THERMAL ARC LM-200 Inverter Arc Welder Instruction manual

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LM-200

INVERTER ARC WELDER

Operating Manual

Version No: 1 Issue Date: November 30, 2005 Manual No.: 0-4835 Operating Features:

SMAW

1/3

PHASE

208V230V460

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 1-800-752-7621, 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.

WARNINGS

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 judgement, the Manufacturer assumes no liability for its use.

LM-200 Inverter Arc Welder Operation Manual Number 0-4835 for: Part Number 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: November 30, 2005

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Precautions de Securite en Soudage à l’Arc ................................................... 1-5

1.04 Dangers Relatifs au Soudage à l’Arc ............................................................... 1-5

1.05 Principales Normes de Securite ..................................................................... 1-8

2.01 How To Use This Manual ................................................................................ 2-1

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 Functional Block Diagram ............................................................................... 2-4

2.07 Transporting Methods .................................................................................... 2-5

2.08 Electrical Input Connections ........................................................................... 2-6

2.09 Specifications ................................................................................................. 2-9

2.10 Duty Cycle .................................................................................................... 2-10

SECTION 3:

OPERATION........................................................................................... 3-1

3.01 LM-200 DC CC Views ..................................................................................... 3-1

3.02 Weld Parameter Descriptions for Pro-Plus LM-200 ....................................... 3-4

3.03 Weld Process selection for the LM-200.......................................................... 3-6

3.04 Weld Parameter Descriptions ......................................................................... 3-7

3.05 Weld Parameters ............................................................................................ 3-9

3.06 Power Source Features................................................................................. 3-10

SECTION 4:

SAVE/LOAD OPERATION ........................................................................... 4-1

4.01 SEQUENCE OF OPERATION ............................................................................ 4-1

4.02 Save / Load Operation .................................................................................... 4-2

4.03 LOAD Operation.............................................................................................. 4-2

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING ...................................... 5-1

5.01 Basic Maintenance ......................................................................................... 5-1

5.02 General Troubleshooting ................................................................................ 5-2

5.03 Common Welding Operation Faults ................................................................ 5-2

5.04 Solving MIG Problems Beyond the Welding Terminals................................... 5-3

5.05 MIG Welding Problems .................................................................................. 5-5

5.06 TIG Welding Problems ................................................................................... 5-6

5.07 Stick Welding Problems ................................................................................. 5-8

5.08 Power Source Problems ............................................................................... 5-10

5.09 Error Codes .................................................................................................. 5-11

5.10 Voltage Reduction Device (VRD) .................................................................. 5-13

5.11 VRD Maintenance .........................................................................................5-13

5.12 Switching VRD On/Off .................................................................................. 5-14

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: SYSTEM SCHEMATIC ..................................................................... A-2

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

LM-200 INVERTER ARC WELDER

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.

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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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LM-200 INVERTER ARC WELDER

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.

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Eye protection filter shade selector for welding or cutting

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

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

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WARNING

LM-200 INVERTER ARC WELDER

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.

November 30, 2005

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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LM-200 INVERTER ARC WELDER

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.

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LM-200 INVERTER ARC WELDER

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.

November 30, 2005

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LM-200 INVERTER ARC WELDER

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

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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

LM-200 INVERTER ARC WELDER

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.

November 30, 2005

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

LM-200 INVERTER ARC WELDER

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.

November 30, 2005

SECTION 2:

INTRODUCTION

LM-200 INVERTER ARC WELDER

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

November 30, 2005

2-1

LM-200 INVERTER ARC WELDER

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

November 30, 2005

LM-200 INVERTER ARC WELDER

2.05 Description

The Thermal Arc™ Pro-Plus LM-200 is a single & three-phase DC arc welding power source with Constant 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), Inductance Control for Gas Metal Arc Welding (GMAW) processes. The power source is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case

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.

(V)

OCV

Art # A-06919

18V

(V)

OCV

10V

160A

200A1A (A)

220A

(V)

OCV

28V

10V

200A25A (A)

Figure 1: Model LM-200 volt-ampere curve

200A1A (A)

220A

November 30, 2005

2-3

LM-200 INVERTER ARC WELDER

2.06 Functional Block Diagram

Input

Power

Mai n Ci rc u i t Switc h

Filter

Transformers

AC115V,AC24V

Current Protect

Rec e p t ac l e

Art # A-06920

Down

(T3)

Ove r

(CON1)

(CON2)

14PIN

19PIN

Input

Di o de

Cap ac i tor

DC Po wer Primary Volt age

Sensor

To eac h control c ircui t

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

IGBT

Inverter

Themal

Det e c t o r

Trouble

Sensi ng

Ci rc u i t

Dri ve

Ci rc u i t

Mai n

Transformers

(T1)

Primary

Ci rc u i t

Sensor

Thermal

Sensor

Ci rc u i t

Current

Adjus tment

Ci rc u i t

Output

Di o de s

Themal

Det e c t o r

Sequence

Con t ro l

Mode select Switch

Panel Ci rcuit Boad

Sti ck Mode

VRD

Sensi ng

Ci rc u i t

Ref e re nc e

Adjus tment &

Ou t pu t

Inductor

Figure 2: LM-200 Model functional block diagram

Lif t Ti g Mode Output Short

Sensi ng

Ci rc u i t

14PIN-19PIN Sele ct Switc h

(S3)

Fan Control

Ci rc u i t

Hal l Curr ent Transformer

(HCT1)

Fan

2-4

November 30, 2005

LM-200 INVERTER ARC WELDER

2.07 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 deenergized supply line before moving welding power source.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

• Lift unit with handle or shoulder strap on top of case.

• Use hand cart or similar device of adequate capacity.

• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

November 30, 2005

2-5

LM-200 INVERTER ARC WELDER

2.08 Electrical Input Connections

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 redtagging circuit breaker or other disconnecting device.

Electrical Input Requirements: Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input 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.

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 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).

The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

NOTE

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

• To operate signal-phase, do not connect the RED

input conductor.

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

• Do not connect the ground (GREEN) conductor to an input line terminal.

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

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

2-6

November 30, 2005

Welding Power Supply

LM-200 INVERTER ARC WELDER

Ground Conductor

Ground Terminal

Line Disconect Switch

Line Fuse

Art # A-06923

Primary Power Cable

Figure 3: Electrical input connections

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

NOTE

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

November 30, 2005

2-7

LM-200 INVERTER ARC WELDER

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

Model

PRO-PLUS

LM-200

Primary Supply

Lead Size

8/4 AWG minimum

(Factory Fitted)

8/3 AWG minimum 1 ?

3 ?

Minimum Primary

Current Circuit Size

(Vin/Amps)

208/39 230/35 460/18 208/29 230/27 460/14 208/45 230/41 460/21 208/51 230/44 208/37 230/33 208/57 230/51 - -

Current & Duty Cycle

MIG TIG STICK

- -

200A @ 60%

- -

200A @ 60%

- -

200A @ 60%

- -

200A @ 60%

Table 2: Primary Current Circuit sizes to achieve maximum current

2-8

November 30, 2005

2.09 Specifications

Parameter LM-200 Rated Output

Amperes Volts Duty Cycle

LM-200 INVERTER ARC WELDER

200 28 60% 200A / 18V @ 60% Duty Cycle TIG 150A / 16V @ 100% 200A / 28V @ 60% STICK 150A / 26V @ 100% 200A / 24V @ 60% MIG 150A / 22V @ 100%

Output Current Range

Output Voltage Range

Open Circuit Voltage 65V Dimensions

Width Height Length Weight 59.5 lb. 27.0 kg Output @ Rated Load Output Amperes 200A Output Volts 28V Duty Cycle 60% KVA 9.3 KW 7.0

Output @ No Load

KVA KW

Input Volts Single Phase

208V 230V

Input Volts Three Phase

208V 230V 460V

TIG STICK

MIG 10 – 28V

1 – 200A

8.27” (210mm)

16.89” (420mm)

17.72” (450mm)

0.5

0.13 Amperage Draw @ Rated Load

57 51

45 41 21

No Load

2.4

1.8

1.4

1.1

0.7

November 30, 2005

2-9

LM-200 INVERTER ARC WELDER

2.10 Duty Cycle

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

To calculate duty cycle:

current

i.e. At 400A rated output current, and 25% rated duty cycle, the operator wants to work on a 50% duty cycle. The maximum allowable current draw is:

(rated current) x(rated duty cycle)

(desired duty cycle)

current

current current

current

(400A) x(.25)

(.50)

160,000x(0.5)

80,000

282.8A

Art # A-05167

Art # A-05168

2-10

November 30, 2005

3.01 LM-200 DC CC Views

LM-200 INVERTER ARC WELDER

SECTION 3:

OPERATION

Art # A-06925

Figure 3-1: Pro-Plus LM-200 Power Source

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 welding 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 Pin Function

A B Input to energize solid state contactor

C 5k ohm (maximum) connection to 5k ohm remote control potentiometer D E Wiper arm connection to 5k ohm remote control potentiometer

F Current feedback Ifb = 100Amps/Volt G 24/115 VAC circuit common, also connected to chassis H Voltage Feedback Vfb = 10 Arc Volts/Volt

I 115 VAC auxiliary high side

K Chassis ground

L,M,N Not used

24VAC auxiliary high side.

(Contact closure between pin A and pin B)

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

115 VAC input to energize solid state contactor (Contact closure between pin I and pin J)

November 30, 2005

3-1

LM-200 INVERTER ARC WELDER

3. Positive Terminal: Welding current flows from the Power Source 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 Source 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).

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 Pin Function

A B Contactor circuit in, (closure between pin A and Pin B will energize output.) C Scaled output voltage signal: Vfb = 10 Arc Volts/Volt D 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 Circuit common P 24 VAC auxiliary power high side R 24/115 VAC neutral S N/C T N/C U Scaled output signal: Ifb = 100 Amps/Volt V N/C

Contactor circuit (+15 Volts)

24 VAC auxiliary power high side

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.

3-2

Nvember 30, 2005

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, 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 switch. 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.

LM-200 INVERTER ARC WELDER

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.

November 30, 2005

3-3

LM-200 INVERTER ARC WELDER

3.02 Weld Parameter Descriptions for Pro-Plus LM-200

Art # A-06930

Figure 3-2: Pro-Plus LM-200 Front Panel with Parameter Description

3-4

Nvember 30, 2005

LM-200 INVERTER ARC WELDER

Parameter Description

ARC CONTROL

HOT START

DC (A)

DC (V)

This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking 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 (Amperage)- when lit parameter knob sets the STICK and TIG WELD current.

(WELD)

current.

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

Contactor ON/OFF

Operation PANEL/REMOTE

INDUCTANCE

Contactor operation in Stick Mode.

Selects in operation Panel boad or Remote.

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

Weld Parameter Descriptions for Pro-Plus LM-200

November 30, 2005

3-5

LM-200 INVERTER ARC WELDER

3.03 Weld Process selection for the LM-200

Weld Mode

Weld Parameter

WELD (V)

INDUCTANCE

HOT START

WELD (A)

ARC CONTROL

STICK

MIG

LIFT TIG

              

Weld Process Selection Verses Weld Mode

Description

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).

3-6

Nvember 30, 2005

LM-200 INVERTER ARC WELDER

3.04 Weld Parameter Descriptions

1. WELD (V) - This parameter sets the MIG weld arc voltage in MIG mode.

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 parameter is set to 0%, ie minimum inductance, the arc has a fast response with a resulting crisp arc noise and coarse spatter. When this parameter is set to 100%, ie maximum inductance, 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. 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 current = 150 amps when Weld Current = 100 amps & HOT START = 50A

4. WELD (A) - This parameter sets the STICK & Lift TIG weld current.

5. ARC CONTROL - This parameter operates in STICK mode only and is used to adjust percentage increase in

welding current and is proportional to arc length (arc voltage). 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 certain situations with particular electrodes, eg cellulose and hydrogen controlled 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) 0A Soft arc, Low spatter, Low penetration

Medium (20%) 32A Normal arc, Improved fusion

Maximum (100%) 160A Hard arc, Deep penetration

Current Increase when Arc Voltage

is less than 18V

Effect on Welding Performance

characteristics,

Normal penetration

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 arc length does not significantly effect the welding current. When the ARC CONTROL set to 100%, it is possible to control the 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.

November 30, 2005

3-7

LM-200 INVERTER ARC WELDER

• 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 weld collapses. If too little 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 decrease until the hole starts to close up but if the hole closes up to much then the arc length decreases which 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.

• Vertical up welding

When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, ie voltage. Weld metal is deposited by “digging” the electrode into the side of the base metal joint and then increasing the arc length with a flicking 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 has to manually decrease the current via a remote current control to freeze the weld pool. This welding current reduction also reduces the penetration.

The arc force allows the weld pool to freeze during the “flick” phase without decreasing the amount of weld current available during the “dig” phase thus maximizing penetration.

3-8

Nvember 30, 2005

3.05 Weld Parameters

Weld Mode

Weld

Parameter

WELD (V)

MIG

INDUCTANCE

HOT START

WELD (A)

TIG or STICK

ARC CONTROL

Parameter Range Factory

10.0 to 28.0V DC 17.0V 0.1V

LM-200 INVERTER ARC WELDER

Incremental

Setting

0 to 100% 10% 1%

0 to 70A 20A 1A

1 to 200A DC 80A 1A

0 to 100% 10% 1%

Unit

STICK

MIG

LIFT TIG

  

     

     

November 30, 2005

3-9

LM-200 INVERTER ARC WELDER

3.06 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)

Control Knob

Self Diagnosis Using Error Codes

• All welding parameters are adjustable

• Touch switches eliminate mechanical 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 after machine is

turned on

• Fan speed increases when internal 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.

• For the selected weld parameter, rotating the knob clockwise

increases the parameter

• Rotating the knob counterclockwise decreases 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

• An error code is displayed on the

occurs with Mains supply voltage or internal component problems.

Digital Meter

when a problem

3-10

Save/Load function

• A total number of 5 programs can be saved into the LM-200

memory

SAVE

the Current Weld Parameters into Memory

SAVE

LOAD

button

Nvember 30, 2005

• Press the

• Select a memory location by rotating 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

• Select a memory location by rotating 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 are loaded onto the control panel

LM-200 INVERTER ARC WELDER

SECTION 4:

SAVE/LOAD OPERATION

4.01 SEQUENCE OF OPERATION

NOTE

Parameter Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.

Art # A-06931

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.

November 30, 2005

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.

NOTE

Use the Scroll Buttons to move to the parameter 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.

4-1

LM-200 INVERTER ARC WELDER

4.02 Save / Load Operation

A total number of 5 programs can be saved into the LM-

200.

SAVE the Current Weld Parameters into Memory

1. Press the Save Button

2. Select a memory location by rotating the control knob. 1to 5 will be displayed on the meter.

3. After selecting the desired memory location (i.e. 1 to 5), press the parameter button and the machine will beep to confirm the weld parameters from the control panel are saved.

LOAD (retrieve) a Saved Welding Parameter from

Memory

1. Press the LOAD button

2. Select the desired memory location, 1 to 5, by rotating the control knob.

3. When the desired memory location has been selected, press the parameter button and the machine will beep to confirm the weld parameter is loaded onto the control panel.

NOTE

If you have not previously saved any weld parameters into the memory, the LOAD function will not work.

4.03 LOAD Operation

The LOAD operation can be performed only when the machine is idling. The machine can be in any mode of operation to LOAD but no welding should be performed during a LOAD operation.

4-2

November 30, 2005

SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING

5.01 Basic Maintenance

LM-200 INVERTER ARC WELDER

Warning! Disconnect input power before maintaining.

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Each Use

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

Maintain more often if used under severe conditions

Visually inspect the Wire feed mechanisms

Replace all broken parts

3 Months

Gas and air lines

6 Months

Visually check and use a vacuum to carefully

clean the interior

Clean exterior of power supply

Art # A-06950

November 30, 2005

5-1

LM-200 INVERTER ARC WELDER

5.02 General Troubleshooting

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 had training in power electronics measurement and troubleshooting techniques.

5.03 Common Welding Operation Faults

The following are some of the more common operating faults that occur during welding operations:

1. Power:

• Main power not connected

• Main power not turned on

• MAIN CIRCUIT BRAKER set on OFF position

• INPUT SELECTOR (Easy Link) Switch in wrong position

2. Poor Weld:

• Wrong polarity

• Wrong electrode used

• Electrode not properly prepared

• Incorrect welding amperage setting

• Speed too slow or too fast

• Incorrect switch settings for intended operation

• Poor weld output connection(s)

If the problem is not resolved after checking the above, the following guide may suggest more specific items to check given the faulty operating symptom(s) you are experiencing.

5-2

November 30, 2005

LM-200 INVERTER ARC WELDER

5.04 Solving MIG Problems Beyond the Welding Terminals

The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW.

A. Porosity

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

Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points:

Porosity Problem Solution

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 between the regulator/cylinder connection and in the

gas hose to 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

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

6 Distance between the MIG torch nozzle and the work piece

7 Maintain the MIG torch in good working order

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

Clean contaminates off the plate

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

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.

November 30, 2005

5-3

LM-200 INVERTER ARC WELDER

B. Inconsistant Wire Feed

Checking the following points can reduce wire-feeding problems:

Wire Feed Problem Solution

1 Wire spool brake is too tight

2 Wire spool brake is too loose Wire spool can unwind and tangle.

3 Worn or incorrect feed roller size

4 Misalignment of inlet/outlet guides Wire will rub against the misaligned guides and reduces

5 Liner blocked with wire debris

6 Incorrect or worn contact tip

Feed roller driven by motor in the cabinet will slip.

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

Use 'V' groove drive feed roller 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.

wire feedability.

Wire debris is produced by the wire passing 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 incorrect feed roller groove shape or size.

Wire debris is fed into the liner where it accumulates thus reducing wire feedability.

The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip.

5-4

When using soft electrode wire such as aluminum it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft electrode wires should be used.

7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the work

piece then the connection point will heat up and result in a reduction of power at the arc.

8 Bent liner

This will cause friction between the wire and the liner thus reducing wire feedability

November 30, 2005

5.05 MIG Welding Problems

LM-200 INVERTER ARC WELDER

Description

1 Undercut A Welding arc voltage too high. A Reduce

B Incorrect torch angle B Adjust angle C Excessive heat input C Increase the torch travel speed and/or reduce

2 Lack of penetration A Welding current too low A Increase welding current by increasing wire

B Joint preparation too narrow or gap

too tight

C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase 4 Excessive spatter A Voltage too high A Lower the voltage by reducing the

B Voltage too low B Raise the voltage by increasing the

5 Irregular weld shape A Incorrect voltage and current settings.

Convex, voltage too low. Concave,

voltage too high. B Wire is wandering B Replace contact tip C Incorrect shielding gas C Check shielding gas. D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage

6 Weld cracking A Weld beads too small A Decrease travel speed

B Weld penetration narrow and deep B Reduce current and voltage and increase MIG

C Excessive weld stresses C Increase weld metal strength or revise design D Excessive voltage D Decrease voltage by reducing the

E Cooling rate too fast E Slow the cooling rate by preheating part to be

7 Cold weld puddle A Faulty rectifier unit A Have an Accredited Thermal Arc Service Agent

B Loose welding cable connection. B Check all welding cable connections. C Low Primary Voltage C Contact supply authority

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.

Possible Cause

Remedy

WELD (V)

feed speed.

welding current by reducing the control or reducing the wire feed speed.

feed speed and increasing

B Increase joint angle or gap

WELD (V)

control or increase the wire

WELD (V)

control.

WELD (V)

control or increase wirespeed control.

WELD (V)

control or reduce wirespeed control.

A Adjust voltage and current by adjusting the

WELD (V)

selection switches.

torch travel speed or select a lower penetration shielding gas.

control and the wirespeed control.

WELD (V)

control.

welded or cool slowly.

to test then replace the faulty component.

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.

November 30, 2005

5-5

LM-200 INVERTER ARC WELDER

5.06 TIG Welding Problems

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

Description Possible Cause Remedy

1 Excessive beard build-

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

Weld bead too wide

and flat or undercut at edges of weld or excessive burn through

3 Weld bead too small or

insufficient penetration or ripples in bead are widely spaced apart

4 Weld bead too wide or

excessive bead build up or excessive penetration in butt joint

5 Uneven leg length in

fillet joint

6 Electrode melts when

arc is struck.

7 Dirty weld pool. A Electrode contaminated through

B Gas contaminated with air. B Check gas lines for cuts and loose

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.

contact with work piece or filler rod material.

Connect the electrode to the ‘−’ terminal.

A Clean the electrode by grinding off

the contaminates.

fitting or change gas cylinder.

5-6

8 Electrode melts or

oxidizes when an arc is

struck. B Torch is clogged with dust. B Clean torch C Gas hose is cut. C Replace gas hose. D Gas passage contains impurities. D

E Gas regulator turned off. E Turn on. F Torch valve is turned off. F Turn on. G

A No gas flowing to welding region. A Check the gas lines for kinks or

breaks and gas cylinder contents.

Disconnect gas hose from torch then raise gas pressure and blow out impurities.

The electrode is too small for the welding current.

Increase electrode diameter or

reduce the welding current.

November 30, 2005

LM-200 INVERTER ARC WELDER

Description Possible Cause Remedy

9 Poor weld finish Inadequate shielding gas.

Arc flutters during TIG

welding

B Absence of oxides in the weld pool. B Refer Basic TIG Welding Guide for

11 Welding arc can not be

established

B Torch lead is disconnected. B C

12 Arc start is not smooth A

B The wrong electrode is being used

C Gas flow rate is too high. C

E Poor work clamp connection to

Tungsten electrode is too large for

the welding current.

A Work clamp is not connected to the

work piece or the work/torch leads are not connected to the right welding terminals.

Gas flow incorrectly set, cylinder empty or the torch valve is off.

Tungsten electrode is too large for the welding current.

for the welding job

Incorrect shielding gas is being used.

work piece.

Increase gas flow or check gas line for gas flow problems.

Select the right size electrode. Refer

to Basic TIG Welding guide.

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.

Connect it to the ‘−‘ terminal. Select the right flow rate, change

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

to Basic TIG Welding Guide.

B Select the right electrode type.

Refer to Basic TIG Welding Guide Select the correct rate for the

welding job. Refer to Basic TIG Welding Guide.

Select the right shielding gas. Refer

to Basic TIG Welding Guide.

E Improve connection to work piece.

November 30, 2005

5-7

LM-200 INVERTER ARC WELDER

5.07 Stick Welding Problems

Description Possible Cause Remedy

1 Gas pockets or voids in

weld metal (Porosity)

2 Crack occurring 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

D Incorrect sequence D Use correct build-up sequence

Incorrect sequence

Insufficient gap

Electrodes are damp

Welding current is too high

Surface impurities such as oil, grease, paint, etc.

Rigidity of joint.

Insufficient throat thickness

Cooling rate is too high

Welding current is too low

Electrode too large for joint

Insufficient gap

Art # A-04991

Figure 5-1 - Example of insufficient gap or incorrect sequence

Dry electrodes before use

Reduce welding current

Clean joint before welding

Redesign to relieve weld joint of severe stresses or use crack resistance electrodes

Travel slightly slower to allow greater build up in throat

Preheat plate and cool slowly

Increase welding current

Use smaller diameter electrode

Allow wider gap

Portions of the weld run

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

C Wrong electrode angle C Adjust angle so the welding arc is

D Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on joint surface E Clean surface before welding

Small electrodes used on heavy cold plate

Welding current is too low

Lack of fusion caused by dirt,

Use larger electrodes and pre-heat the plate

Increase welding current

directed more into the base metal

Art # A-04992

electrode angle incorrect, rate of travel too high

Lack of inter-run fusion

Lack of side fusion, scale dirt, small electrode,

Lack of root fusion

amperage too low

5-8

Figure 5-2 - Example of Lack of Fusion

November 30, 2005

LM-200 INVERTER ARC WELDER

Non-metallic particles

are trapped in the weld metal (slag inclusion)

B Joint preparation too restricted B Allow for adequate penetration and

C Irregular deposits allow slag to be

D Lack of penetration with slag

E Rust or mill scale is preventing full

F Wrong electrode for position in

A Non-metallic particles may be

trapped in undercut from previous run

trapped

trapped beneath weld bead

fusion

which welding is done

A If bad undercut is present, clean slag

out and cover with a run from a smaller diameter electrode.

room for cleaning out the slag

C If very bad, chip or grind out

irregularities

D Use smaller electrode with sufficient

current to give adequate penetration. 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, otherwise proper control of slag is difficult

Art # A-04993

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

Figure 5-3 - Eamples of Slag

November 30, 2005

5-9

LM-200 INVERTER ARC WELDER

5.08 Power Source Problems

Description Possible Cause Remedy

1 The welding arc cannot

be established

C Loose connections internally. C Have an Accredited Thermal Arc

The Primary supply voltage has not

been switched ON. The Welding Power Source switch is

switched OFF.

Switch ON the Primary supply

voltage. Switch ON the Welding Power

Source.

Service Agent repair the connection.

2 Maximum output

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

Welding current

reduces when welding

4 No gas flow when the

torch trigger switch is depressed.

C Gas regulator turned off. C Turn gas regulator on. D Torch trigger switch lead is

5 Gas flow won’t shut off A Weld Mode (

B Gas valve is faulty. B Have an Accredited Thermal Arc

C Gas valve jammed open. C Have an Accredited Thermal Arc

D 6 The TIG electrode has

been contaminated due to the gas flow shutting off before the programmed time has elapsed

POST-FLOW

Defective control circuit Have an Accredited Thermal Arc

Service Agent inspect then repair the welder.

Poor work lead connection to the work piece.

A B Gas hose is cut.

Gas passage contains impurities. A B

disconnected or switch/cable is faulty.

STD, SLOPE, REPEAT

SPOT

) was changed before

POST-FLOW

The Weld Process Mode (STICK, HF

TIG or LIFT TIG) was changed before finished.

gas time had finished.

control is set to 60 sec. D Reduce

POST-FLOW

gas time had

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

Replace gas hose. Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities.

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.

Service Agent replace gas valve.

Service Agent repair or replace gas valve.

POST-FLOW

Do not change Weld Process Mode

before the finished.

POST-FLOW

time.

gas time had

5-10

November 30, 2005

LM-200 INVERTER ARC WELDER

5.09 Error Codes

Description Possible Cause Remedy Remarks

1 E01 error code

displayed Temperature sensor TH1 (protects IGBTs) is greater than 80ºC for about 1 second

E02 error code

displayed Temperature sensor TH2 (protects secondary diodes) is greater than 80ºC for about 1 second

3 E03 error code

displayed Primary (input) current too high

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked

Primary current is too high because welding arc is too long.

Mains supply voltage is

more than 10% below nominal voltage

Let Power Source cool down then keep within its duty cycle.

Have an Accredited Thermal

Arc Service Agent investigate

Unblock vents then let Power Source cool down.

Let Power Source cool down then keep within its duty cycle.

Have an Accredited Thermal

Arc Service Agent investigate

Unblock vents then let

Power Source cool down.

Reduce length of welding arc.

Have an Accredited Thermal

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

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

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

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

4 E11 error code

displayed Over Primary supply (input) voltage at primary capacitors is exceeded for one second

5 E14 error code

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

E12 error code

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

Primary supply voltage is

greater than the nominal voltage plus 10%.

Mains supply voltage is

less than the nominal operating voltage less 10%.

Mains supply voltage is down to a dangerously low level.

Have an Accredited Thermal

Arc Service Agent or a qualified electrician check the Primary voltage.

Have an Accredited Thermal

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

Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

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

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.

November 30, 2005

5-11

LM-200 INVERTER ARC WELDER

Description Possible Cause Remedy Remarks

7 E81 error code

displayed Wrong Primary supply (input) voltage connected

8 E82 error code

displayed Link switch plug not connected

9 E83 error code

displayed CPU checks mains supply (input) voltage when the on/off switch on rear panel of machine is turned ON.

E93 error code

displayed Memory chip (EEPROM) on control PCB can not read/write weld parameters

When 3 phase machine is

first turned on with the wrong Primary supply (input) voltage connected

Link switch plug not

connected

The Primary supply

(input) voltage fluctuates and is not stable.

Memory chip (EEPROM) error

Have an Accredited Thermal

Arc Service Agent or a qualified electrician check the Mains voltage

Have an Accredited Thermal

Arc Service Agent check connector plug on input PCB

Have an Accredited Thermal

Arc Service Agent check connector plug on input PCB and the Mains voltage

Have an Accredited Thermal Arc Service Agent check the control PCB

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

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.

11 E94 error code

displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit

12 E99 error code

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

The Welding Power

Source’s temperature sensors have malfunctioned.

Main on/off switch on machine has been turned off

Mains supply (input) voltage has been turned off

Have an Accredited Thermal

Arc Service Agent check or replace the temperature sensors.

Turn on/off switch on.

Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses

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

Weld current ceases. Buzzer sounds constantly. Must switch machine off then on to reset E99 error.

5-12

November 30, 2005

5.10 Voltage Reduction Device (VRD)

VRD Specification:

LM-200 INVERTER ARC WELDER

Description

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding terminals VRD Resistance 148 to 193 ohms The required resistance between welding terminals

VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding power once

5.11 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; and B) For fixed equipment, at least once every 12 months. The owners of the equipment shall keep a suitable record

of the periodic tests.

NOTE

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

Notes

to turn ON the welding power

the welding current has stopped

In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Thermal Arc service agent.

Description IEC 60974-1 Requirements

VRD Open Circuit Voltage VRD Turn ON

Resistance

VRD Turn OFF

Time

Less than 20V; at Vin=460V

Less than 200 ohms

Less than 0.3 seconds

November 30, 2005

Periodic Tests

If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should be carried out prior to entering this location.

5-13

LM-200 INVERTER ARC WELDER

5.12 Switching VRD On/Off

Switch the machine Off. A) Remove the clear plastic cover from the control panel (see Figure 5-4).

• 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

Art # A-07079

Figure 5-4: VRD ON/OFF Step A

B) Remove the four mounting screws from the the control panel (see Figure 5-5).

Art # A-07080

5-14

Figure 5-5: VRD ON/OFF Step B

November 30, 2005

LM-200 INVERTER ARC WELDER

C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see

Figure 5-6).

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.

VR1

Art # A-07081

Figure 5-6: VRD ON/OFF Step C and D

D) Turning the VRD ON/OFF (see Figure 5-6)

• To turn VRD ON: rotate the trim potentiometer 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: rotate the trim potentiometer 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.

November 30, 2005

5-15

LM-200 INVERTER ARC WELDER

5-16

November 30, 2005

LM-200 INVERTER ARC WELDER

APPENDIX 1: OPTIONS AND ACCESSORIES

ACCESSORIES PART NO. DESCRIPTION

Stick Kit 10-4082A Work clamp with 10’ cable, and stick electrode with 25’ #1 cable TIG Kit 10-4080 Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with

valve, accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”,

5/16”, 3/8” alumina cup Dinse Connector 10-2020 T50mm Dinse style male plug Hand Held Pendant 10-2005 Includes contactor On/Off switch and current control

with 25ft cable and 14-pin male plug Foot Control 10-2008 Contactor On/Off and current control with 15ft cable

and 14-pin male plug 10-2007 Contactor On/Off and current control with 25ft cable

and 14-pin male plug Extension Cable 10-2030 3ft with 14-pin male plug and 14-pin female cable receptacle 10-2031 15ft with 14-pin male plug and 14-pin female cable receptacle 10-4032 25ft with 14-pin male plug and 14-pin female cable receptacle 10-4033 50ft with 14-pin male plug and 14-pin female cable receptacle 10-4034 75ft with 14-pin male plug and 14-pin female cable receptacle Torch Switch On/Off 10-2001 25ft torch mounted with 14-pin male plug Torch Switch On/Off w/current control 10-2003 25ft torch mounted with 14-pin male plug

10-2004 25ft torch mounted with 14-pin male plug

Rack Systems 10-4029 4 pack w/electrical 10-4031 6 pack w/electrical 10-4033 8 pack w/electrical WIRE FEEDERS

A2000 W3200001 UltraFeed 2 Roll VA2000 W3300001 UltraFeed 2 Roll VA4000 W3400001 UltraFeed 4 Roll VS212 W3512002 PortaFeed 2 Roll

10-2002 25ft torch mounted with 14-pin male plug

- adapts to 5/8”-7/8” torch

- adapts to 7/8”-1-1/8” torch handle

- adapts to 1-1/8”-1-3/8” torch handle

November 30, 2005

A-1

LM-200 INVERTER ARC WELDER

APPENDIX 2: SYSTEM SCHEMATIC

1 2

Art # A-06951

Ground

SIDE CHASSIS 1

460V

230V

FAN 1

REAR PANEL

CN33

CN1 8

1 2 3 4 5 6

1 2 3 4

1 2 3

Lin e1

Lin e2

Lin e3

PCB21

Filte r

Circ uit Bord

[WK-4917 ]

CN1

CN11

MCB2

2 3 4 5

2 3

CN2

1 2 3

CN4

CN31 CN30

Cone ct Circ uit Bord

[WK-5696]

CN131 CN130

1 2 3

CN20

1 2

CN2 0

(1 )

K(7)

G(6)

R(3)

(0 )

S(4)

T(5)

(2 )

1 2 3 4

230V

460V

24V

115V

MCB1

1 2

24V

CN3

PCB4

Detect

Circ uit Bord

[WK-4819]

CN5 CN6 CN4

CN32

PCB5

CN132

CN27

CN1

2 3 4 5 6 7 1 2 3

115V

4 5

2 3

CN7

CN1CN6CN5

CN30CN31

Control So uc e

Circ uit Bord [WK-5548]

CN130CN131

CN18

CN3

TB1

TB2

CN5

TB3

PCB2

Link Circ uit Bord [WK-5597]

TB4

CN2

CN1

CN4

2 3

CN10

PCB3

PCB7

Filte r Cir cuit Bo rd

[WK-5689 ]

UB3

Circ uit Bord

[WK-5493]

TB1

TB2

TB3

TB4

1 2 3

CN7

TB1 4

TB1 5

PCB1 Main

G1 E1

G2 E2

TB1 8

TB1 9

TB2 0

G3 E3

G4 E4

CT1 CT2 CT3 CT4

2 3 4 5 6

CN20

CN3

CN13

PCB8 IGBT Gate Circ uit Bord [WK-5479 ]

1 2 3

1 2 3 4

PCB9 IGBT Gate Circ uit Bord [WK-5479 ]

1 2 3

1 2 3 4

1 2 3 4 5

CN1

CN2

CN1

CN2

2 3 4 5 6 7

CN15

G E

CN21

Q10

Q11

Q12

CN16

2 3 4

TB1 3

TB1 0

TB1 1

TB1 2

G4 E4

G3 E3

TB5

UB1

TB6

TB7

G7 E7

G8 E8

2 3 4 5 6

CN22

PCB6

Control Circ uit Bord [WK-5688]

PCB10

IGBT Gate Circ uit Bord [WK-5479]

1 2

CN1

1 2 3

CN2

PCB11

IGBT Gate Circ uit Bord [WK-5479]

1 2

CN1

1 2 3

CN2

2 3 4 5 6

Q13

G E

Q14

G E

Q15

G E

Q16

G E

Q17

G E

Q18

G E

Q19

G E

Q20

G E

Q21

G E

Q22

G E

Q23

G E

Q24

G E

2 3 4 5 6 7

CN23

CN19

2 3

A-2

24V

115V

1 2 3 4

CN1

5 6

19P

CON 2 CON 1

14P

2 3 4 5 6 7

U J H N KVAB MLRF D PG ETS

2 3 4 5 1 2 3 6 74 5

CN3

CN7

CN6

2 38

PCB17

Socket Receptacle Circuit Bord

[WK-5689 ]

CN5

2 3 4 5 6

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

CN15

TB1

November 30, 2005

UB2

UB4

TB7

TB2 1

TB8

TB1 7

TB1 6

TB2 2

CT3

CT1

PCB14

TRANS Bord

[WK-5594]

CT2

TB3 5

TB3 3

TB3 4

TB3 0

TB3 2

TB3 1

AC4

PCB15

DIODE Snubber

Circ uit Bord [WK-5606]

AC2 AC1

LM-200 INVERTER ARC WELDER

-15

+15

GND

SH.D ET +

FCH1

HCT1

1 2 3

Filte r Cir cuit Bo rd

CN3

2 3 4 5

CN1

PCB18

[WK-5499 ]

TO1

Grou nd

SIDE CHASSIS 3

TO2

+Output

Term inal

-Output

Term inal

2 3 4 5

CN8

CT3

RSHD

CT4

GFE

AC4

AC2

2 3 4 5 6 789

CN9

JKTP

CL NH

SH.D ET -

SH.D ET +

BKI

DMG

TH2 TH1

2 3

CN9

2 3 4

CN8

FRONT

PCB12

Panel

[WK-5527]

PANEL

Gro und

PCB13

Encorder Board

[WK-5528]

CN1

1 2 3 4

SH.D ET -

UB2UB1

1 2 3 4

CN17

5 6 7

GND

+15

-1 5

1 2 3 4 5 6

1 2 3

CN2 1

1 2 3

CN1

SIDE CHASSIS 2

UB4UB3

Circ uit Boa rd

CN2

CN1

1 2 3 4

Art # A-06951

November 30, 2005

CON 2 CON1

A-3

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 ("Purchase r") 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 pr ofits and business interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of Thermal A rc with respect to any contract, 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. P urchaser’s righ ts under this warr ant are void if the product is sold to purchaser by unauthorized per sons.

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) d ays 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 goods 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.

WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout, Raider, Ex p lorer

Original Main Power Stators and Inductors.................................................................................. 3 years

Original Main Power Rectifiers, Control P.C. Boards................................................................... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine’s Warranty for Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors............................................................... ....1 year

GTAW (TIG) & MULTI-PROCES S IN VERTER WELDING EQUIP MENT WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors............................................................... ....1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years

Welding Console, Weld Con tr o lle r , Weld Timer............................................. .................... .......... 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................ ................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Control P.C. Bo a r d s............................................... .....................1 year 1 year

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

160S, 300S, 400S

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards....................... ............................................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators.......................................................................................................................1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts. .................. ............................ ....... ...................... .................................90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years 3 years

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com

www.thermalarc.com

THERMAL ARC LM-200 Inverter Arc Welder Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.05 Principales Normes de Securite

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 Symbol Chart

2.05 Description

2.06 Functional Block Diagram

2.07 Transporting Methods

2.08 Electrical Input Connections

2.09 Specifications

2.10 Duty Cycle

3.01 LM-200 DC CC Views

3.02 Weld Parameter Descriptions for Pro-Plus LM-200

3.03 Weld Process selection for the LM-200

3.04 Weld Parameter Descriptions

3.05 Weld Parameters

3.06 Power Source Features

4.01 SEQUENCE OF OPERATION

4.02 Save / Load Operation

4.03 LOAD Operation

SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING

5.01 Basic Maintenance

5.02 General Troubleshooting

5.03 Common Welding Operation Faults

5.04 Solving MIG Problems Beyond the Welding Terminals

5.05 MIG Welding Problems

5.06 TIG Welding Problems

5.07 Stick Welding Problems

5.08 Power Source Problems

5.09 Error Codes

5.10 Voltage Reduction Device (VRD)

5.11 VRD Maintenance

5.12 Switching VRD On/Off

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: SYSTEM SCHEMATIC

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION