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LM-200

INVERTER ARC
WELDER

Operating Manual
Version No: 1
Operating Features:

Issue Date: November 30, 2005

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Manual No.: 0-4835

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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 employers 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
Copyright 2005 by
Thermadyne Industries, Inc.
All rights reserved.
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
1.02
1.03
1.04
1.05
2.01

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


Principal Safety Standards ............................................................................. 1-4
Precautions de Securite en Soudage lArc ................................................... 1-5
Dangers Relatifs au Soudage lArc ............................................................... 1-5
Principales Normes de Securite ..................................................................... 1-8
How To Use This Manual ................................................................................ 2-1

SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10

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


Receipt Of Equipment ..................................................................................... 2-1
Symbol Chart ................................................................................................. 2-2
Description ..................................................................................................... 2-3
Functional Block Diagram ............................................................................... 2-4
Transporting Methods .................................................................................... 2-5
Electrical Input Connections ........................................................................... 2-6
Specifications ................................................................................................. 2-9
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

TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
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: SAFETY IN WELDING AND CUTTING. This publication and other
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

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.

WARNING

9. Do not wrap cables around your body.


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

ELECTRIC SHOCK can kill.

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

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.

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


parts at once.

1. Do not touch live electrical parts.

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.
15. Keep all panels and covers securely in place.

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 Owners
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.

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.

November 30, 2005

1-1

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.

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

WELDING can cause fire or explosion.

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

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.

WARNING

FUMES AND GASES can be hazardous to your health.

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

Welding produces fumes and gases. Breathing these


fumes and gases can be hazardous to your health.

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

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

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.

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

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

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

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

4. Read the Material Safety Data Sheets (MSDSs) and the


manufacturers instruction for metals, consumables, coatings, and
cleaners.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition


can cause fire on the hidden side.

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 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.

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.

Eye protection filter shade selector for welding or cutting


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

Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc

1-2

Electrode Size

Filter
2
3 or 4

Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm

3 or 4
4 or 5
5 or 6

Under 1/8 in., 3 mm


1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm

4 or 5
5 or 6
6 or 8
10
12
14

Welding or cutting

Electrode Size

Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp

Filter
11
12
12
12
12
12

12
14
9
12
14

November 30, 2005

LM-200 INVERTER ARC WELDER


WARNING
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

2. If used in a closed area, vent engine exhaust outside and away


from any building air intakes.

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.

CYLINDERS can explode if damaged.

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

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.

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

1. Protect compressed gas cylinders from excessive heat, mechanical


shocks, and arcs.

WARNING
MOVING PARTS can cause injury.

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.

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

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

1. Keep all doors, panels, covers, and guards closed and


securely in place.

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

2. Stop engine before installing or connecting unit.

5. Use only correct shielding gas cylinders, regulators, hoses, and


fittings designed for the specific application; maintain them and
associated parts in good condition.

3. Have only qualified people remove guards or covers for


maintenance and troubleshooting as necessary.

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

4. To prevent accidental starting during servicing, disconnect


negative (-) battery cable from battery.

7. Keep protective cap in place over valve except when cylinder is in


use or connected for use.

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

8. Read and follow instructions on compressed gas cylinders,


associated equipment, and CGA publication P-1 listed in Safety
Standards.

6. Reinstall panels or guards and close doors when servicing


is finished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;


BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.

WARNING

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


2. Stop engine before disconnecting or connecting battery cables.

ENGINE EXHAUST GASES can kill.


3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.

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

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

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

November 30, 2005

1-3

LM-200 INVERTER ARC WELDER


1.02
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.

Principal Safety Standards

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.

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

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

The following is a quotation from the General Conclusions Section of


the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): ...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.

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

1-4

November 30, 2005

LM-200 INVERTER ARC WELDER


1.03

Precautions de Securite en Soudage lArc

MISE EN GARDE

LE SOUDAGE A LARC EST DANGEREUX


PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
SAPPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QUILS NAIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL DOPERATION OU LES INSTRUCTIONS AVANT DINSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procds de soudage peuvent sauser des blessures graves ou la mort, de mme que des dommages au reste du matriel et la
proprit, si lutilisateur nadhre pas strictement toutes les rgles de scurit et ne prend pas les prcautions ncessaires.
En soudage et coupage, des pratiques scuritaires se sont dveloppes suite lexprience passe. Ces pratiques doivent tre apprises par
tude ou entranement avant dutiliser lequipement. Toute personne nayant pas suivi un entranement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les quipements raccords aux lignes dalimentation alors que dautres sadressent aux
groupes lectrognes.
La norme Z49.1 de lAmerican National Standard, intitule SAFETY IN WELDING AND CUTTING prsente les pratiques scuritaires suivre.
Ce document ainsi que dautres guides que vous devriez connatre avant dutiliser cet quipement sont prsents la fin de ces instructions de
scurit.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX DINSTALLATION, DE REPARATION, DENTRETIEN ET DESSAI.

1.04

Dangers Relatifs au Soudage lArc

AVERTISSEMENT
LELECTROCUTION PEUT ETRE MORTELLE.

6. Arrtez tout quipement aprs usage. Coupez lalimentation de


lquipement sil est hors dusage ou inutilis.
7. Nutilisez que des porte-lectrodes bien isols. Ne jamais plonger
les porte-lectrodes dans leau pour les refroidir. Ne jamais les
laisser traner par terre ou sur les pices souder. Ne touchez
pas aux porte-lectrodes raccords deux sources de courant en
mme temps. Ne jamais toucher quelquun dautre avec llectrode
ou le porte-lectrode.
8. Nutilisez pas de cbles lectriques uss, endommags, mal
pisss ou de section trop petite.
9. Nenroulez pas de cbles lectriques autour de votre corps.

Une dcharge lectrique peut tuer ou brler gravement.


Llectrode et le circuit de soudage sont sous tension
ds la mise en circuit. Le circuit dalimentation et les
circuits internes de lquipement sont aussi sous tension ds 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 dentrainement
et toutes les pices mtalliques en contact avec le fil de
soudage sont sous tension. Un quipement
inadquatement install ou inadquatement mis la terre
est dangereux.

10. Nutilisez quune bonne prise de masse pour la mise la terre de


la pice souder.
11. Ne touchez pas llectrode lorsquen contact avec le circuit de
soudage (terre).
12. Nutilisez que des quipements en bon tat. Rparez ou remplacez
aussitt les pices endommages.
13. Dans des espaces confins ou mouills, nutilisez pas de source
de courant alternatif, moins quil soit muni dun rducteur de
tension. Utilisez plutt une source de courant continu.
14. Portez un harnais de scurit si vous travaillez en hauteur.

1. Ne touchez pas des pices sous tension.

15. Fermez solidement tous les panneaux et les capots.

2. Portez des gants et des vtements isolants, secs et non trous.


3

Isolez-vous de la pice souder et de la mise la terre au moyen


de tapis isolants ou autres.

4. Dconnectez la prise dalimentation de lquipement ou arrtez le


moteur avant de linstaller ou den faire lentretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
lalimentation afin dviter une mise en marche accidentelle.
5. Veuillez installer cet quipement et le mettre la terre selon le
manuel dutilisation et les codes nationaux, provinciaux et locaux
applicables.
November 30, 2005

1-5

LM-200 INVERTER ARC WELDER


AVERTISSEMENT

AVERTISSEMENT
LE RAYONNEMENT DE LARC PEUT BRLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER LOUIE.

LES VAPEURS ET LES FUMEES SONT DANGEREUSES


POUR LA SANTE.

Larc de soudage produit une chaleur et des rayons


ultraviolets intenses, susceptibles de brler les yeux et
la peau. Le bruit caus par certains procds peut
endommager loue.

Le soudage dgage des vapeurs et des fumes


dangereuses respirer.
1. Eloignez la tte des fumes pour viter de les respirer.

1. Portez une casque de soudeur avec filtre oculaire de nuance


approprie (consultez la norme ANSI Z49 indique ci-aprs) pour
vous protger le visage et les yeux lorsque vous soudez ou que
vous observez lexcution dune soudure.

2. A lintrieur, assurez-vous que laire de soudage est bien ventile


ou que les fumes et les vapeurs sont aspires larc.

2. Portez des lunettes de scurit approuves. Des crans latraux


sont recommands.

4. Lisez les fiches signaltiques et les consignes du fabricant relatives aux mtaux, aux produits consummables, aux revtements
et aux produits nettoyants.

3. Entourez laire de soudage de rideaux ou de cloisons pour protger


les autres des coups darc ou de lblouissement; avertissez les
observateurs de ne pas regarder larc.
4. Portez des vtements en matriaux ignifuges et durables (laine et
cuir) et des chaussures de scurit.
5. Portez un casque antibruit ou des bouchons doreille approuvs
lorsque le niveau de bruit est lev.

3. Si la ventilation est inadequate, portez un respirateur adduction


dair approuv.

5. Ne travaillez dans un espace confin que sil est bien ventil; sinon,
portez un respirateur adduction dair. Les gaz protecteurs de
soudage peuvent dplacer loxygne de lair et ainsi causer des
malaises ou la mort. Assurez-vous que lair est propre la respiration.
6. Ne soudez pas proximit doprations de dgraissage, de
nettoyage ou de pulvrisation. La chaleur et les rayons de larc
peuvent ragir 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 8.2-73)
Dimension d'lectrode ou
Epiasseur de mtal ou
Intensit de courant

Nuance de
filtre oculaire

Brassage tendre
au chalumeau

toutes conditions

Brassage fort
au chalumeau

toutes conditions

3 ou 4

Opration de coupage
ou soudage

Soudage l'arc sous gaz


avec fil plein (GMAW)
mtaux non-ferreux

toutes conditions

11

mtaux ferreux

toutes conditions

12

toutes conditions

12

toutes conditions

12

toutes conditions

12

toutes dimensions

12

Oxycoupage
mince

moins de 1 po. (25 mm)

moyen de 1 6 po. (25 150 mm)


pais

plus de 6 po. (150 mm)

2 ou 3
4 ou 5
5 ou 6

Soudage aux gaz

Dimension d'lectrode ou
Nuance de
Epiasseur de mtal ou
filtre oculaire
Intensit de courant

Opration de coupage
ou soudage

Soudage l'arc sous gaz avec


lectrode de tungstne (GTAW)
Soudage l'hydrogne
atomique (AHW)
Soudage l'arc avec
lectrode de carbone (CAW)
Soudage l'arc Plasma (PAW)

mince

moins de 1/8 po. (3 mm)

moyen de 1/8 1/2 po. (3 12 mm)


pais
Soudage l'arc avec
lectrode enrobees
(SMAW)

4 ou 5

Gougeage Air-Arc avec


lectrode de carbone

5 ou 6

mince

12

plus de 1/2 po. (12 mm)

6 ou 8

pais

14

moins de 5/32 po. (4 mm)

10

5/32 1/4 po. (4 6.4 mm)

12

mince

moins de 300 ampers

plus de 1/4 po. (6.4 mm)

14

moyen

de 300 400 ampers

12

plus de 400 ampers

14

Coupage l'arc Plasma (PAC)

pais

1-6

November 30, 2005

LM-200 INVERTER ARC WELDER


7. Ne soudez des tles galvanises ou plaques au plomb ou au
cadmium que si les zones souder ont t grattes fond, que si
lespace est bien ventil; si ncessaire portez un respirateur adduction dair. Car ces revtements et tout mtal qui contient ces
lments peuvent dgager des fumes toxiques au moment du
soudage.

AVERTISSEMENT

AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
mtalliques volantes. En refroidissant, la soudure peut
projeter du clats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE


EXPLOSION

1. Portez un cran facial ou des lunettes protectrices


approuves. Des crans latraux sont recommands.

Larc produit des tincellies et des projections. Les


particules volantes, le mtal chaud, les projections de
soudure et lquipement surchauff peuvent causer un
incendie et des brlures. Le contact accidentel de
llectrode ou du fil-lectrode avec un objet mtallique
peut provoquer des tincelles, un chauffement ou un
incendie.

2. Portez des vtements appropris pour protger la peau.

1. Protgez-vous, ainsi que les autres, contre les tincelles et du


mtal chaud.
2. Ne soudez pas dans un endroit o des particules volantes ou des
projections peuvent atteindre des matriaux inflammables.
3. Enlevez toutes matires inflammables dans un rayon de 10, 7
mtres autour de larc, ou couvrez-les soigneusement avec des
bches approuves.
4. Mfiez-vous des projections brulantes de soudage susceptibles
de pntrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Mfiez-vous des incendies et gardez un extincteur porte de la
main.
6. Noubliez pas quune soudure ralise sur un plafond, un plancher,
une cloison ou une paroi peut enflammer lautre ct.
7. Ne soudez pas un rcipient ferm, tel un rservoir ou un baril.
8. Connectez le cble de soudage le plus prs possible de la zone
de soudage pour empcher le courant de suivre un long parcours
inconnu, et prvenir ainsi les risques dlectrocution et dincendie.

AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommages peuvent
exploser. Comme les bouteilles font normalement partie
du procd de soudage, traitez-les avec soin.
1. Protgez les bouteilles de gaz comprim contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles un support ou un cadre
fixe pour les empcher de tomber ou dtre renverses.
3. Eloignez les bouteilles de tout circuit lectrique ou de tout soudage.
4. Empchez tout contact entre une bouteille et une lectrode de
soudage.
5. Nutilisez que des bouteilles de gaz protecteur, des dtendeurs,
des boyauxs et des raccords conus pour chaque application
spcifique; ces quipements et les pices connexes doivent tre
maintenus en bon tat.
6. Ne placez pas le visage face louverture du robinet de la bouteille
lors de son ouverture.

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


10. Otez llectrode du porte-lectrode ou coupez le fil au tube-contact lorsquinutilis aprs le soudage.
11. Portez des vtements protecteurs non huileux, tels des gants en
cuir, une chemise paisse, un pantalon revers, des bottines de
scurit et un casque.

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


lorsque raccord pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprim et aux quipements connexes, ainsi que la publication
P-1 de la CGA, identifie dans la liste de documents ci-dessous.

AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ DECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz dchappement nocifs.

November 30, 2005

1-7

LM-200 INVERTER ARC WELDER


1. Utilisez lquipement lextrieur dans des aires ouvertes et bien
ventiles.

Les accumulateurs contiennent de llectrolyte acide et


dgagent des vapeurs explosives.

2. Si vous utilisez ces quipements dans un endroit confin, les


fumes dchappement doivent tre envoyes lextrieur, loin
des prises dair du btiment.

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

AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.

2. Arrtez le moteur avant de connecter ou de dconnecter des cbles


daccumulateur.
3. Nutilisez que des outils anti-tincelles pour travailler sur un
accumulateur.
4. Nutilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanment un vhicule.
5. Utilisez la polarit correcte (+ et ) de laccumulateur.

1. Arrtez le moteur avant de vrifier le niveau e carburant ou de


faire le plein.
2. Ne faites pas le plein en fumant ou proche dune source dtincelles
ou dune flamme nue.

AVERTISSEMENT

3. Si cest possible, laissez le moteur refroidir avant de faire le plein


de carburant ou den vrifier le niveau au dbut du soudage.

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT


BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.

4. Ne faites pas le plein de carburant ras bord: prvoyez de lespace


pour son expansion.

Le liquide de refroidissement dun radiateur peut tre


brlant et sous pression.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout


carburant renvers avant de faire dmarrer le moteur.

1. Ntez pas le bouchon de radiateur tant que le moteur nest pas


refroidi.

AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pices en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien ferms.
2. Avant dinstaller ou de connecter un systme, arrtez le moteur.
3. Seules des personnes qualifies doivent dmonter des protecteurs
ou des capots pour faire lentretien ou le dpannage ncessaire.
4. Pour empcher un dmarrage accidentel pendant lentretien,
dbranchez le cble daccumulateur la borne ngative.
5. Napprochez pas les mains ou les cheveux de pices en
mouvement; elles peuvent aussi accrocher des vtements amples
et des outils.
6. Rinstallez les capots ou les protecteurs et fermez les portes aprs
des travaux dentretien et avant de faire dmarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN


ACCUMULATEUR; LELECTROLYTE DUN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8

2. Mettez des gants et posez un torchon sur le bouchon pour lter.


3. Laissez la pression schapper avant dter compltement 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.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
November 30, 2005

LM-200 INVERTER ARC WELDER

SECTION 2:
INTRODUCTION
2.01 How To Use This Manual

2.02 Equipment Identification

This Owners Manual applies to just specification or part


numbers listed on page i.

The units 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.

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.

2.03 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 Owners 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.

On

Single Phase

Wire Feed Function

Off

Three Phase

Wire Feed Towards


Workpiece With
Output Voltage Off.

Dangerous Voltage

Three Phase Static


Frequency ConverterTransformer-Rectifier

Welding Gun

Increase/Decrease

Remote

Purging Of Gas

Duty Cycle

Continuous Weld
Mode

Percentage

Spot Weld Mode

Circuit Breaker

AC Auxiliary Power

2-2

Spot Time

Fuse

Panel/Local

Amperage

Shielded Metal
Arc Welding (SMAW)

Voltage

Gas Metal Arc


Welding (GMAW)

Hertz (cycles/sec)

Gas Tungsten Arc


Welding (GTAW)

Frequency

Air Carbon Arc


Cutting (CAC-A)

Negative

Constant Current

Positive

Constant Voltage
Or Constant Potential

Direct Current (DC)

High Temperature

Protective Earth
(Ground)

Fault Indication

Line

Arc Force

IPM

Inches Per Minute

Line Connection

Touch Start (GTAW)

MPM

Meters Per Minute

Auxiliary Power

Variable Inductance

Receptacle RatingAuxiliary Power

Voltage Input

Preflow Time

t1

t2

Postflow Time
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

Art # A-04130

115V 15A

X
%

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
160A
1A

200A 220A(A)

(V)

(V)

OCV

OCV

28V
10V

10V
25A

200A

(A)

1A

200A 220A (A)

Figure 1: Model LM-200 volt-ampere curve

November 30, 2005

2-3

LM-200 INVERTER ARC WELDER


2.06 Functional Block Diagram

Input
Power

Main
Circuit
Switch
Filter

Input
Diode

Capacitor
DC Power
Primary
Voltage
Sensor

Down
Transformers
AC115V,AC24V
(T3)

Over
Current
Protect

IGBT
Inverter
Themal
Detector

Hall Current

Output
Diodes
Themal
Detector

Main
Transformers
(T1)

Transformer
(HCT1)
Output
Inductor

To each control circuit


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

Trouble
Sensing
Circuit

Thermal
Sensor
Circuit

Drive
Circuit

StickMode
VRD
Sensing
Circuit

Lift Tig Mode


Output Short
Sensing
Circuit

Primary
Circuit
Sensor

14PIN
Receptacle
(CON1)

Sequence
Control

Fan Control
Circuit

Fan

19PIN
Receptacle
(CON2)
Current
Adjustment
Circuit
Art # A-06920

Reference
Adjustment &
Mode select Switch

14PIN-19PIN
Select Switch
(S3)

Panel Circuit Boad

Figure 2: LM-200 Model functional block diagram

2-4

November 30, 2005

LM-200 INVERTER ARC WELDER


2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.

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.

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.

November 30, 2005

2-5

LM-200 INVERTER ARC WELDER


2.08 Electrical Input Connections

3. Use Table 1 and Table 2 as a guide to select line fuses


for the disconnect switch.

NOTE

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.

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
208 VAC
230 VAC
460 VAC

Fuse Size
60 Amps
50 Amps
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

LM-200 INVERTER ARC WELDER


Welding Power Supply
Ground Conductor
Ground Terminal
Line Disconect Switch

Line Fuse

Primary Power Cable

Art # A-06923

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. SCRs 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

Primary Supply
Lead Size

Minimum Primary
Current Circuit Size
(Vin/Amps)
208/39
230/35

Current & Duty Cycle


MIG

200A @ 60%

460/18
8/4 AWG minimum
(Factory Fitted)

3?

PRO-PLUS
LM-200

230/27

460/14

208/45

230/41

460/21

230/44
208/37
1?

STICK

208/29

208/51

8/3 AWG minimum

TIG

230/33

200A @ 60%
-

200A @ 60%

200A @ 60%

200A @ 60%

208/57

230/51

200A @ 60%

Table 2: Primary Current Circuit sizes to achieve maximum current

2-8

November 30, 2005

LM-200 INVERTER ARC WELDER


2.09 Specifications

Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle

LM-200

TIG
STICK
MIG

200
28
60%
200A / 18V @ 60%
150A / 16V @ 100%
200A / 28V @ 60%
150A / 26V @ 100%
200A / 24V @ 60%
150A / 22V @ 100%

Output Current
Range

TIG
STICK

1 200A

Output Voltage
Range

MIG

10 28V

Open Circuit Voltage


Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
208V
230V
Input Volts Three Phase
208V
230V
460V

November 30, 2005

65V
8.27 (210mm)
16.89 (420mm)
17.72 (450mm)
59.5 lb. 27.0 kg
200A
28V
60%
9.3
7.0
0.5
0.13
Amperage Draw @ Rated Load
57
51

No Load
2.4
1.8

45
41
21

1.4
1.1
0.7

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:
Art # A-05167
2

current

(rated current) x(rated duty cycle)


(desired duty cycle)

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:
Art # A-05168

current
current
current
current

2-10

(400A) x(.25)
(.50)
160,000x(0.5)
80,000
282.8A

November 30, 2005

LM-200 INVERTER ARC WELDER

SECTION 3:
OPERATION
3.01 LM-200 DC CC Views

1
6
8

7
10
11

2
3
4

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
A

24VAC auxiliary high side.

Input to energize solid state contactor


(Contact closure between pin A and pin B)

C
D

5k ohm (maximum) connection to 5k ohm remote control potentiometer


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

Wiper arm connection to 5k ohm remote control potentiometer

Current feedback Ifb = 100Amps/Volt

24/115 VAC circuit common, also connected to chassis

Voltage Feedback Vfb = 10 Arc Volts/Volt

115 VAC auxiliary high side

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

Chassis ground

L,M,N
November 30, 2005

Function

Not used
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

Contactor circuit (+15 Volts)

Contactor circuit in, (closure between pin A and Pin B will energize output.)

C
D

Scaled output voltage signal: Vfb = 10 Arc Volts/Volt


24 VAC auxiliary power high side

115 VAC auxiliary power high side

Chassis ground

Remote control maximum

Remote control wiper (0 10 Volts)

Remote Control minimum

Remote control wiper (0 10 Volts)

Control circuit common

Arc Establish = +12 Volts

Control Circuit common

24 VAC auxiliary power high side

24/115 VAC neutral

N/C

N/C

Scaled output signal: Ifb = 100 Amps/Volt

N/C

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

LM-200 INVERTER ARC WELDER


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.
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
This parameter provides a suitable short circuit current in STICK welding to improve
electrode sticking and arc stability.

ARC CONTROL
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.

HOT START
DC (A)

DC (V)

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

Contactor operation in Stick Mode.

Contactor ON/OFF
Selects in operation Panel boad or Remote.

Operation
PANEL/REMOTE
INDUCTANCE

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

LIFT TIG
STICK

WELD (V)
INDUCTANCE
HOT START
WELD (A)
ARC CONTROL

MIG

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).

Weld Process Selection Verses Weld Mode

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

Current Increase when Arc Voltage


is less than 18V

Effect on Welding Performance

Minimum (0)

0A

Soft arc, Low spatter, Low penetration

Medium (20%)

32A

Normal arc, Improved fusion


characteristics,
Normal penetration

Maximum (100%)

160A

Hard arc, Deep 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

LM-200 INVERTER ARC WELDER


3.05 Weld Parameters
Weld Mode
Weld
Parameter

WELD (V)
MIG
INDUCTANCE
HOT START
WELD (A)
TIG or STICK
ARC CONTROL

November 30, 2005

Parameter Range

Factory
Setting

Incremental
Unit

10.0 to 28.0V DC

17.0V

0.1V

0 to 100%

10%

1%

0 to 70A

20A

1A

1 to 200A DC

80A

1A

0 to 100%

10%

1%

LIFT TIG
STICK

MIG

3-9

LM-200 INVERTER ARC WELDER


3.06 Power Source Features

Feature

New Digital Control

All welding parameters are adjustable

Touch Panel Switches

Touch switches eliminate mechanical damage

Front Control Cover

Protects front panel controls

Digital Meter Volt & Ammeter

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

Intelligent Fan Control

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

ON/OFF switch

Mains ON/OFF switch located on rear panel

Voltage Reduction Device (VRD)

VRD fully complies to IEC 60974-1


VRD light is ON and operational when in STICK mode.

Control Knob

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

Self Diagnosis Using Error Codes

An error code is displayed on the Digital Meter when a problem


occurs with Mains supply voltage or internal component
problems.

Save/Load function

3-10

Description

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


memory
SAVE the Current Weld Parameters into Memory
Press the SAVE button
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 LOAD button
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
Nvember 30, 2005

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 LEDs 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.

2
4

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 LM200.
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

LM-200 INVERTER ARC WELDER

SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING


5.01 Basic Maintenance

Warning!
Disconnect input power before maintaining.

Maintain more often


if used under severe
conditions

Each Use
Visual check of torch
Consumable parts

Visual check of
regulator and pressure

Weekly

Visually inspect the torch


body and consumables

Visually inspect the


cables and leads.
Replace as needed

Visually inspect the Wire


feed mechanisms

3 Months

Replace all
broken parts

Gas and
air lines

Clean
exterior
of power supply

6 Months

Visually check and


use a vacuum to carefully
clean the interior

Art # A-06950

November 30, 2005

5-1

LM-200 INVERTER ARC WELDER


5.02 General Troubleshooting

5.03 Common Welding Operation Faults

Troubleshooting and repairing this unit is a process which


should be undertaken only by those familiar with high
voltage, high power electronic equipment.

The following are some of the more common operating


faults that occur during welding operations:
1. Power:
Main power not connected

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.

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

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

5 Welding dirty, oily, painted, oxidized or Clean contaminates off the plate
greasy plate
6 Distance between the MIG torch nozzle Keep the distance between the MIG torch nozzle and the work piece to a
and the work piece
minimum.
7 Maintain the MIG torch in good
working order

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

WARNING!

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

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

Feed roller driven by motor in the cabinet will slip.

2 Wire spool brake is too loose

Wire spool can unwind and tangle.

3 Worn or incorrect feed roller size

Use 'U' groove drive feed roller matched to the 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 will rub against the misaligned guides and reduces
wire feedability.

4 Misalignment of inlet/outlet guides


5 Liner blocked with wire debris

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.

6 Incorrect or worn contact tip

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.
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.

5-4

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

LM-200 INVERTER ARC WELDER


5.05 MIG Welding Problems

Possible Cause

Description
1

Undercut

Lack of penetration

Lack of fusion

Excessive spatter

Irregular weld shape

Weld cracking

Cold weld puddle

Arc does not have a


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

November 30, 2005

Reduce WELD (V) control or increase the wire


feed speed.
Adjust angle
Increase the torch travel speed and/or reduce
welding current by reducing the WELD (V)
control or reducing the wire feed speed.

Welding arc voltage too high.

B
C

Incorrect torch angle


Excessive heat input

B
C

Welding current too low

Joint preparation too narrow or gap


too tight
Shielding gas incorrect

Increase welding current by increasing wire


feed speed and increasing WELD (V) control.
Increase joint angle or gap

Change to a gas which gives higher penetration

C
3

Remedy

Increase WELD (V) control.

Voltage too low


A

Voltage too high

Voltage too low

B
C
D

Incorrect voltage and current settings.


Convex, voltage too low. Concave,
voltage too high.
Wire is wandering
Incorrect shielding gas
Insufficient or excessive heat input

A
B

Weld beads too small


Weld penetration narrow and deep

C
D

Excessive weld stresses


Excessive voltage

Cooling rate too fast

Faulty rectifier unit

B
C

Loose welding cable connection.


Low Primary Voltage

B
C

The MIG torch has been connected to


the wrong voltage polarity on the front
panel.

Lower the voltage by reducing the WELD (V)


control or increase wirespeed control.
Raise the voltage by increasing the WELD (V)
control or reduce wirespeed control.
Adjust voltage and current by adjusting the
WELD (V) control and the wirespeed control.

B Replace contact tip


C Check shielding gas.
D Adjust the wirespeed control or the voltage
selection switches.
A
B

Decrease travel speed


Reduce current and voltage and increase MIG
torch travel speed or select a lower penetration
shielding gas.
C Increase weld metal strength or revise design
D Decrease voltage by reducing the WELD (V)
control.
E Slow the cooling rate by preheating part to be
welded or cool slowly.
Have an Accredited Thermal Arc Service Agent
to test then replace the faulty component.
Check all welding cable connections.
Contact supply authority
Connect the MIG torch to the positive (+)
welding terminal for solid wires and gas
shielded flux cored wires. Refer to the
electrode wire manufacturer for the correct
polarity.

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

Remedy

Excessive beard buildup or poor penetration


or poor fusion at edges
of weld.

Welding current is too low

Increase weld current and/or faulty


joint preparation

Weld bead too wide


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

Welding current is too high

Decrease weld current

Weld bead too small or


insufficient penetration
or ripples in bead are
widely spaced apart

Travel speed too fast

Reduce travel speed

Weld bead too wide or


excessive bead build up
or excessive penetration in butt joint

Travel speed too slow

Increase travel speed

Uneven leg length in


fillet joint

Wrong placement of filler rod

Re-position filler rod

Electrode melts when


arc is struck.

A Electrode is connected to the +


terminal.

A Connect the electrode to the


terminal.

Dirty weld pool.

A Electrode contaminated through


contact with work piece or filler rod
material.

A Clean the electrode by grinding off


the contaminates.

B Gas contaminated with air.

B Check gas lines for cuts and loose


fitting or change gas cylinder.

5-6

Possible Cause

Electrode melts or
A No gas flowing to welding region.
oxidizes when an arc is
struck.

A Check the gas lines for kinks or


breaks and gas cylinder contents.

B Torch is clogged with dust.

B Clean torch

C Gas hose is cut.

C Replace gas hose.

D Gas passage contains impurities.

D Disconnect gas hose from torch


then raise gas pressure and blow
out impurities.

E Gas regulator turned off.

E Turn on.

F Torch valve is turned off.

F Turn on.

G The electrode is too small for the


welding current.

G Increase electrode diameter or


reduce the welding current.

November 30, 2005

LM-200 INVERTER ARC WELDER

Description

Possible Cause

Poor weld finish

Inadequate shielding gas.

10 Arc flutters during TIG


welding

11 Welding arc can not be


established

12 Arc start is not smooth

November 30, 2005

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

A Tungsten electrode is too large for


the welding current.

A Select the right size electrode. Refer


to Basic TIG Welding guide.

B Absence of oxides in the weld pool.

B Refer Basic TIG Welding Guide for


ways to reduce arc flutter.

A Work clamp is not connected to the


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

A Connect the work clamp to the work


piece or connect the work/torch
leads to the right welding terminals.

B Torch lead is disconnected.

B Connect it to the terminal.

C Gas flow incorrectly set, cylinder


empty or the torch valve is off.

C Select the right flow rate, change


cylinders or turn torch valve on.

A Tungsten electrode is too large for


the welding current.

A Select the right size electrode. Refer


to Basic TIG Welding Guide.

B The wrong electrode is being used


for the welding job

B Select the right electrode type.


Refer to Basic TIG Welding Guide

C Gas flow rate is too high.

C Select the correct rate for the


welding job.
Refer to Basic TIG Welding Guide.

D Incorrect shielding gas is being


used.

D Select the right shielding gas. Refer


to Basic TIG Welding Guide.

E Poor work clamp connection to


work piece.

E Improve connection to work piece.

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)

A Electrodes are damp


B Welding current is too high
C Surface impurities such as oil,
grease, paint, etc.
2 Crack occurring in weld A Rigidity of joint.
metal soon after
solidification
commences
B Insufficient throat thickness
C Cooling rate is too high
A Welding current is too low
B Electrode too large for joint

3 A gap is left by failure


of the weld metal to fill
the root of the weld

C Insufficient gap
D Incorrect sequence

A Dry electrodes before use


B Reduce welding current
C Clean joint before welding
A Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes
B Travel slightly slower to allow greater
build up in throat
C Preheat plate and cool slowly
A Increase welding current
B Use smaller diameter
electrode
C Allow wider gap
D Use correct build-up sequence

Art # A-04991

Incorrect sequence
Insufficient
gap

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

4 Portions of the weld run A Small electrodes used on heavy cold A Use larger electrodes and pre-heat
do not fuse to the
plate
the plate
surface of the metal or B Welding current is too low
B Increase welding current
edge of the joint
C Wrong electrode angle
C Adjust angle so the welding arc is
directed more into the base metal
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

Lack of fusion caused by dirt,


electrode angle incorrect,
rate of travel too high

Art # A-04992

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

Lack of root fusion

Figure 5-2 - Example of Lack of Fusion


5-8

November 30, 2005

LM-200 INVERTER ARC WELDER


5 Non-metallic particles
are trapped in the weld
metal (slag inclusion)

A Non-metallic particles may be


trapped in undercut from previous
run
B Joint preparation too restricted
C Irregular deposits allow slag to be
trapped
D Lack of penetration with slag
trapped beneath weld bead

E Rust or mill scale is preventing full


fusion
F Wrong electrode for position in
which welding is done

A If bad undercut is present, clean slag


out and cover with a run from a
smaller diameter electrode.
B Allow for adequate penetration and
room for cleaning out the slag
C If very bad, chip or grind out
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
1 The welding arc cannot
be established

Possible Cause

A The Primary supply voltage has not A Switch ON the Primary supply
voltage.
been switched ON.
B The Welding Power Source switch is B Switch ON the Welding Power
Source.
switched OFF.
C Loose connections internally.

C Have an Accredited Thermal Arc


Service Agent repair the connection.

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

Defective control circuit

Have an Accredited Thermal Arc


Service Agent inspect then repair the
welder.

3 Welding current
reduces when welding

Poor work lead connection to the


work piece.

Ensure that the work lead has a


positive electrical connection to the
work piece.

4 No gas flow when the


torch trigger switch is
depressed.

A Gas hose is cut.


B Gas passage contains impurities.

C Gas regulator turned off.


D Torch trigger switch lead is
disconnected or switch/cable is
faulty.
5 Gas flow wont shut off A Weld Mode (STD, SLOPE, REPEAT
or SPOT) was changed before
POST-FLOW gas time had finished.

5-10

Remedy

A Replace gas hose.


B Disconnect gas hose from the rear of
Power Source then raise gas
pressure and blow out impurities.
C Turn gas regulator on.
D Reconnect lead or repair faulty
switch/cable.

A Strike an arc to complete the weld


cycle.
OR
Switch machine off then on to reset
solenoid valve sequence.
B Gas valve is faulty.
B Have an Accredited Thermal Arc
Service Agent replace gas valve.
C Gas valve jammed open.
C Have an Accredited Thermal Arc
Service Agent repair or replace gas
valve.
D POST-FLOW control is set to 60 sec. D Reduce POST-FLOW time.
The Weld Process Mode (STICK, HF
The TIG electrode has
Do not change Weld Process Mode
TIG or LIFT TIG) was changed
been contaminated due
before the POST-FLOW gas time had
before POST-FLOW gas time had
to the gas flow shutting
finished.
off before the profinished.
grammed POST-FLOW
time has elapsed

November 30, 2005

LM-200 INVERTER ARC WELDER


5.09 Error Codes

Description

Possible Cause

1 E01 error code


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

A The Welding Power


Sources duty cycle has
been exceeded.
B Fan ceases to operate.

C Air flow is restricted by


vents being blocked

2 E02 error code


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

A The Welding Power


Sources duty cycle has
been exceeded.
B Fan ceases to operate.

3 E03 error code


displayed
Primary (input) current
too high

A Primary current is too


high because welding arc
is too long.
B Mains supply voltage is
more than 10% below
nominal voltage

C Air flow is restricted by


vents being blocked

Remedy

C
A

Remarks

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.

Weld current ceases.


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

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.

Weld current ceases.


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

Reduce length of welding


arc.

Weld current ceases.


Buzzer sounds constantly.
Switch machine off then on to
Have an Accredited Thermal reset E03 error.
Arc Service Agent or a
qualified electrician check
for low Mains voltage.

4 E11 error code


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

Primary supply voltage is


greater than the nominal
voltage plus 10%.

Have an Accredited Thermal


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

Weld current ceases.


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

5 E14 error code


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

Mains supply voltage is


less than the nominal
operating voltage less
10%.

Have an Accredited Thermal


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

Weld current available.


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

6 E12 error code


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

Mains supply voltage is


down to a dangerously
low level.

Have an Accredited Thermal


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

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

When 3 phase machine is


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

Have an Accredited Thermal No weld current is available.


Arc Service Agent or a
Buzzer sounds constantly.
qualified electrician check
Switch machine off.
the Mains voltage

8 E82 error code


displayed
Link switch plug not
connected

Link switch plug not


connected

Have an Accredited Thermal No weld current is available.


Arc Service Agent check
Buzzer sounds constantly.
connector plug on input
Switch machine off.
PCB

9 E83 error code


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

The Primary supply


(input) voltage fluctuates
and is not stable.

Have an Accredited Thermal


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

10 E93 error code


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

Memory chip (EEPROM)


error

Have an Accredited Thermal Weld current ceases.


Arc Service Agent check the Buzzer sounds constantly.
control PCB
Switch machine off.

11 E94 error code


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

The Welding Power


Sources temperature
sensors have
malfunctioned.

Have an Accredited Thermal Weld current ceases.


Arc Service Agent check or Buzzer sounds constantly.
replace the temperature
Switch machine off.
sensors.

12 E99 error code


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

A Main on/off switch on


machine has been turned
B off
Mains supply (input)
voltage has been turned
off

5-12

A
B

No weld current is available.


Buzzer sounds constantly.
Switch machine off then on to
reset E83 error.

Turn on/off switch on.

Weld current ceases.


Buzzer sounds constantly.
Have an Accredited Thermal Must switch machine off then on
to reset E99 error.
Arc Service Agent or a
qualified electrician check
the Mains voltage and fuses

November 30, 2005

LM-200 INVERTER ARC WELDER


5.10 Voltage Reduction Device (VRD)
VRD Specification:

Description
VRD Open Circuit Voltage

Notes
15.3 to 19.8V

Open circuit voltage between welding terminals

VRD Resistance

148 to 193 ohms

The required resistance between welding terminals


to turn ON the welding power

VRD Turn OFF Time

0.2 to 0.3 seconds

The time taken to turn OFF the welding power once


the welding current has stopped

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

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.

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.

Description
VRD Open
Circuit Voltage
VRD Turn ON
Resistance
VRD Turn OFF
Time

IEC 60974-1 Requirements


Less than 20V; at Vin=460V
Less than 200 ohms
Less than 0.3 seconds
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.

November 30, 2005

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

3
1

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

1
1
2

Figure 5-5: VRD ON/OFF Step B

5-14

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
Stick Kit
TIG Kit

PART NO.
10-4082A
10-4080

Dinse Connector
Hand Held Pendant

10-2020
10-2005

Foot Control

10-2008
10-2007

Extension Cable

Torch Switch On/Off


Torch Switch On/Off
w/current control

10-2030
10-2031
10-4032
10-4033
10-4034
10-2001
10-2002
10-2003
10-2004

Rack Systems

WIRE FEEDERS
A2000
VA2000
VA4000
VS212

November 30, 2005

10-4029
10-4031
10-4033
W3200001
W3300001
W3400001
W3512002

DESCRIPTION
Work clamp with 10 cable, and stick electrode with 25 #1 cable
Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with
valve, accessory kit includes 1 ea of 0040x7, 1/16x7,
3/32x7 2% Tungsten with collet & collet bodies, 1 ea 1/4,
5/16, 3/8 alumina cup
T50mm Dinse style male plug
Includes contactor On/Off switch and current control
with 25ft cable and 14-pin male plug
Contactor On/Off and current control with 15ft cable
and 14-pin male plug
Contactor On/Off and current control with 25ft cable
and 14-pin male plug
3ft with 14-pin male plug and 14-pin female cable receptacle
15ft with 14-pin male plug and 14-pin female cable receptacle
25ft with 14-pin male plug and 14-pin female cable receptacle
50ft with 14-pin male plug and 14-pin female cable receptacle
75ft with 14-pin male plug and 14-pin female cable receptacle
25ft torch mounted with 14-pin male plug
25ft torch mounted with 14-pin male plug
- adapts to 5/8-7/8 torch
25ft torch mounted with 14-pin male plug
- adapts to 7/8-1-1/8 torch handle
25ft torch mounted with 14-pin male plug
- adapts to 1-1/8-1-3/8 torch handle
4 pack w/electrical
6 pack w/electrical
8 pack w/electrical
UltraFeed 2 Roll
UltraFeed 2 Roll
UltraFeed 4 Roll
PortaFeed 2 Roll

A-1

LM-200 INVERTER ARC WELDER

APPENDIX 2: SYSTEM SCHEMATIC

P
TB1

G1
E1

R2

1
2
3

R2

CN11

CN4

1 2 3

1 2

TB4

CN18

1
2
3

1
2
3

G3
E3

19P

CN1

CN5

CN6

CN4

CN31

CN32

CN30

CN31

CN32

CN30

A-2

CE

TB7

G
E

CN131

CN132

CN130

CN131

CN132

CN130

G7

Q10 E7

1
2
3

Q21

G
E

Q22

C
G
E

G8
E8

Q12

Q23

1
2
3
4

CN2

Q11

G
E

Q24

G
E

G
E

1 2 3 4 5 6

1 2 3 4 5 6 7

1 2 3 4 5 6

1 2 3 4 5 6 7

CN20

CN21

CN22

CN23

PCB6
Control
Circuit Bord
[WK-5688]
CN27

CN18

CN27

CN18

CN1

CN3

PCB7
Filter Circuit Bord
[WK-5689]

PCB17
Socket Receptacle Circuit Bord
[WK-5689]

CN1

CN3

CN7
1 2 3 4 5 6 7 8

CN3
CN13

CN15

CN16

CN2

CN19

1 2 3

1 2 3 4 5

1 2 3 4

1 2 3 4 5 6

1 2 3

1 2 3 4 5 6 7

1 2 3 4 5 6

1 2 3

CN4

CN2

CN15

CN6

CN5

CN10

CN9

CN8

1 2 3

1 2 3 4 5 6

1 2 3 4 5 6 7

1 2 3 4

1 2 3 4 5 6

TB1

EC

CON2 S T V C U J H N K

Q20

Q9

G
E

CT1
CT2
CT3
CT4

Q19

PCB11 G
IGBT Gate E
Circuit Bord C
[WK-5479]

G
E

1
2
3
4

1
2
3
4

PCB3
Control Souce
Circuit Bord
[WK-5548]

S3
14P

1
2
3

TB6

E8
G8

CN6

1 2 3 4 5

115V

Q8

TB5

E3
G3

CN10

1 2 3 4 5 6 7

24V

UB1

CN20

1
2
3
4

Q7

PCB9 G
IGBT Gate E
Circuit Bord C
[WK-5479]

CN2

1 2

CN7

CN5

CN20

CN33

1
2
3

CN2

CN5
CN1

1 2 3

PCB5
Conect Circuit Bord
[WK-5696]

Q18

G
E

PCB4
Detect
Circuit Bord
[WK-4819]

FAN1
+

1
2
3
4
5
6

E5
G5

230V

0V

TB20

G
E

G4
E4

S2

1
2
3
4

CE

CN3

1
2
3
4

G
E

G
E

E2
G2

CN2

460V

TB19

E1
G1

R2

TB4

CN7

TB18

1 2 3 4 5

CN4

1
2
3
4
5
6

Q6

Q17

1
2
3
4

G
E

CN1

G3
E3

E7
G7

1 2 3

Q5

CN2

REAR
PANEL

Q16

TB3

115V

24V

0V

1 2

1
2
3

G4
E4

Q15

G
E

G
E

TB2

Q14

G
E

TB3

1
2
3
4
5

115V

SIDE CHASSIS 1

Q13

PCB10 G
IGBT Gate E
Circuit Bord
C
[WK-5479]

Q4

1
2
3
4

PCB2
Link
Circuit Bord
[WK-5597]

MCB1

MCB2

G2
E2
TB2

T1

CN1

TB12

G
E

G
E

1
2
3
4
5

CE

Q3

CN1

PCB21
Filter
Circuit Bord
[WK-4917]

24V

(2)

460V

230V

0V

Ground

0V

T(5)

TB11

G
E

G
E

N
Line3

Q2

TB10

E4
G4

(0)
S(4)

Line2

Q1

E6
G6

Line1

TB15

G
E

CN2

G(6)
R(3)

CE

PCB1
Main
PCB8
Circuit Bord IGBT Gate
[WK-5493] Circuit Bord
[WK-5479]
TB1

K(7)

S1

TB14

CN1

+
(1)

TB13

CN1

UB3

CN1

Art # A-06951

CN3

1
2

D1

A
L

B M G R F D P

EC

CON1 M N C D E H F N J

K
B

November 30, 2005

AC1

PCB14
TRANS Bord
[WK-5594]

SH.DET+

PCB15
DIODE Snubber
Circuit Bord
[WK-5606]
D5

+15
-15
IS
GND

LM-200 INVERTER ARC WELDER

4
1 2 3

TO1

TB35

+Output
Terminal

AC2

TB33

CT2

CT1

TB7

HCT1

TB21
TB34

CT2

D7

TB8
UB2

1 2 3 4 5

L1

D2

UB4

CN3

1
2
3

TB30

TB16

Ground

CN1

PCB18
Filter Circuit Bord
[WK-5499]

SIDE CHASSIS 3

TB32

TB22

TB31

-Output
Terminal

FRONT
PANEL

SH.DET-

CT4

CT3

TO2

D4

AC4

CT3
TB17

FCH1

EB

R2
TH2

TH1

UB1

UB2

CN8

CN9

CN8

CN1
A M L
B
C

N
V

P
D

R
E

T
S

CON2

November 30, 2005

A
K

B
J

H
G

PCB12
Panel
Circuit Board
[WK-5527]

1
2
3
4

1
2
3
4

1
2
3
4
5
6
+15
-15
IS
GND

PCB13
Encorder Board
[WK-5528]

CN1
CN1

1 2 3 4

1 2 3 4

I
N

M
E

1
2
3
4
5
6
7

J
K

UB4

CN2

1 2 3 4 5 6 7 8 9

CN9

SIDE CHASSIS 2

UB3

CN21

1 2 3 4 5

1 2 3 4

CN17

SH.DET+

SH.DET-

AC2

AC4

EB

R3
1 2 3

Ground

H
G

Art # A-06951

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 ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
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,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty of


merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc 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, whether
arising out of contract, tort, including 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 by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermals 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. Purchasers rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc is a Registered
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
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years

LABOR
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,
1 year
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 Engines Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
WARRANTY PERIOD
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
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 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-PROCESS INVERTER WELDING EQUIPMENT
WARRANTY PERIOD
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 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
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 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
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 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
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
GENERAL ARC EQUIPMENT
WARRANTY PERIOD
Water Recirculators ....................................................................................................................... 1 year
Plasma Welding Torches.............................................................................................................180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days

LABOR

1 year
LABOR
1 year
180 days
Nil

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


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

Nil
Nil

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

Nil

3 years
3 years
1 year
LABOR

3 years
3 years
1 year
LABOR
3 years
3 years
3 years
1 year
LABOR
1 year
1 year
1 year
3 years
3 years

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION


Thermadyne USA

Thermadyne Asia Sdn Bhd

2800 Airport Road


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

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

Thermadyne Canada

Cigweld, Australia

2070 Wyecroft Road


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

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

Thermadyne Europe

Thermadyne Italy

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

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

Thermadyne, China

Thermadyne International

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

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