INVERTER ARC WELDER - Victor Technologies
Contents
1. 1 1 Output R71 Filter 1 Network JGJ v MC 2 D3 Ig E 5 ee 3 oos 2 alale t Islo 14 Receptacle gt x 4 L 5 gs Front View sols gt CALIE kad ing Receptacles support industry standard 515 Bo z geo pinouts signal names used are for clarity 5 8 in interconnection diagram only E Refer to Appendix C for receptacle signal connections gt gt gt gt Im gt gt 17 Pin Receptacle gt Front View gt Tripping Relay Control 12 gt Input Changeover Switch 11 CN6 gt Input Changeover Switch 10 1 Contactor 24 Brown gt Thyristor Gate Drive 4 9 2 Contactor 115 Ac gt Pre charge Control 8 3 Orange gt Common OV 7 9 o 4 ommon Yellow gt Undervollage ES Input Remote Blue gt 6 Current Detect Pink gt Reset Signal i 7 Current Detect Gray gt 12VDC 3 8 Chassis Green PCB Common gt 2 gt Input Voltage Detect 1 1 24V Brown gt 10V Red gt Input 1 3 Phase Detect 15 3 24V Orange gt Input Changeover Control 14 4 1V 100A Yellow gt2. 32 4 02 Specific oen aln i eto e iis 32 4 03 Remote 14 Pin Connections sueur 36 4 04 Remote 17 Pin Connections ss 37 APPENDIX ACCESSORIES smmeeeeennnneessnse 38 APPENDIX B INTERCONNECTION DIAGRAMS 39 INTRODUCTION employer s safety practices before installing operating or servicing WARNING Read and understand this entire Operating Manual and your the equipment our best judgement Thermal Dynamics Corporation assumes no WARNING While the information contained in this Operating Manual represents liability for its use Thermal Arc Models LM300 CC CV Welder Operating Manual Number 0 2506 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1997 by Thermal Dynamics Corporation 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 Operating Manual whether such error results from negligence accident or any other cause Printed in the United States of America July 1 1997 MANUAL 0 2506 1 GENERAL 1 0 GENERAL INFORMATION 1 01 NOTES CAUTIONS AND WARNINGS Throughout this manual notes cautions and warnings are used to highlight important information Th
3. 17 OTE MANUAL 0 2506 This switch determines whether the amperage voltage is adjusted by the front panel AMPERAGE VOLTAGE control or by a REMOTE control device If remote control function is not desired place this switch in PANEL position For remote amperage voltage control place AMPERAGE VOLTAGE switch in REMOTE 14 position if remote control connections are made to the REMOTE 14 receptacle or to the REMOTE 17 position if remote control connections are made to the REMOTE 17 receptacle When using the REMOTE 14 receptacle remote control is a percentage of the value set by the front panel AMPERAGE VOLTAGE control For example if the AMPERAGE VOLTAGE control is set at half maximum output the maximum output available from the remote control will be half the welding power source maximum output When using the REMOTE 17 receptacle two possibilities exist If Socket K is used to determine remote output the REMOTE 17 receptacle functions the same as the REMOTE 14 remote control is a percentage of the value set by the front panel AMPERAGE VOLTAGE control If Socket B is used to determine remote output the REMOTE 17 receptacle commands the full range of the welding power source output independent of the front panel AMPERAGE VOLTAGE setting Determining which socket to use depends on the remote control device used in the application If the OUTPUT CONTACTOR switch is in ON position open circuit voltage will be present at
4. gt ums m gt w 4 17 Pin Ri tacl Pin Receptacle gt Front View gt Tripping Relay Control 12 gt Input Changeover Switch 1 ENG gt Input Changeover Switch 10 1 Contactor 24 Brown gt gt Thyristor Gate Drive lt 9 2 Contactor 115 Red Pre charge Control 5 3 Output Reference Orange gt PCB Common OV 7 9 o 4 Common Yellow Di gt 4 Undervollage s Z 5 Input Remote Blue gt gt Overvoltage gt 5 6 Current Detect Pink gt Reset Signal lt 7 Current Detect Gray NT gt 4 12VDC 8 Chassis Green 1 gt PCB Common 2 gt Input Voltage Detect 1 ME gt 2 Red gt gt Input 1 3 Phase Detect 15 24V Orange EI Input Changeover Control 3 1V 100A Yellow 12 gt gt 12VDC 4 1V 10A Blue 2 gt gt PWM Gale Di 13 oL 5 M2 gt gt EL Gate IT 12 26 Common Pink F gt iate Drive Output Reference Gray 11 gt Input Changeover Control 2 7 Amplitude White gt Input Changeover Control 10 Ip 92 5 9 9 2 5 Contactor Black gt Torch Switch Control 98 D2 gt gt orch switch Contro 8 10 Lt Blue gt Output Short Circuit Detect Chassis Green a Common OV 5 11 52 gt gt Primary Current Detect 3 gt Primary Current Detect 2 gt Primary Current 1 gt Thermal Control 11 gt Thermal Control 10 gt Output Voltage Detect 9 gt Output Voltage Detect
5. Yellow 115V Brown 18V Gray Green Blue 460V Input Select 230V Thermal Detect Black 24VAC Thermal Detect Black lt 115VAC 2 v o jajo co APPENDIX B 40 MANUAL 0 2506 INTERCONNECTION DIAGRAMS R2 C2 A Ti IH ES Eole p TES 1 1 Output R71 Filter B 1 Network A T2 w gt WAND 1ndino x BEL 2 2985 tl slo BRIS 51142 D 14 Pin Receptacle gt 3 ihig 5 5 2 Front View gt 9151 lt 255 9 E O Receptacles support industry standard 22815 515 la pinouts signal names used are for clarity a i ignal for clari 518 8 5 9 5 interconnection diagram only Refer to Appendix C for receptacle signal connections gt gt
6. 8 3 Output Reference Orange gt PCB Common OV 7 9 4 Common Yellow i Undervollage gt s 5 Input Remote Blue gt Overvoltage 5 6 Current Detect Pink Reset Signal 7 Detect Gray E 12VDC 8 Chassis Green PCB Common gt 1 Volt D t 2 gt Input Voltage Detec 1 1 24V Brown 10V Red 2 gt Input 1 3 Phase Detect 15 24V Orange gt Input Changeover Control 14 7 1V 100A Yellow 12VDC 18 5 1V 10A Blue gt PWM Gate Drive lt 12 g 5 Common Pink gt PWM Gate Drive 11 x 7 Output Reference Gray gt Input Changeover Control 10 38 8 Amplitude White gt Input Changeover Control 9 gt 95 9 Contactor Black gt Torch Switch Control 8 E Ss Common Lt Blue Output Short Circuit Detect e 10 Chassis Green d Common OV 5 11 52 gt gt Primary Current Detect 3 gt Primary Current Detect 2 gt Primary Current Detect 1 gt Thermal Control 1 gt Thermal Control 10 gt Output Voltage Detect 9 gt Output Voltage Detect 8 gt Output Current Detect 7 m gt PCB Common 0V 9 PIS 12VDC gt 5VDC aS 70 4 7 gt 5VDC 3 95 NE gt PCB Common 2 E 12VDC 1 gt 8 lolo I amp Torch Control Pink 2 o Torch Control Yellow 1 Fs A 2 o gt gj Ilo gt 1 1 MANUAL 0 2506 43 APPENDIX B INTERCONNECTION DIAGRAMS LM300 460 575V Intercon
7. X X 8002 0 10 000 1004 X X 2002 01 104JU09 1004 X X S00c 0L pueH X X V00c 0L U9IMS U910L X X 00c 0L U9IIMS U9JO X X 2002 01 U9IMS X LOOZ OL yoo TOYLNOD 110 NO ON 1V9 TOHLINOO INSYYND 310IN3H MANUAL 0 2506 38 APPENDIX A ACCESSORIES APPENDIX INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all LM300 models in current production to aid in the identification of replacement parts MANUAL 0 2506 39 APPENDIX B INTERCONNECTION DIAGRAMS LM300 230 460V Interconnection Diagram IGBT Inverter Q1 IGBT Inverter Q2 Input Diode Bridge D1 Black Line 1 Black G White Line 3 White R2 Orange Line2 Red 515115151515 5 09 019015 5 Ground E 3 BRR AAAS m 5 9 os 5 9 5 lt lt ls 121015 0 5 515 22 O19 GIB S los jolo 2 9 2 9 2 2 9 2 12 219 5 s alai amp is z2 o o o jojo amp TB2 d o Fo cd TRS lo SE 5 0 sels sses 05 2 gt Z 5 5 a F 0151515151015 5 50 5 5 Line 3 Black Line 2 White Line 1 Red Red Black 99 Green OV T3 lt K1 Gray 24V
8. APPENDIX B 42 MANUAL 0 2506 INTERCONNECTION DIAGRAMS R2 C2 JOVI Vieni 1 1 Output R71 Filter B 1 Network A T2 D PL A K D3 I 5 o 5 5 2905 5 RA zio 241310 14 Pin Receptacle gt Sos Front View S 3 5 gt 515 888 malol fo Receptacles support industry standard 5 51212 Ar inouts signal names used are for clarity DIS 515 9 2 we 5199 in interconnection diagram only Refer to Appendix C for receptacle signal connections gt gt gt gt m gt a gt 17 Pin Receptacle gt Front View gt Tripping Relay Control 12 gt Input Changeover Switch 11 CN6 gt Input Changeover Switch 10 1 Contactor 24 Brown gt Thyristor Gate Drive lt 9 2 Contactor 115 Red 4 Pre charge Control 4
9. The following are some of the more common operating faults that occur during welding operations A Power Main power not connected Main power not turned on MAIN CIRCUIT BREAKER set on the OFF position INPUT SELECTOR Easy Link Switch in wrong position B 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 C Remote Operation Incorrect contactor switch settings Remote not connected 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 4 02 Specific Problems How to Use This Guide The following information is a guide to help you determine the most likely causes for various symptoms This guide is set up in the following manner A Symptom Bold Type Any special instructions Text Type 1 Cause Italic Type a Remedy Text Type Locate your symptom check the cause s the simplest or most likely is listed first then perform the remedy given Repair as needed being sure to verify that the unit is fully operational after any repairs BASIC TROUBLESHOOTING 32 MANUAL 0 2506 MANUAL 0 2506 A No Weld Output Unit is Completely Inoperative 1 Line disconnect switch is in OFF position a Place line disconnect switch in O
10. process Warning Indicator The Warning Indicator located on the front panel will become activated under the following conditions Input voltage is too low Input voltage is too high Thermal overload AC Power Indicator The AC Power indicator located on the front panel lights when the PRIMARY POWER Switch is in the ON position indicating the unit is energized Amperage Voltage Switch This selector switch determines the adjustment of amperage voltage In the PANEL position amperage voltage is controlled by the front panel control For remote amperage voltage control set the switch in either the REMOTE 14 or REMOTE 17 position depending on which remote control receptacle is used Output Contactor Switch With the PRIMARY POWER Switch ON open circuit voltage will be present at the weld output receptacle when the OUTPUT CONTACTOR SWITCH is in the ON position For remote contactor control set the switch in either the REMOTE 14 or REMOTE 17 position depending on which remote control receptacle is used Open circuit voltge will be present at the weld output receptacles whenever the torch switch or remote device is closed 24V Circuit Breaker Push to reset Controls 24V power source for wire feeders controlled through 14 Pin receptacle 115V Circuit Breaker Push to reset Controls 115V power source for wire feeders controlled through 14 Pin receptacle Amperage Voltage Selector Switch Selects digital meter dis
11. 12VDC 13 5 1V 10A Blue gt PWM Gate Drive lt 12 Q 5 Common Pink gt PWM Gate Drive lt 11 7 Output Reference Gray gt Input Changeover Control 10 38 8 Amplitude White gt Input Changeover Control 9 2 a Contactor Black gt Torch Switch Control 8 10 Common Lt Blue gt Output Short Circuit Detect 5 2 i Chassis Green gt PCB 4 gt Primary Current Detect 3 gt Primary Current Detect 2 gt Primary Current Detect 1 gt Thermal Control 11 gt Thermal Control 10 gt Output Voltage Detect 9 gt Output Voltage Detect 8 gt Output Current Detect 7 9 9 gt PCB Common OV 5 9 5 15 12VDC N 4 5VDC 5 gt 4 82 5VDC we gt 3 Xo gt PCB Common 2 Fe gt 12VDC 1 8 10 90 212 Torch Control Pink 2 lo Torch Control Yellow 1 lt A 2 o gt amp gt 1 MANUAL 0 2506 45 APPENDIX B INTERCONNECTION DIAGRAMS
12. 8 ojo gt Output Current Detect 7 919 gt 5 9 m 12VDC lt 5VDC 5 gt 4 og gt 5VDC 3 LE Me gt PCB Common 2 Dew 12VDC 1 s 8 lolo I 5 lt Torch Control Pink 2 o gt Torch Control Yellow 1 gt I 2 o gt 1 SSS SS MANUAL 0 2506 41 APPENDIX INTERCONNECTION DIAGRAMS LM300 380 415V Interconnection Diagram IGBT Inverter Q1 IGBT Inverter Q2 Input Diode Black Bridge D1 G Line 1 Black White R2 Orange R Line3 White Line2 _ Red ct Bus Bar ERN sl 5151151515 ge 02 0101010101105 te Ground E 3 31 41 10 5 21221515 015 1312 2 5 S S 515161012155 8 gt 2 5 lt 5 212 20 81515 5 5 2 5 515 151010 2 SiL TB6 TBi TB2 5 2 9 2 8 1 05 0 212 121520555 le Z 1515151015 51 10 2155 Line 3 Black Line 2 White z Line 1 Red 2 8 Red SE Black m m lt i Green ov_ T3 24V E gt Green CB3 Brown 18V 575V Gray Input Select i 11 ue 460V 10 9 Thermal Detect Black 8 24VAC Thermal Detect Black d 6 lt T 5 115VAC 4 3 2 1 gt gt gt
13. Duty Cycle Three phase Input Single phase Input 208 V 40A 86A 230 V 37A 78A 380 V 22A 400 V 21A 415V 20A 460 V 18A 39A 575 V 15A KVA 14 6 17 9 KW 11 3 11 3 35 Duty Cycle Three phase Input Single phase Input 208 V 32A 67A 230 V 29A 61A 380 V 17A 400 V 16A 415 V 15A 460 V 14A 30A 575 V 11A KVA 11 4 14 0 KW 8 8 8 8 575 V 11A INTRODUCTION 20 MANUAL 0 2506 2 06 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 calcul amp duty current rated current x rated duty cycle desired duty cycle ie At the 300A rated output current and 25 rated duty cycle the operator wants to work on a 50 duty cycle The maximum allowable current draw is 300A 2 x 25 50 current current 90 000 x 0 5 current 45 000 current 212 1A MANUAL 0 2506 21 INTRODUCTION 3 0 OPERATOR CONTROLS 3 0
14. L ARC AU JET DE PLASMA PEUVENT PRESENTER DES RISQUES ET DES DANGERS DE SANTE Il faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions FUM E et GAZ amp GENERAL La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS cont
15. Remote Amperage Control e Wire Feeder one which provides contactor control to welding power source e Combination of the above To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the supplied cord is not suitable and it is necessary to wire a plug or cord to interface with the REMOTE 14 Pin receptacle Socket A BASIC TROUBLESHOOTING Function Up to 10 amps of 24 VAC 60Hz with respect to Socket G circuit common protected by circuit breaker MCB3 Input to energize the solid state contactor 24 VAC contact closure is provided between Sockets A and B to energize the solid state contactor Amperage remote control MAXIMUM input command signal 10 volts for maximum Amperage remote control MINIMUM PC board common use as return for remote control inputs outputs Remote amperage reference signal WIPER 0 to 10 volts peak current set by main rheostat in CC or CV mode Not used 24 and 115 VAC circuit common also connected to welding power source chassis Not used Up to 1 5 amperes of 115 VAC 60Hz with respect to Socket G circuit common protected by circuit breaker MCB2 115 VAC input control to energize solid state contactor contact closure is provided between Sockets and J Chassis common Not used Not used Not used Figure 7 REMOTE 14 Pin Connections 36 MANUAL 0 2506 4 04 REMOTE 17 Pin Connectio
16. au Code lectrique national des Etats Unis Voir la page 6 article 9 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du A m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lors quelles sont coupe s sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau mains que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm MANUAL 0 2506 9 GENERAL PRECAUTIONS DE SECURITE IMPORTANTES RAYONS D A
17. 1 Front amp Rear panel controls Amperage Voltage Control The amperage voltage control selects the desired amperage or open circuit voltage within the entire range of the welding power source Rotating this control in a clockwise direction increases the amperage or voltage output The scale surrounding the control represents approximate actual amperage innerscale or voltage outerscale values 2 Hot Start Control The Hot Start Control operates in the STICK mode The Hot Start time is approximately 0 06 seconds in STICK The current value is adjusted from 0 to 100 Amps over the determined weld current set by the Amperage Control Rotating the Control clockwise increases Hot Start current Arc Inductance Control In the STICK welding SMAW mode this control provides a variation of short circuit amperage In the MIG CV mode this control functions as an inductance control allowing for the adjustment of the dynamic properties of the arc The zero 0 setting provides a minimum inductance and a fast responding arc The 100 setting provides maximum inductance and a slower responding arc As the inductance is increased the AMPERAGE VOLTAGE control may need to be adjusted to achieve the desired weld characteristics 3s OO 2 2 Co 955 9 CD Process Selector Switch The process selector switch allows the operator to select the STICK welding SMAW LIFT TIG GTAW or MIG GMAW
18. CAUTIONS CONTINUED PLASMA ARC RAYS MANUAL 0 2506 Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as recommended in the Operating Manual 5 GENERAL 1 03 PUBLICATIONS Refer to the following standards or their latest revisions for more information 1 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTI
19. CES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 N
20. Constant Current OCV Less than 70V C V 32V 10V 25A 310A Output Current Limit 310A 4 Figure 1b LM300 model Volt Ampere curve Constant Voltage 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 MANUAL 0 2506 15 INTRODUCTION 2 02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the LM300 power supplies Input Main Input Output Current Coupling Circuit ipu Inrush Current _ Capacitor IGBT Inverter Output Hu END 6s BN Power Diode Suppresor Module Transformers Diodes Transformer Coil 1 TEE Dc Thermal Control Sensor Transformer Config Drive Circuit Primary Lift Tig Mode Current Output Short Y Sensor Sensing Circuit Rower Voltage Sensor Thermal upply for Sensor Control Circuit Circuit Output gt Inductor 2 To each control circuit 12VDC 20VDC 24VDC 5VDC v Trouble gt Sensing Sequence Circuit k At v Output Torch Control Reference Voltage Connection Adjustments 4 Sensor CON1 Control Switch
21. IHERMAL Zinc A THERMADYNE Company INVEHTEH ARC WELDER MODEL LM300 CC CV e STICK e TIG LIFT START MIG SHORT CIRCUIT GLOBULAR SPRAY OPERATING MANUAL July 1 1997 Manual No 0 2506 TABLE OF CONTENTS 1 0 GENERAL INFORMATION sn 2 1 01 Notes Cautions and Warnings 2 1 02 Important Safety Precautions o aero auras 3 1 09 Publications eus aeta mr ene e RR 6 1 04 Note Attention et Avertissement 7 1 05 Precautions De Securite 8 1 06 Documents De R f rence entendent 11 1 07 Declaration of init 12 1 08 Statement of Warranty inner 13 2 0 INTRODUCTION amp DESCRIPTION sn 15 2 01 Description 15 2 02 Functional Block aue aterert e ote te des 16 2 03 Transporting Metliods osi aeter t debeat i e 17 2 04 Electrical Input Connections esee 17 2 05 Specifications nn nettes 20 2 06 D ty Cy CL Re s L red uti 21 3 0 OPERATOR CONTROLS ic sites 22 3 01 Front amp Rear panel controls ss mnt 22 3 02 Setup for Operation seats 24 Shielded Metal Arc Welding GMAW 26 Gas Tungsten Arc Welding GTAW Lift 27 Gas Metal Arc Welding Pulsed 29 4 0 BASIC TROUBLESHOOTING sn 32 4 01 Common Welding Operation amp
22. Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in the Publications Section in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors MANUAL 0 2506 3 GENERAL IMPORTANT SAFETY PRECAUTIONS CONTINUED ELECTRIC SHOCK FIRE AND EXPLOSION GENERAL NOISE Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer
23. N position 2 Line fuse s open a Check and replace line fuse s 3 Improper electrical input connections a See Section 2 04 Electrical Input Requirements page 17 for proper input connections 4 MAIN CIRCUIT BREAKER in OFF position a Check and reset MAIN CIRCUIT BREAKER if necessary 5 INPUT SELECTOR Easy Link switch is set to incorrect position for applied input voltage a Verify primary source voltage and set INPUT SELECT switch to correct setting B WARNING Indicator is ON 1 Unit is in thermal shutdown mode a Allow cooling period of approximately five 5 minutes with the power ON Duty cycle should be reviewed To reset the WARNING indicator the power supply must be turned OFF then ON again 2 Input voltage fluctuation causing protection circuits to activate a Monitor input power for spikes and high voltage condition Most power utilities will monitor and verify line voltage b Measure input voltage and verify that it matches the INPUT SOLECTOR Easy Link switch setting The length of the input power cable must be considered as there will be a considerable voltage drop along its length C Erratic or Improper Weld Output 1 Loose welding cable connections a Tighten all welding cable connections 2 Incorrect welding cable size a Use proper size and type of cable see Table 2 page 31 3 Improper input connections a Refer to Section 2 04 Electrical Input Requirements page 17 4 Poor electrode condition a Rep
24. Polarity Positive Reverse Polarity Pure Tungsten Green Band 0 010 in 0 25mm 1 15 m 0 020 in 0 51mm 5 20 0 040 in 1 02mm 15 80 1 16 in 1 59mm 70 150 10 20 3 32 in 2 38mm 125 225 15 20 1 8 in 3 18mm 225 360 25 40 5 32 in 3 97mm 360 450 40 55 3 16 in 4 76mm 450 720 55 80 1 4 in 6 35mm 720 950 80 125 296 Thorium Alloyed Tungsten Red Band 0 010 in 0 25mm 1 25 0 020 in 0 51mm 15 40 0 040 in 1 02mm 25 85 1 16 in 1 59mm 50 160 10 20 3 32 in 2 38mm 135 235 15 30 1 8 in 3 18mm 250 400 25 40 5 32 in 3 97mm 400 500 40 55 3 16 in 4 76mm 500 750 55 80 1 4 in 6 35mm 750 1 000 80 125 Table 3 Weld Cable Size Maximum Total Cable Length in Weld Circuit Under 100 ft 150 ft 200ft 250ft 300ft 350ft 400 ft Under 30m 45m pe 70m 90m 105m 120m Welding Amperes 100 4 1 0 150 2 3 0 200 1 4 0 250 1 0 2 2 0 300 1 0 2 0 2 3 0 400 2 0 3 0 2 4 0 MANUAL 0 2506 31 SETUP FOR OPERATION 4 0 BASIC TROUBLESHOOTING General h WARNING Troubleshooting and repairing this unitis a process which should be undertaken only by those familiar with high voltage high power electronic equipment There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had train ing in power electronics measurement and troubleshooting techniques 4 01 Common Welding Operation Faults
25. RC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Respectez le teint de lentille recommand dans le manuel de consignes BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d vez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie Pour prot ger votre ouie contre les bruits forts portez des tampons protecteurs et ou des protections auriculai
26. WSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 GENERAL 6 MANUAL 0 2506 1 04 NOTE ATTENTION ET AVERTISSEMENT Hou Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTET oute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me Vers Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur T ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question MANUAL 0 2506 7 GENERAL AVERTISSEMENT 1 05 PRECAUTIONS DE SECURITE IMPORTANTES L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE A
27. ard Rexdale Ontario Canada M9W 1R3 13 ivret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York 10018 MANUAL 0 2506 11 GENERAL 1 07 DECLARATION OF CONFORMITY Manufacturer Thermal Dynamics Corporation Address Industrial Park 2 West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EU as recently changed in Directive 93 63 EU and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details descripti
28. e 1430 Broadway New York NY 10018 6 Norme ANSI 749 2 PREVENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE DE SOUDAGE disponible aupr s de 1 American National Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulev
29. epair facility within thirty 30 days of the repair Authorized Thermal Arc repair facilities are authorized distributors and authorized Thermal Arc Service Centers No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Thermal Arc is a Registered Trademark of Thermal Dynamics Effective January 18 1991 MANUAL 0 2506 13 GENERAL 14 MANUAL 0 2506 2 0 INTRODUCTION amp DESCRIPTION 2 01 Description The Thermal Arc Model LM300 is a single or three phase DC arc welding power source with Constant Current CC output characteristics It also features Constant Voltage CV output characteristics and a digital panel meter All of the other models are available with an standard digital AMPERAGE VOLTAGE panel meter standard in European models The LM300 unit is equipped with selectable Constant Current CC or Constant Voltage CV output characteristics It is designed for use with Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW and Gas Tungsten Arc Welding Lift Start GTAW processes OCV Less than 70V C C Arc Characteristics VOLTS CURRENT Control 19gV k 7 5 145 300 310 AMPS Figure 1a LM300 model Volt Ampere curve
30. es Current Adjustment Circuit 2 LM300 Model functional block diagram INTRODUCTION 16 MANUAL 0 2506 2 03 Transporting Methods These units are equipped with a handle for carrying purposes A WARNING ELECTRIC SHOCK can kill e DO NOT TOUCH live electrical parts e Disconnect input power conductors from de energized supply line before moving welding power source damage WARNING FALLING EQUIPMENT can cause serious personal injury and equipment e Lift unit with handle on top of case e Use hand cart or similar device of adequate capacity e If using a fork lift vehicle place and secure unit on a proper skid before transporting 2 04 Electrical Input Connections A WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power e DO NOT TOUCH live electrical parts e SHUT DOWN welding power source disconnect input power employing lockout tag out procedures Lockout tag out procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device Electrical Input Requirements Operate the welding power source from a single or three 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 electr
31. ese highlights are categorized as follows NOTE An operation procedure or background information which requires additional emphasis or is helpful in efficient operation of the system A procedure which if not properly followed may cause damage to the equipment A WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area GENERAL 2 MANUAL 0 2506 WARNING 1 02 IMPORTANT SAFETY PRECAUTIONS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health A Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium
32. heck primary supply breaker or fuses and replace if necessary NOTE Verify that for single phase operation the RED input line is not connected 4 Open conductor in input power line a Check continuity and replace if necessary Red WARNING Indicator ON No Weld Output 1 Input voltage fluctuation causing protection circuits to activate a Monitor input power for spikes and high voltage condition Most power utilities will monitor and verify line voltage 2 Thermal sensor TH1 open thermal shutdown a Allow the unit to cool for five minutes before turning the power supply ON G Front Panel 24V or 115V Circuit Breaker s Trips When Remote Contactor Points are Closed or when the AMPERAGE VOLTAGE Selector in PANEL Position 1 Faulty feeder remote device a Verify operation of external feeder device and replace if necessary H No Weld or Output Fan Operating WARNING Indicator OFF 1 OUTPUT CONTACTOR selector in REMOTE 14 position with no remote contactor connected a Place OUTPUT CONTACTOR selector to ON position or connect remote contactor control to remote receptacle BASIC TROUBLESHOOTING 34 MANUAL 0 2506 MANUAL 0 2506 2 Faulty Remote Control Device Set OUTPUT selector to ON position and AMPERAGE VOLTAGE selector to PANEL position If amperage and voltage can be adjusted with front panel controls repair or replace remote control device 3 Line voltage is too high a Verify that input voltage
33. ical service available how proper connections should be made and inspection required 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 four conductor with earth power cable that is connected at the welding power source end for single or three phase electrical input power MANUAL 0 2506 17 INTRODUCTION operate single phase do not connect the RED input conductor Do not connect an input WHITE BLACK or RED conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Refer to figure 3 and 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 line 2 WHITE and line 3 RED input conductors to a de energized line disconnect switch 3 Use Table 1 below as guide to select line fuses for the disconnect switch Table 1 Fuse Size Selection Single Phase 208 230VAC 60 60 380 415 VAC 30 N A 460 VAC 25 30 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 Ground Conductor Ground Terminal Line Fuse Disconnect Switch Line Fuse Welding Power Supp
34. iennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 11 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e 8 MANUAL 0 2506 PRECAUTIONS DE SECURITE IMPORTANTES CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette A nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le mat riel conform ment
35. l and connect unit according to the installation instructions in section 2 04 page 17 of this manual 2 Install and connect wire feed system according to its Owners Manual 3 Wear dry insulating gloves and clothing 4 Connect work clamp to clean bare metal on workpiece For the majority of electrodes in use the work clamp is connected to the POSITIVE output terminal 5 Connect MIG Pulser to 17 Pin connecter 6 Place the PROCESS SELECTOR switch 4 per Pulser Manual 7 Place the OUTPUT CONTACTOR switch 8 per Pulser Manual 8 Place the AMPERAGE VOLTAGE switch 11 per Pulser Manual 9 Rotate AMPERAGE VOLTAGE control 1 per Pulser Manual 10 Rotate ARC CONTROL INDUCTANCE control 3 to desired position 11 Turn on shielding gas supply and set desired flow rate 12 Wear welding helmet with proper filter lens according to ANSI Z49 1 13 Place PRIMARY POWER switch 18 in ON position 14 Begin welding MANUAL 0 2506 29 SETUP FOR OPERATION Shut off gas supply when not in use WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill Shutting Down 15 Stop welding 16 Move the PRIMARY POWER switch 18 to the OFF position 17 Turn off the shielding gas and water supplies if applicable SETUP FOR OPERATION 30 MANUAL 0 2506 3 03 SETUP FOR OPERATION Table 2 Electrode Selection Table Electrode Diameter Amperage Range DC Argon Electrode DC Argon Electrode Negative Straight
36. lace electrode 5 If using a wire feeder ensure that the wire is feeding at a consistent rate a Adjust wire feeder 6 If in GTAW mode check the condition of the tungsten electrode a Use the recommended 2 Thoriated tungsten 7 In GTAW mode incorrect argon gas flow a Verify that argon gas flow is approximately 12 15 SCFH 8 Incorrectly set PROCESS SELECTOR switch a Verify the PROCESS SELECTOR switch is set to match the type of welding process being conducted 9 Wrong welding polarity a Verify output torch connections 33 BASIC TROUBLESHOOTING D Wandering Arc Poor Control of Arc Direction 1 Wrong size tungsten electrode typically larger than recommended a Use proper size electrode for amperage selected see Table 2 page 31 2 Improperly prepared tungsten electrode a Prepare tungsten properly 3 Gas flow rate too high a Reduce flow rate 4 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone from drafts and check condition of tungsten electrode a Check and tighten all gas fittings 5 Water in torch a Refer to torch parts list for part s requiring replacement and repair torch as necessary E Green AC POWER Indicator OFF Fan Not Operating 1 Input line disconnect switch in OFF position a Place input line disconnect switch to ON position 2 Power supply MAIN CIRCUIT BREAKER MCB in OFF position a Place MCB to ON position 3 Input line breaker tripped fuses blown a Reset MCB c
37. lding situations when operating in the STICK welding GMAW mode Main Knob Arc Control 5 300A 19V 10V 100A Droop 0 25 50 75 100 e 145 Arc Control Knob Main Knob Arc Control Knob Less Than 310 Output Current Limit Figure 6 Arc Control Characteristics Inductance for In the MIG CV mode the ARC INDUCTANCE control functions MIG CV mode as a inductance control allowing for the adjustment of the dynamic properties of the arc enhancing the weld puddle control when operated in the Gas Metal Arc GMAW and Flux Cored Arc FCAW welding processes The 0 zero setting provides a minimum inductance i e a stiff fast responding arc and a small fast freezing weld puddle Best for mild steel solid wire CO Gas The 100 setting provides maximum inductance characteristics i e a soft slower responding low spatter arc and high weld puddle fluidity For Stainless Steel use a setting of 8 for solid wire As the inductance is increased it may be required to reduce the arc voltage at the AMPERAGE VOLTAGE control to achieve the desired weld characteristics Select a setting best suited for the application and electrode type NOTE Hotstart is not active SETUP FOR OPERATION 24 MANUAL 0 2506 3 02 Setup for Operation AMPERAGE VOLTAGE Switch PANEL 7 REM Z REM 14 OTE 17 OTE OUTPUT CONTACTOR A Switch NOTE ON 14 REMOTE 7 REM
38. ly Xe Primary Power Cable Figure 3 Electrical input connections INTRODUCTION 18 MANUAL 0 2506 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT BREAKER is turned on the inrush circuit provides a pre charging of the input capacitors SCR s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds NOTE Note the available input power Damage to the PCA could occur if 575VAC is applied with the INPUT SELECT switch in the 208 230V position 208VAC 50 60Hz three phase single phase 230VAC 50 60Hz three phase single phase 460VAC 50 60Hz three phase single phase 575VAC 50 60Hz three phase MANUAL 0 2506 19 INTRODUCTION 2 05 Specifications LM300 Models Parameter Rated Output 85 duty cycle Three phase Amperes Volts Single phase Amperes Volts 25 duty cycle Single Three phase Amperes Volts Output Range Min Max STICK LIFT TIG MIG Amperes Volts 10 32 Open Circuit Voltage 230 V 460 V Dimensions Weight Width Height Length Weight 8 3 in 210 mm 16 9 in 430 mm 16 5 in 420 mm 40 7 lb 18 5 kg Output at No Load Single phase Input Three phase Input 208 V 1 4A 24 230 V 1 3A 2 2A 380 V 0 8A 400 V 0 7A 415 V 0 7 A 460 V 0 6A 1 1A 575 V 0 5 A KVA 0 5 KW 0 3 Output at Rated Load 25
39. matches setting on rear panel INPUT SELECTOR switch I Low or Maximum Weld Output With No Control 1 Faulty remote control device Set OUTPUT selector to ON position and AMPERAGE VOLTAGE selector to PANEL position If amperage and voltage can be adjusted with front panel controls repair or replace remote control device J Limited Weld Output 1 Poor primary input voltage a Check primary input voltage is within 10 of nominal voltage i e 230VAC 10 K Erratic or Improper Weld Output 1 Loose welding cable connections a Tighten all welding cable connections 2 Improper setup a Check for proper connection of input power 3 Faulty Remote Device a Check all remote devices and repair or replace if necessary L No 115VAC or 24VAC at 14 Pin Connector 1 Front panel circuit breakers are tripped a Reset front panel circuit breakers M No Weld Output Fan Not Operating WARNING Indicator OFF 1 Line voltage too low a Verify that input voltage matches setting on rear panel INPUT SELECTOR switch 2 Incompatible remote control device a Verify remote device wiring matches receptacle 3 Faulty remote control device a Jumper output contractor If unit produces output the remote device is faulty 35 BASIC TROUBLESHOOTING 4 03 REMOTE 14 Pin Connections The REMOTE 14 Pin receptacle is used to connect any of the following equipment to the welding power source circuitry e Remote Contactor Control e
40. nection Diagram IGBT Inverter Q2 IGBT Inverter Q1 Input Diode Black Bridge D1 R G Line 1 Black White Line 3 White R2 Orange Line 2 _ Red Dls 5151151559500 05 Ground zi 5S8 SI EE E lt o alza 5 065 5 15121210 9 F S 21215 2 150029 SERIERERERHEHESE alzi amp 2 o 9 9 Jojo a TB6 TB TB2 51818121 ESORS 10 01 05 0 5 5 5 5 2 5 5 5 5 5 S 0 515 15121515 515 0 2 S T Line 3 Black Line 2 White Line 1 Red Red Black 1494 preog ure Green OV T3 Gt i Gray 24V Yellow 115V CB2 Orange 18V ES Green OV CB3 Brown 18V 11 10 Thermal Detect Black 24VAC Thermal Detect Black AM APPENDIX 44 MANUAL 0 2506 INTERCONNECTION DIAGRAMS R2 C2
41. ns The REMOTE 17 Pin receptacle provides a junction point for connecting various remote controls to the welding power source The functions available from this receptacle are e Remote MIG synergic and Manual MIG Pulsers e Remote Control Weld current and voltage signals for remote metering To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the supplied cord is not suitable and it is necessary to wire a plug or cord to interface with the REMOTE 17 Pin receptacle 17 MANUAL 0 2506 Function Amperage voltage reference output signal 10 volts for use with pulse controls Amperage voltage remote control input command signal 10 volts for machine maximum Not used Solid state contactor remote control command signal 24 volts operates above 13 volts turns contactor on 0 volts open or ground turns contactor off Actual weld current signal 1 volt per 100 amperes of output current PC board common use as return for remote control inputs outputs only from terminals A B C D E J and K Not used 24 volts unregulated fused for 1 2 ampere Not used Remote amperage voltage reference signal 0 to 10 volts set by main rheostat in CC and CV mode 24 volts unregulated fused for 1 2 ampere Load voltage output signal 1 volt per 10 volts of load voltage Not used Circuit common PC board common and inte
42. on parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are CSA Canadian Standards Association standard C22 2 number 60 M1990 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment March 1995 EC 974 1 BS 638 PT10 EN 60 974 1 applicable to welding equipment and associated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process to ensure the product is safe and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products that perform in a safe manner for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative David Ashworth Vice President amp Managing Director Thermadyne Europe Chorley England CE GENERAL 12 MANUAL 0 2506 1 08 STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Should an
43. per the following a PROCESS SELECTOR switch 4 to STICK position b Rotate the AMPERAGE control 1 to output current level desired c Set OUTPUT CONTACTOR 8 and AMPERAGE VOLTAGE 7 switch to desired position 6 Insert electrode into electrode holder For the majority of electrodes in use the electrode holder is connected to the POSITIVE output terminal 7 Wear welding helmet with proper filter lens according to ANSI 7491 8 Place the PRIMARY POWER switch 18 to ON 9 Begin welding SETUP FOR OPERATION 26 MANUAL 0 2506 3 02 Setup for Operation Gas Tungsten Arc Welding GTAW Lift Start T WARNING Read and follow all safety precautions on pages 2 5 of this manual before preceding with operation 1 Install and connect unit according to the installation instructions in section 2 04 page 17 of this manual 2 Select proper tungsten electrode refer to Electrode Selection Table 2 page 31 3 Prepare tungsten electrode and insert into torch For the majority of electrodes in use the electrode holder is connected to the NEGATIVE output terminal 4 Wear dry insulating gloves and clothing 5 Connect remote control device to 14 pin receptacle NOTE The maximum output that can be obtained using the remote control is set by the main current knob 6 Connect work clamp to clean bare metal on workpiece For the majority of electrodes in use the work clamp is connected to the POSITIVE output te
44. play of output amperage or voltage Preview Pushbutton Switch Allows digital meter to be used to set voltage in MIG mode or amperage in TIG or STICK modes prior to welding LCD Display Positive Terminal 50mm DIN style female receptacle Negative Terminal 50mm DIN style female receptacle 14 Pin Receptacle Used for remote contactor amperage controls and wire feeder controls 17 Pin Receptacle Used for MIG Pulsers Figure 4 LM300 model front operator controls OPERATOR CONTROLS 22 MANUAL 0 2506 19 Primary Power Switch Placing the Primary Power Switch circuit breaker located on the rear panel to the ON position energizes the welding power source Voltage Selector Manual slide switch selects the proper input voltage range If this slide switch is not set to the position that matches the input voltage from the electrical 20 source the Smart Logic will inhibit welding power source turn on and the warning indicator will be illuminated Not installed in 380 415V models Input Cable 10 feet Figure 5 300 Series rear panel operator controls MANUAL 0 2506 23 OPERATOR CONTROLS 3 02 Setup for Operation ARC INDUCTANCE The ARC INDUCTANCE CONTROL may be adjusted while Control welding Operation of this control depends on the welding mode selected Arc Control The ARC INDUCTANCE CONTROL provides a variable for STICK mode selection of short circuit amperage to suit individual we
45. res Prot gez galement les autres personnes se trouvant sur le lieu de travail l faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 11 GENERAL 10 MANUAL 0 2506 1 06 DOCUMENTS DE REFERENCE Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OPERATIONS DE COUPE ET DE SOUDAGE ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institut
46. rminal 7 Referto the Operator Control section page 22 and set the controls per the following a PROCESS SELECTOR switch 4 to LIFT START Gas Tungsten Arc Welding position GTAW MANUAL 0 2506 27 SETUP FOR OPERATION LIFT TIG In this mode the unit provides weld output for the Gas Tungsten GTAW without Arc Welding GTAW process When the PROCESS SELECTOR High Frequency switch is in this position the HOT START ARC CONTROL will not function The unit will provide a low open circuit voltage and approximately 15 amps to the tungsten electrode when touched to the work After the Tungsten Electrode is lifted away and the welding arc becomes established the output current will be regulated at the current level determined by the AMPERAGE control 1 b Rotate the AMPERAGE control 1 to output current level desired 8 Turn on shielding gas 9 Wear welding helmet with proper filter lens according to ANSI ZA9 1 10 Place the PRIMARY POWER switch 18 to ON 11 Activate remote control device a In LIFT TIG mode touch electrode to work and lift to start arc 12 Begin welding Shut off gas supply when not in use 2 WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill SETUP FOR OPERATION 28 MANUAL 0 2506 3 02 Setup for Operation Gas Metal Arc Welding Pulsed GMAW Q WARNING Read and follow all safety precautions on pages 2 5 of this manual before preceding with operation 1 Instal
47. rnal chassis ground use as return 18 volts logic supply only pins H and L Not used Chassis ground Not used Figure 8 REMOTE 17 Pin Connections BASIC TROUBLESHOOTING APPENDIX A ACCESSORIES VIN V N V N V N V N V N V N V N V N V N V N V N V N 8 8 lek ejpueH 9 L 9 e pueH 5 6 II HOHOL epeuio 4 ulg 4 9 SIN 2 8 ere epeuuo 4 Uld Z SIN 8 ere Uld Z ipm 9 ee Uld Z ulq Z Uld Z uld Uld v Uld V uld r L9 N epeuio 4 9 OLN epeuuo 4 9 SIN eeu 4 9 ere e euuo 4 9 ON ss ere SER uld t 1 N Uld L eN Uld L ae Uld 7 N Uld L N Uld 7 L SHOLO3NNOO LOS W6 E WYy 0E 001 Uug eo SZ wg S LOS WUG LE 2192 H15N31 X X 660 01 2199 1X4 X X 8 0c0L X X 1 0c0L 8199 1X4 X X 9602 01 2149 1X3 X X S 0c 0L 2199 1X4 X X vedc Ol 1X3 X X 6602 01 1X3 X X c 0c 0L 1X3 X X 606 0 8I9E9 Ka X X 0202 01 1X3 OOEINT 101 10 8JOLWUSH 10 Se qe
48. s upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal products shall be as follows A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the following further limitations on such two 2 year period PAK UNITS POWER SUPPLIES PARTS LABOR MAIN POWER MAGNETICS eee 2 1 YEAR ORIGINAL MAIN POWER RECTIFIER 2 1 YEAR CONTROL PC BOARD ss 2 5 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS 1YEAR 1 YEAR INCLUDING BUT NOT LIMITED TO STARTING CIRCUIT CONTACTORS RELAYS SOLENOIDS PUMPS POWER SWITCHING SEMI CONDUCTORS CONSOLES CONTROL EQUIPMENT HEAT 1 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS Rosset tees 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc r
49. the output receptacles whenever the PRIMARY POWER switch is in ON position Although the term Contactor is used on the nameplate and throughout this manual the output is not switched on or off by a physical contactor rather the unit uses solid state output control For remote contactor control place the OUTPUT CONTACTOR switch in REMOTE 14 position if remote contactor connections are made to the REMOTE 14 receptacle or to the REMOTE 17 position if remote contactor connections are made to the REMOTE 17 receptacle Open circuit voltage will be present at the weld output receptacles whenever the torch switch or remote device is closed If remote contactor control is not desired place the OUTPUT CONTACTOR switch in ON position Open circuit voltage will be available whenever the PRIMARY POWER switch is in ON position 25 SETUP FOR OPERATION 3 02 Setup for Operation Shielded Metal Arc Welding SMAW WARNING Read and follow all safety precautions on pages 2 5 of this manual before preceding with operation 1 Install and connect unit according to the installation instructions in section 2 04 page 17 of this manual 2 Wear dry insulating gloves and clothing 3 Connect work clamp to clean bare metal on workpiece For the majority of electrodes in use the work clamp is connected to the GROUND or NEGATIVE output terminal 4 Select proper electrode 5 Refer to Operator Control section page 22 and set the controls
50. to item 4 in the Publications section of this manual Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in the Publications section of this manual 4 MANUAL 0 2506 IMPORTANT SAFETY PRE
51. y failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s specifications instructions recommen dations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the good
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