]

3 ) Remove one screw and one te rminal. Remo ve one bolt, one toothed washer, on e washer, and o ne ter-

minal. Disconnect one connector. Remove one screw and one nut and detach the bus bar.

CN1

9 – 33

LM-200 9 ADVANCED TROUBLESHOOTING

4) Disconnect two connectors. Remove four board supports and remove PCB18 (WK-5499).

CN1

2.4.16 Inductor (FCH1) 

1) Remove the side cover. [Reference page: 9-1]

2) Disconnect one connector. Remove one screw and three ground terminals.

CN21

3) Remove two bolts and three terminals. Remove four screws and open the front cabinet.

9 – 34

LM-200 9 ADVANCED TROUBLESHOOTING

4) Remove one screw, one terminal and one nut.

5) Remove four screws and remove the inductor (FCH1).

2.4.17 Thermistor (TH1)

1) Remove the side cover. [Reference page: 9-1]

Cut off one snap band and disconnect one connector. Remove one screw and remove the thermistor (TH1).

 When replacing the the rmistor wit h a new one, apply an oil compound (SHINETSU SILI CONE G-747

or equivalent) evenly to the base.

CN8

9 – 35

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.18 Thermistor (TH2)

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699).

3) Cut off three snap bands and disconnect one connector. Remove one screw and remove the thermistor (TH2).

 When replacing the the rmistor wit h a new one, apply an oil compound (SHINETSU SILI CONE G-747

or equivalent) evenly to the base.

2.4.19 Cooling Fan (FAN1) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove four screws and open the rear cabinet.

CN9

3) Cut off one snap band and disconnect one connector.

CN11

9 – 36

LM-200 9 ADVANCED TROUBLESHOOTING

4) Remove two screws and remove the cooling fan (FAN1).

 Pay attention to the installation direction of the fan.

AIR FLOW

ROTATION

2.4.20 Switch (S1) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove six screws and six terminals.

3) Remove two screws and remove the switch (S1). Remove three posts.

9 – 37

2.4.21 Switch (S2 and S3) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove six screws and six terminals.

LM-200 9 ADVANCED TROUBLESHOOTING

3) Remove four screws and open the rear panel.

4 ) Cut off one snap band an d disconnect one connector from PCB4 ( WK-4819). Remov e two screws and

two nuts and remo ve the sw itc h ( S2) . Di sc on nect one connector from the switch ( S3). Remo ve two nuts and remove the switch (S3).

CN4

9 – 38

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.22 Current Sensor (HCT1) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699). [Reference page: 9-33]

3 ) Remove one scr ew and one terminal. Remove one bolt and one termina l. Disconnect one connector.

Remove one screw and one nut and detach the bus bar.

CN1

4) Remove one screw and remove the current sensor (HCT1).

2.4.23 Diode (D1) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB3 (WK-5548). [Reference page: 9-24]

3) Remove six screws and 13 terminals. Remove two screws and remove the diode (D1).

 When replacing the diode with a new one, apply an oil compound ( SHINETSU SILICONE G-747 or

equivalent) evenly to the base.

9 – 39

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.24 Diode (D2, D4, D5, and D7) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB17 (WK-5699). [Reference page: 9-33]

3) Remove PCB15 (WK-5606). [Reference page: 9-31]

4) Remove one screw and one nut. Remove 20 screws and one terminal and detach the bus bar.

5) Remove eight screws and remove the diodes (D2, D4, D5, and D7).

 When replacing the diode with a new one, apply an oil compound ( SHINETSU SILICONE G-747 or

equivalent) evenly to the base.

 Pay attention to the installation direction of the diode.

9 – 40

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.25 Current Transformer (CT2 and CT3) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove PCB6 (WK-5688). [Reference page: 9-27]

3) Remove four screws and open the rear cabinet.

4 ) Cut off one snap band an d disconnect one connector from PCB3 ( WK-5548). Remov e two screws and

two terminals from PCB1 (WK-5493). Cut off two snap bands and remove the current transformers (CT2 and CT3).

CN7

2.4.26 Reactor (L1) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove four screws and open the rear cabinet.

9 – 41

LM-200 9 ADVANCED TROUBLESHOOTING

3) Remove two screws and two terminals. Cut off one snap band and remove the reactor (L1).

2.4.27 Molded Case Circuit Breaker (M C B1 a nd MC B 2 ) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove six screws and six terminals.

3) Remove four screws and open the rear panel.

9 – 42

LM-200 9 ADVANCED TROUBLESHOOTING

4 ) Remove four terminals. Remove two nuts and remove the molded case circuit breakers (MCB1 and

MCB2).

purple

orange

Blue

brown

2.4.28 Resistor (R2 and R3 ) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove the switch (S1). [Reference page: 9-37]

3) Remove four screws and four terminals.

4) Remove two screws and the resistors (R2 and R3).

9 – 43

LM-200 9 ADVANCED TROUBLESHOOTING

2.4.29 Transformer (T1) 

1) Remove the side cover. [Reference page: 9-1]

2 ) Cut off one snap band and disconnec t one connector. Rem ove one screw and th ree ground termin als.

Cut off two snap bands.

CN1

3) Cut the tap wires on the primary side of the transformer (T1), which are connected with the insulated terminal.

 Incorrect wir ing of each t ap wire when reins talling the trans former may damage the welding m achine.

Check the electrical schematic diagram before connecting the tap wires.

4) Remove four screws and open the rear cabinet.

9 – 44

LM-200 9 ADVANCED TROUBLESHOOTING

5) Cut off three snap bands.

 When reinstalling the transformer, secure the harnesses to the holders using snap bands.

6 ) Cut off one snap band. Cut off one snap band that ties together the harne ss of CN7 on PCB17 (WK-

5699) and the harness wired to the rear side. Cut off one snap band that ties together the harness on the secondary side of the transformer (T1) and the harnesses of CN7/CN1 on PCB17 (WK-5699).

7) Remove four terminals.

CN7

CN1

purple

orange brown

Blue

9 – 45

LM-200 9 ADVANCED TROUBLESHOOTING

8) Remove four screws and remove the transformer (T1).

2.4.30 14-Pin Receptacle (CON1) 

1) Remove the side cover. [Reference page: 9-1]

2) Disconnect three connectors. Remove one screw and three ground terminals. Cut off two snap bands.

CN10

CN9

CN8

3) Remove two bolts and three terminals. Remove four terminals and open the front cabinet.

9 – 46

LM-200 9 ADVANCED TROUBLESHOOTING

4) Cut off five snap bands.

 When reinsta lling the receptacle, bend both the har nesses of CN6/CN7/CN9/CN10 on PCB17 (W K-

5699) and the ones of N-pin/L-pin of 19-pin receptacle (CON2), and then use snap bands to tie together the bent harnesses and the ones of CN1/CN5/CN8 on PCB17 (WK-5699).

CN7

CN10

CN6

CN9

CN1 CN5 CN8

5) Remove two screws. Remove the cap and remove the 14-pin receptacle (CON1).

2.4.31 19-Pin Receptacle (CON2) 

1) Remove the side cover. [Reference page: 9-1]

2) Remove four screws and open the rear cabinet.

9 – 47

LM-200 9 ADVANCED TROUBLESHOOTING

3) Cut off three snap bands.

 When reinstalling the receptacle, secure the harnesses to the holders using snap bands.

4 ) Cut off one snap band. Cut off one snap band that ties together the harne ss of CN7 on PCB17 (WK-

5699) and the harness wired to the rear side. Cut off one snap band that ties together the harness on the secondary side of the transformer (T1) and the harness of CN7/CN1 on PCB17 (WK-5699).

CN7

CN1

5) Remove five snap bands.

 When reinsta lling the receptacle, bend both the har nesses of CN6/CN7/CN9/CN10 on PCB17 (W K-

5699) and the ones of N-pin/L-pin of the 19-pi n receptacle (CON2), a nd then use snap bands to ti e together the bent harnesses and the ones of CN1/CN5/CN8 on PCB17 (WK-5699).

CN7

CN10

CN6

CN9

CN1 CN5 CN8

9 – 48

LM-200 9 ADVANCED TROUBLESHOOTING

6) Disconnect three connectors. Remove one screw and three ground terminals. Cut off two snap bands.

CN7

CN6

CN5

7 ) Cu t the harnesses of N-pin/L-pin of th e 19-pin receptacle (CON2) , which are connected with the ins u-

lated terminals.

8) Remove two screws. Remove the cap and remove the 19-pin receptacle (CON2).

9 – 49

LM-200 9 ADVANCED TROUBLESHOOTING

PAGE LEFT INTENTIONALLY BLANK

9 – 50

APPENDIX 1 P ARTS LIST

DRAFT

APPENDIX 1 Parts List

Equipment Identification

All identification numbers as de scrib ed in the Introd uction chap ter must be fur nished when or dering parts or making inquiries. This informa tion is usual ly found on th e nameplate at tached to the e quipment. Be sure to include any dash numbers following the Specification or Assembly numbers.

How To Use This Parts List

The Parts List is a c ombination of an illus tration and a correspon ding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except for commercia lly available hardw are, bulk items such as wire, cable, sleeving, tubing, etc., and pe rmanently attached ite ms which ar e so lde re d, r iveted, or welded to other parts. The part descriptions may be indented to show part relations hi ps. T o dete rm ine the pa r t numb er , desc ripti on, qu ant ity , or appl icat ion of an item, simply loca te the ite m in que stion from the illu stration and ref er to tha t item nu mbe r in the co rrespo nding Parts List.

SPEC NUMBERS: LM-200 ******-***

DWG No. Description Type & Rating QTY. Code No.

1 CON1 Remote Socket

2 CON2 Remote Socket 3 CT1-2 Current Trans F2A503001 CT 1:40 2 F2A503001

4 D1 Diode D FA100BA160 1 454180160 5 D2-5 Diode DBA200UA60 4 4583A0060 6 FAN1 Fan 109E5724H507 DC 24V 16.8W 1 U0A912300 7 FCH1 Inductor F3A207601 400A MIG FCH 1 F3A207601 8 HCT1 Current Sensor HC-TN200V4B15M 200A 4V 1 11251003000 10-5003 9 L1 Reactor GP-7 1 479531341

10 MCB1

11 MCB2 12 PCB1 Printed Circuit Board WK-54 93 U01 MAIN PCB 1 P0A549301

13 PCB2 Printed Circuit Board WK-55 97 U01 LINK PCB 1 P0A559701 14 PCB3 Printed Circuit Board WK-55 48 U01 DDC PCB 1 P0A554801 15 PCB4 Printed Circuit Board WK-48 19 U01 DETEC T PCB 1 P0A481901 10-6635 16 PCB5 Printed Circuit Board WK-56 96 U01 CONECT P CB 1 P0A569601 17 PCB6 Printed Circuit Board WK-56 88 U01 MIG CTRL PCB 1 P0A568801 18 PCB7 Printed Circuit Board WK-56 89 U01 FILTER PCB 1 P0A568901

19 PCB8-11 Printed Circuit Board 20 PCB12 Printed Circuit Board WK-5527 U05 PANEL PCB 1 P0A552705

21 PCB13 Printed Circuit Board WK-5528 U01 ENCODER PCB 1 P0A552801 22 PCB14 Printed Circuit Board WK-5594 U01 TRANS PCB 1 U0A860700 23 PCB15 Printed Circuit Board WK-5606 U01 24 PCB16 Printed Circuit Board WK-4917 U04 INPUT FILTER PCB 1 P0A491704 10-6740 25 PCB17 Printed Circuit Board WK-5699 U01 26 PCB18 Printed Circuit Board WK-5499 U01 FIL TER PCB 1 P0A549901 27 R2-3 Resistor MHS20A151JI 20W 150OHM 2 40322117900 28 S1 Switch DCP-103SR100C-480V 3P-480V 1 25850003700 10-6841

Molded Case Circuit Breaker

MS3102A20-27S (NIC) 14P (with Wiring Assembly)

MS3102A22-14S (NIC) 19P (with Wiring Assembly)

TBC5071-01-0820 1P 125V 2.5AT 1 25720000200

TBC5071-20-1420 1P 125V 10AT 1 25720000300

WK-5479 U01 GATE PCB (with IRGP20B60PD)

DIODE SNUBBER PCB

14/19 CONNECT PCB

1 U0A910900

1 U0A911000

4 U0A835900

1 P0A560601

1 P0A569901

Order No.

LM-200 PARTS LIST

DRAFT

DWG No. Description Type & Rating QTY. Code No. 29 S2 Switch SDKGA4-A-1-A 1 24704531400 10-6699 30 S3 Switch SDKGA4-A-1-A 1 24704531400 10-6699 31 T1 Tranceformer F3A216701 1 F3A216701 32 TH1, 2 Thermistor ERTA53D203 20kΩ/25°C B=3950K 2 46965000900 33 Front Panel E0D006301 1 E0D006301 34 Rear Panel E0D004901 1 E0D004901 35 Side Panel E0D005207 2 E0D005207 36 Front Contro l Co ver E0C346000 1 E0C346000 37 Front Board JEA496001 1 JEA496001 38 Rear Control Cover JDA788900 1 JDA788900 39 Protection Cover E0C299200 1 U0A921900 40 Encoder Cover EBA514400 1 EBA514400 41 PCB Cover E1B537600 (with Dustcover Sheet) 1 U0A839800 42 Name Label N4A831500 (LM-200) 1 N4A831500 43 Side Label N4A785200 2 N4A785200 N/A 44 Warning Label 1 N1B029700 1 N1B029700 45 Warning Label 2 N1B029800 1 N1B029800 46 Output Terminal Label N4A178600 1 N4A178600 47 Switch Label N4A146500 1 N4A146500 48 14/19 Switch Label N4A311800 1 N4A311800 49 MCB Label N4A144200 1 N4A144200 50 VRD Label N4A919100 1 N4A919100 51 VRD Caution Label N4A598700 1 N4A598700

52 53 Input Cable SOOW AWG8X4C L=3.4m 1 52026001200

54 Input Cable Clamp EBA156800 1 EBA156800 55 Heatsink E1B895000 2 E1B895000 56 Heatsink E1B870100 1 E1B870100

57 58 PCB1 Chassis J5B017500 1 J5B017500

59 Chassis J3C356600 1 J3C356600 60 Knob 2621603 1 50990001600 61 Knob Cap 3021104 1 50990000300 62 Control Cover Sheet N1B039200 1 N1B039200 63 Silicone Rubber Sheet EDA227700 4 EDA227700 64 Post1(M5) EBA643600 (M5-M5) 3 EBA643600 10-1068 65 D Bus Bar EDA761400 1 EDA761400 66 T-D Bus Bar EDA003800 4 EDA003800 67 D Bus Bar1 EDA046900 1 EDA046900 68 D Bus Bar2 EDA047000 1 EDA047000 69 D Bus Bar3 EDA047100 1 EDA047100 70 D Bus Bar4 EDA047200 1 EDA047200 71 S1 Bus Bar ECA321000 3 ECA321000 72 Output Bus Bar EDA761300 1 EDA761300 73 T-CC Bus Bar EDA047300 1 EDA047300 74 Output Post ECA867900 2 ECA867900

Output Terminal (female)

IGBT(Q1-Q24) Spring Clip

Heatsink Insulated Board

TRAK-BE35-70S 2 26999025900

E1B850100 8 E1B850100

E1B872000 2 E1B872000

Order No.

LM-200 PARTS LIST

DRAFT

DWG No. Description Type & Rating QTY. Code No. 76 PCB1 Insulated Sheet E1B859700 1 E1B859700 77 PCB2 Insulated Sheet EDA079800 1 EDA079800

Dust Cover Sheet (Front)

Dust Cover Sheet (Rear)

E1B933900 1 E1B933900

E1B933100 1 E1B933100

80 Clip #74 NATURAL 4 606024220 81 CON1 Cover 1070500-20 (with String) 1 U0A728200 82 CON2 Cover 97121-422R (with String) 1 U0A764300 83 Edge Protect EH 18U 2 53692118900 84 Output Plug TRAK-SK50 1 26999025800 85 Operating Manual Operating Manual 1 K1A445600

Order No.

LM-200 PARTS LIST

APPENDIX 2 CONNECTION WIRING GUIDE

CONNECTION WIRI NG GUI DE

Destination Destination Destination A PCB2 CN1 ↔ B PCB2 CN2 ↔ C PCB2 CN3 ↔ D PCB2 CN4 ↔

E PCB2 CN5 ↔

F PCB3 CN2 ↔

G PCB3 CN20 ↔

H PCB3 CN21 ↔

I PCB3 CN22 ↔

PCB4 PCB3 D1 PCB4 D1 T1 T1 PCB16 PCB8 PCB9 PCB8 PCB9 PCB10 PCB11

APPENDIX 2 Connection Wiring Guide

CN7 CN3

CN10 L PCB3 CN33 ↔

230V N PCB6 CN1 ↔ 460V O PCB6 CN21 ↔ CN1 P PCB7 CN1 ↔ CN1 Q PCB7 CN2 ↔ CN2 CN2 PCB7 CN15 CN1 PCB7 CN16 CN2 S PCB12 CN1 ↔ CN1

J PCB3 CN23 ↔

K PCB3 CN18 ↔

M PCB4 CN4 ↔

PCB7 CN13

↔ PCB17 CN4

PCB10 PCB11 PCB7 PCB6 S2 HCT1 PCB12 PCB17 PCB17

PCB13

CN1 CN2 CN20 CN20

CN2 CN3 PCB17 CN9 CN2 PCB17 CN10

CN1

T PCB17 CN1 ↔

PCB17 CN5 PCB17 CN6

PCB17 CN7 PCB17 CN8

W PCB17 CN7 ↔

T1 MCB1 MCB2

↔ CON2

↔ CON1

LM-200 CONNECTION WIRING GUIDE

PCB12

CN1

CN2

CON1

CN2

CN1

PCB11

CN2

CN1

PCB13

CN2

CN3

PCB2

PCB10

CN1

CN2

CN4

HCT1

PCB7

CN1

CN5

CN23

CN15

CN16

CN10

CN22

CN20

CN13

CN7

PCB4

CN33

PCB3

CN2

CN1

CN4

CN3

CN9

PCB6

CN3

CN2

PCB17

CN6

CN21

CN10

CN18

CN20

CN7

CN20

MCB1

CN1

CN8

CN2

PCB8

CN5

MCB2

PCB16

CN1

CN2

PCB9

CN1

CON2

CN1

APPENDIX 3 INTERCONNECT DIA GRAM

INTERCONNECT DI AGR AM

Ground

SIDE CHASSIS 1

REAR

PANEL

460V

230V

FAN1

CN33

CN18

Line1

Line2

Line3

Circuit Bord

[WK-4917]

1 2 3 4 5 6

1 2 3 4

1 2 3

PCB16

Filter

CN1

CN2

CN1

CN11

2 3

1 2 3 4

1 2 3

230V

24V

MCB2

24V

2 3 4 5

CN3

1 2 3 4

PCB4

Detect

Circuit Bord

CN4

[WK-4819]

CN5 CN6 CN4

CN32

CN31

CN32

PCB5

Conect Circuit Bord

[WK-5696]

CN131

CN132 CN132

CN131

CN20

CN27 CN27

CN20

2 3 4 5 6 7 1 2 3

K(7) G(6)

R(3)

S(4)

T(5)

CN1

(0)

(2)

460V

115V

MCB1

115V

CN30CN31 CN30

CN130 CN130

(1)

CN7

APPENDIX 3 Interconnect Diagram

1 2

CN3

1 2 3

CN5

4 5

PCB2

Circuit Bord

[WK-5597]

1 2 3

CN2

4 5

CN1

2 3

CN10

CN1CN6CN5

PCB3

Control Souce

Circuit Bord

[WK-5548]

CN18 CN18

Filter Circuit Bord

TB1

TB2

TB3

Link

TB4

CN4

PCB7

[WK-5689]

CN7

UB3

Circuit

[WK-5493]

TB1

TB2

TB3

TB4

1 2 3 4

TB13

TB14

TB15

PCB1

Main

Bord

G1 E1

G2 E2

TB18 TB19 TB20

G6 E6

G5 E5

CT1 CT2 CT3 CT4

2 3 4 5 6

CN20

CN3 CN3

CN13

C CE E

PCB8 IGBT

Gate

Circuit

Bord

[WK-5479]

1 2

CN1

1 2 3

CN2

C CE E

PCB9

IGBT

Gate

Circuit

Bord

[WK-5479]

1 2

CN1

1 2 3

CN2

CN15

1 2 3 4 5

G E

Q7 G E

Q8 G E

Q9 G E

Q10 G E

Q11 G E

Q12 G E

2 3 4 5 6 7

CN21

CN16

2 3 4

TB10 TB11 TB12

G4 E4

G3 E3

UB1

G7 E7

G8 E8

PCB6

Control

Circuit Bord

[WK-5688]

C CE E

[WK-5479]

1 2 3

1 2 3 4

TB5

TB6

TB7

[WK-5479]

1 2 3

1 2 3 4

2 3 4 5 6

CN22

CN2

2 3 4 5 6

PCB10

IGBT

Gate

Circuit

Bord

CN1

CN2

PCB11

IGBT

Gate

Circuit

Bord

CN1

CN2

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

2 3 4 5 6 7

CN23

Q13

Q14

Q15

Q16

Q17

Q18

Q19

Q20

Q21

Q22

Q23

Q24

CN19

2 3

24V

115V

1 2 3 4

CN1 5 6

19P

14P

CON2 CON1

2 3 4 5 6 7

U H J N KVAB MLRF D PG ETS

CN7

2 3 4 5 1 2 3 6 74 5

CN3

Socket Receptacle Circuit Bord

CN6

2 38

CN5

2 3 4 5 6

PCB17

[WK-5699]

CN4 CN2

CN10

2 3 4 5 6 7

D E H F N JCKGBILANM

CN9 2 3 4

2 3 4 5 6

CN8

2 3 4 5 6

2 3

CN15

TB1

UB2

UB4

TB7

TB21

TB8

TB16

CT1

PCB14

TRANS

Bord

[WK-5594]

CT2

TB35

TB33

TB34

TB30

TB32

PCB15

DIODE Snubber

Circuit Bord

[WK-5606]

AC2 AC1

SH.DET+

LM-200 INTERCONNECT DIAGRAM

-15

+15

GND

HCT1

1 2 3

2 3 4 5

CN1

PCB18

Filter Circuit

CN3

Bord

[WK-5499]

TO1

+Output

Terminal

Ground

SIDE CHASSIS 3

TB17

TB22

CT3

2 3 4 5

CN8

CT4

TB31

AC4

AC2

2 3 4 5 6 789

CN9

SH.DET-

SH.DET+

TH2 TH1

2 3

CN9

2 3 4

CN8

FCH1

CN17

CN21

CN1

TO2

-Output

Terminal

FRONT PANEL

SH.DET-

UB2UB1

1 2 3 4 5 6 7

+15

-15 IS

GND

1 2 3 4 5 6

1 2 3 4

SIDE CHASSIS 2

UB4UB3

CN2

1 2 3 4

PCB12

Panel

Circuit Board

[WK-5527]

CN1

Ground

PCB13

Encorder

Board

[WK-5528]

CN1

1 2 3 4

RSHD

JKTP

BK I

CLNH

DMG

GFE

CON2 CON1

APPENDIX 4 DIODE TESTING BASIC

DIODE TESTIN G BAS IC

APPENDIX 4 DIODE Testing Basic

Testing of diode modules requires a digital Volt/ Ohmmeter that has a diode test scale.

1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to isolate them within the module.

3. Set the digital volt/ohm meter to the diode test scale.

4. Using figure 1 and 2, check each diode in the module. Each diode must be checked in both the forward bias (positive to negative) and reverse bias (negative to positive) direction.

5. To check the diode in the forward bias direction, connect the volt/ohm meter positive lead to the anode (positive, +) of the diode and the negative lead to the cathode (negative, –) of the diode (refer to Figure 10-1). A properly functioning diode will conduct in the forward bias direction, and will indicate between 0.3 and 0.9 volts.

6. To check the diode in the reverse bias direction, reverse the meter leads (refer to Figu re 10-1). A properly functioning diode will block current flow in the reverse bias direction, and depending on the meter function, will indicate an open or "OL".

7. If any diode in the module tests as faulty, replace the diode module.

8. Reconnect all cables to the proper terminals.

Anode

COM AVR

Forward Bias Diode Conducting

Cathode

Figure 10-1: Forward bias diode test

COM AVR

Reverse Bias Diode Not Conducting

AnodeCathode

Figure10-2: Reverse bias diode test

LIMITED WARRANTY

This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006

LIMITED WARRANTY: Thermal Arc

, Inc., A Thermadyne Company ("Thermal Arc"), warrants to customers of authorized distributors ("Purchaser") that its products will be free of defects in workmanship or material. Should any failure to conform to this warrant appear within the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc's specifications, instructions, recommendat ions and recognized stan dard industry practic e, and not subject to misu se, repair, neglect, alteration, or damage, correct such defects by suitable repair o replacement, at Thermal Arc's sole option, of any components or parts of the produc determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o merchantability, fitness for any particular purpose, or other warranty o quality, whether express, implied, or statutory.

Limitation of liability: Therma l Arc shall not under an y circumstances be lia ble for special, indirect, incidental, or consequential damages, including but not limited to lost profits and business interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of Thermal A rc with respect to any co ntract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe arising out of contract, tort, in cluding negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the goods upon which such liability is based.

No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the safety or performance of any Thermal Arc product. Purchaser’s rights under this warrant are void if the product is sold to purchaser by unauthorized persons.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned good s shall be at the Purchaser's risk and expense. This warranty dated April 1

supersedes all previous Thermal Arc warranties. Thermal Arc

is a Registered

2006

Trademark of Thermal Arc, Inc.

Thermal Arc LM-200 ARCMASTER Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual