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INVERTER
ARC
WELDER
MODEL LS300 CC
• STICK
• TIG - LIFT START

OPERATING MANUAL

July 1, 1997

Manual No. 0-2504

TABLE OF CONTENTS

1.0 GENERAL INFORMATION ........................................................ 2
1.01 Notes, Cautions and Warnings ................................................. 2
1.02 Important Safety Precautions .................................................... 3
1.03 Publications ................................................................................. 6
1.04 Note, Attention et Avertissement ............................................. 7
1.05 Precautions De Securite Importantes....................................... 8
1.06 Documents De Reference ......................................................... 11
1.07 Declaration of Conformity ...................................................... 12
1.08 Statement of Warranty ............................................................. 13
2.0 INTRODUCTION & DESCRIPTION ...................................... 15
2.01 Description ................................................................................ 15
2.02 Functional Block Diagrams ..................................................... 16
2.03 Transporting Methods.............................................................. 17
2.04 Electrical Input Connections ................................................... 17
2.05 Specifications ............................................................................. 20
2.06 Duty Cycle ................................................................................. 21
3.0 OPERATOR CONTROLS ........................................................... 22
3.01 LS Front & Rear Panels ............................................................ 22
3.02 Setup for Operation .................................................................. 24
Shielded Metal Arc Welding (SMAW) ......................................... 25
Gas Tungsten Arc Welding (GTAW) Lift Start ............................ 26
4.0 BASIC TROUBLESHOOTING .................................................. 29
4.01 Common Welding Operation Faults ...................................... 29
4.02 Specific Problems ...................................................................... 29
4.03 Remote 8-Pin Connections ...................................................... 33
APPENDIX A – ACCESSORIES ...................................................... 34
APPENDIX B – INTERCONNECTION DIAGRAMS ................. 37

WARNING

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

WARNING

While the information contained in this Operating Manual represents
our best judgement, Thermal Dynamics Corporation assumes no
liability for its use.

Thermal Arc Models LS300 CC Welder
Operating Manual Number 0-2504
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 0-2504

GENERAL

1.0 GENERAL INFORMATION
1.01 NOTES, CAUTIONS AND WARNINGS
Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:
NOTE

GENERAL

An operation, procedure, or background information which requires
additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the
equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the
operator or others in the operating area.

MANUAL 0-2504

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.
• 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
Arsenic
Barium
Beryllium
Cadmium

Chromium
Cobalt
Copper
Lead
Manganese

Mercury
Nickel
Selenium
Silver
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 0-2504

GENERAL

IMPORTANT SAFETY PRECAUTIONS (CONTINUED)

ELECTRIC SHOCK

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 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

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

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.

GENERAL

MANUAL 0-2504

IMPORTANT SAFETY PRECAUTIONS (CONTINUED)

PLASMA ARC RAYS

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.

MANUAL 0-2504

GENERAL

1.03 PUBLICATIONS

Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. 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
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING
PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York,
NY 10018
7. 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
8. 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
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
11. 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
12. 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
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. 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
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from
American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL

MANUAL 0-2504

1.04 NOTE, ATTENTION ET AVERTISSEMENT

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important. Ces
mises en relief sont classifiées comme suit :
NOTET

ATTENTION

AVERTISSEMENT

MANUAL 0-2504

oute opération, procédure ou renseignement général sur lequel il
importe d’insister davantage ou qui contribue à l’efficacité de
fonctionnement du système.
Toute procédure pouvant résulter l’endommagement du matériel en cas
de non-respect de la procédure en question.
Toute procédure pouvant provoquer des blessures de l’opérateur
ou des autres personnes se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.

GENERAL

AVERTISSEMENT
1.05 PRECAUTIONS DE SECURITE IMPORTANTES

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE
À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER
DES RISQUES ET DES DANGERS DE SANTÉ.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre
tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent
du genre de métal utilisé, des revêtements se trouvant sur le métal et
des différents procédés. Vous devez prendre soin lorsque vous coupez
ou soudez tout métal pouvant contenir un ou plusieurs des éléments
suivants:
antimoine
argent
arsenic
baryum
béryllium

cadmium
chrome
cobalt
cuivre
manganèse

mercure
nickel
plomb
sélénium
vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle
américain “MSDS”); celles-ci devraient être fournies avec le matériel
que vous utilisez. Les MSDS contiennent des renseignements quant à
la quantité et la nature de la fumée et des gaz pouvant poser des
dangers de santé.
• Pour des informations sur la manière de tester la fumée et les gaz de
votre lieu de travail, consultez l’article 1 et les documents cités à la
page 11.
• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée provenant des
solvants et des produits de nettoyage chlorés. Eliminez toute source
de telle fumée.

GENERAL

MANUAL 0-2504

PRECAUTIONS DE SECURITE IMPORTANTES

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
de plasma requiert et produit de l’énergie électrique haute tension. Cette
énergie électrique peut produire des chocs graves, voire mortels, pour
l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail ou des
autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou
moite.
• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page 6, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou
de réparation.
• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET
EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des
étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du
métal, des étincelles, des scories chaudes pouvant mettre le feu aux
matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se
trouve sur le lieu de travail. Protégez toute telle matière qu’il est
impossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables ou
explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des
matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces de
travail en aluminium lors’quelles sont coupeés 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 à mains que le gas hydrogène peut s’échapper ou
se dissiper. Le gas hydrogène accumulé explosera si enflammé.

MANUAL 0-2504

GENERAL

PRECAUTIONS DE SECURITE IMPORTANTES

RAYONS D’ARC
DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran de
soudeur. Portez toujours des lunettes de sécurité munies de parois
latérales ou des lunettes de protection ou une autre sorte de protection
oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail contre
les rayons de l’arc en fournissant des cabines ou des écrans de
protection.
• Respectez le teint de lentille recommandé dans le manuel de
consignes.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dúvez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également les
autres personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le
bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 11.

GENERAL

MANUAL 0-2504

1.06 DOCUMENTS DE REFERENCE

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus
amples renseignements :
1.

OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR
1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE
À L’ARC ET AU GAZ, disponible auprès 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 Américain des Normes Nationales
(American National Standards Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de
l’American National Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES
SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE
ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN
CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas
Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible
auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès 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 Américaine de Soudage, RECOMMANDATIONS DE
PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE
CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible
auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430 Broadway, New York, NY 10018

MANUAL 0-2504

GENERAL

1.07 DECLARATION OF CONFORMITY

Manufacturer:
Address:

Thermal Dynamics Corporation
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 description, 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.
* IEC 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 & Managing Director
Thermadyne Europe
Chorley England.

GENERAL

MANUAL 0-2504

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 any 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 goods 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 ........................................ 2 YEARS ................... 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ....................... 2 YEARS ................... 1 YEAR
CONTROL PC BOARD .................................................. 2 YEARS ................... 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ........... 1 YEAR .................... 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS,
PUMPS, POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT ...................... 1 YEAR .................... 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ............................................................ 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® repair 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 0-2504

GENERAL

MANUAL 0-2504

2.0 INTRODUCTION & DESCRIPTION

2.01 Description
The Thermal Arc™ Model LS300 is a single or three-phase DC arc welding
power source with Constant Current (CC) output characteristics. It is
available with an optional digital AMPERAGE/VOLTAGE panel meter
(standard in European models).
The LS300 unit is designed for use with Shielded Metal Arc Welding
(SMAW) and Gas Tungsten Arc Welding -Lift Start (GTAW) processes.

Arc Characteristics
"AMPERAGE" Control

VOLTS
19V

145

AMPS

300 310

Figure 1. LS300 model Volt-Ampere curve

NOTE

MANUAL 0-2504

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.

INTRODUCTION

2.02 Functional Block Diagrams
Figure 2 illustrates the functional block diagram of the LS300 power supply.
Input
Power

Main
Circuit
Breaker

Input
Diode

Inrush Current
Suppresor

Capacitor

IGBT Inverter
Module
Thermal
Sensor

Control
Transformer
(-c Config.)

Primary
Current
Sensor

Drive Circuit
DC Power
Supply for
Control Circuit

Output
Diodes

Output
Transformers

Coupling
Coil

Lift Tig Mode
Output Short
Sensing Circuit

Thermal
Sensor
Circuit

Voltage Sensor

Current
Transformer
(CT-1)

Output
Inductor

–

To each control circuit
+12VDC +20VDC
+24VDC +5VDC
Trouble
Sensing
Circuit

Torch Control
Connection
(CON1)

Sequence
Control

–
+

Reference
Adjustments &
Control Switches
Current
Adjustment
Circuit

Figure 2. LS300 Model functional block diagram

INTRODUCTION

MANUAL 0-2504

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

WARNING

ELECTRIC SHOCK can kill.

•

DO NOT TOUCH live electrical parts.

•

Disconnect input power conductors from de-energized supply line
before moving welding power source.

FALLING EQUIPMENT can cause serious personal injury and equipment
damage.

•

Lift unit with handle 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.

2.04 Electrical Input Connections
WARNING

Electrical Input
Requirements

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/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.

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 electrical 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

MANUAL 0-2504

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.

INTRODUCTION

•

To 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.
Connect ends of line 1 (BLACK), line 2 (WHITE) and line 3 (RED)
input conductors to a de-energized line disconnect switch.
Use Table 1 below as a guide to select line fuses for the disconnect
switch.

2.
3.

Table 1. Fuse Size Selection

NOTE

Input Power/Input Voltage

Fuse Size (Amperes)

208-230VAC

Three-Phase
60

Single-Phase
60

380-415 VAC

N/A

460 VAC

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

INPUT SELECT
SWITCH
460V

PRIMARY POWER

208-230V

PRIMARY CABLE
OFF

3/1

f1
f2

IEC974
X
U0

64
U2

3/1

U1
V
208V
230V
460V
60/80 Hz

5A/10V - 400A/36V
60%
25%
400/
300/
280A
210A
36/
32/
31V
28V

61/78A
66/70A
27/36A
21.9/
16.2kVA

40/63A
37/48A
18/24A
14.6/
10.9kVA

100%
230/
160A
28/
26V

28/37A
26/34A
13/17A
10/
8.0kVA

THERMADYNE
Thermal Dynamics
WEST LEBANON, NEW HAMPSHIRE USA 03784
MADE IN JAPAN

400S
TURN OFF YOUR MAIN POWER SOURCE AND
CIRCUIT BREAKER OF THIS WELDER BEFORE
MAINTENANCE OR INSPECTION

IP 23S

Line
Disconnect
Switch

Line Fuse

Welding Power Supply

Primary Power Cable

Figure 3. Electrical input connections

INTRODUCTION

MANUAL 0-2504

Input Power

NOTE

MANUAL 0-2504

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 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

INTRODUCTION

2.05 Specifications
LS300 Models
Parameter
Rated Output
40% duty cycle
Three-phase
Amperes
Volts
Single-phase
Amperes
Volts
25% duty cycle
Three-phase
Amperes
Volts
Single-phase
Amperes
Volts

250
30
170
27

300
32
210
28

Output Range (Min. - Max.)
Amperes
Volts10-32

STICK/LIFT TIG
5-300

Open Circuit Voltage
230 V/460 V

64 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
208 V
230 V
380 V
400 V
415 V
460 V
575 V
KVA
KW
Output at Rated Load
25% Duty Cycle
208 V
230 V
380 V
400 V
415 V
460 V
575 V
KVA
KW
40% Duty Cycle
208 V
230 V
380 V
400 V
415 V
460 V
575 V
KVA
KW

INTRODUCTION

Three-phase Input
1.4A
1.3 A
0.8 A
0.7 A
0.7 A
0.6 A
0.5 A

Single-phase Input
2.4 A
2.2 A

1.1 A
0.5
0.3

Three-phase Input
40 A
37 A
22 A
21 A
20 A
18 A
15 A
14.6
11.3
Three-phase Input
32 A
29 A
17 A
16 A
15 A
14 A
11 A
11.4
8.8

Single-phase Input
53 A
48 A

24 A
10.9
6.9
Single -phase Input
41 A
37 A

19A
8.5
5.7

MANUAL 0-2504

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 calculate duty cycle:

current =

(rated current)2 x (rated duty cycle)
(desired duty cycle)

i.e. 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:

current =

(300A)2 x (.25)
(.50)

current = 90,000 x (0.5)
current = 45,000
current = 212.1A

MANUAL 0-2504

INTRODUCTION

3.0 OPERATOR CONTROLS
3.01 LS Front & Rear Panels

2 12

1
6

Amperage Control - The Amperage Control selects
the desired amperage within the entire range of the
welding power source. Rotating this control in a
clockwise direction increases the amperage output.
The scale surrounding the amperage control
represents approximate actual amperage values.

Process Selector Switch - The Process Selector
Switch allows the operator to select the STICK
welding (SMAW) process or LIFT TIG (GTAW) 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 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.

Hot Start Control - The Hot Start Control provides a
variable selection of start circuit current that 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 Control - The Arc Control is in use in the SMAW
mode only. Rotate the control clockwise to increase the
short circuit current available to control the welding arc;
adjust to reduce sticking of electrode to plate.

Amperage/Voltage Selector Switch - Selects digital
meter display of output amperage or voltage. Part of
optional meter kit, part number 10-4000.

Preview Pushbutton Switch - Allows digital meter to
be used to set amperage (in TIG or STICK modes)
prior to welding. Part of optional meter kit, part number
10-4000.

8-Pin Receptacle - Used for remote contactor and
amperage controls.

5
9

3
4
10
11

Positive Terminal - 50mm DIN-style female receptacle.

Negative Terminal - 50mm DIN-style female receptacle.

LCD Display - Part of optional meter kit, part number
10-4000.

Figure 4. Front panel operator controls

OPERATOR CONTROLS

MANUAL 0-2504

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
source the Smart Logic will inhibit welding power source
turn on and the warning indicator will be illuminated. Not
installed in 460V/575V units.

Input Cable - 10 feet

Figure 5. Rear panel operator controls

MANUAL 0-2504

OPERATOR CONTROLS

3.02 Setup for Operation
Arc Control

The ARC CONTROL provides a variable selection of short circuit amperage
to suit individual welding situations when operating in the STICK welding
(SMAW) mode.
Main Knob
300A

Arc Control
19V 10V/100A Droop

25%

50%

100%

75%

145A
Arc Control Knob
Main Knob = Arc Control Knob
= Less Than 310 Output Current Limit

Figure 6. Arc Control Characteristics

SETUP FOR OPERATION

MANUAL 0-2504

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.

Install and connect unit according to the installation instructions in
section 2.04, page 17, of this manual.

Wear dry insulating gloves and clothing.

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.

Select proper electrode.

Refer to Operator Control section, page 22, and set the controls per
the following:
a. PROCESS SELECTOR switch [2] to STICK position.
b. Rotate the AMPERAGE control [1] to output current level
desired.

NOTE

MANUAL 0-2504

Insert electrode into electrode holder. For the majority of electrodes
in use, the electrode holder is connected to the POSITIVE output
terminal.

Wear welding helmet with proper filter lens according to ANSI
Z49.1.

Place the PRIMARY POWER switch [13] to ON.

Begin welding.

The Output Contactor is on when the LS300 is in the STICK mode.

SETUP FOR OPERATION

3.02 Setup for Operation
Gas Tungsten Arc Welding (GTAW) Lift Start
WARNING

NOTE

Read and follow all safety precautions on pages 2-5 of this manual before
preceding with operation.

Install and connect unit according to the installation instructions in
section 2.04, page 17, of this manual.

Select proper tungsten electrode (refer to Electrode Selection Table 2,
page 28).

Prepare tungsten electrode and insert into torch. For the majority of
electrodes in use, the electrode is connected to the NEGATIVE
output terminal.

Wear dry insulating gloves and clothing.

Connect shielding gas supply to gas fitting on back panel.

Connect remote control device to 8-pin receptacle.

The maximum output that can be obtained using the remote control is set
by the main current knob.
7.

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.

Refer to the Operator Control section, page 22, and set the controls
per the following:
a. PROCESS SELECTOR switch [2] to LIFT START Gas Tungsten Arc
Welding position (GTAW).

SETUP FOR OPERATION

MANUAL 0-2504

In this mode, the unit provides weld output for the Gas Tungsten
Arc Welding (GTAW) process. When the process selector 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].

LIFT START
(GTAW WITHOUT HIGH
FREQUENCY)

b. Rotate the AMPERAGE control [1] to output current level desired.
8.

Turn on shielding gas.

Wear welding helmet with proper filter lens according to ANSI
Z49.1.

10. Place the PRIMARY POWER switch [13] to ON.

NOTES

11. Activate remote control device.
a. In LIFT TIG mode, touch electrode to work and lift to start arc.
12. Begin welding.

WARNING

MANUAL 0-2504

HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill.
Shut off gas supply when not in use.

SETUP FOR OPERATION

3.02 Setup for Operation
Table 2. Electrode Selection Table
Electrode/Diameter

Amperage Range
DC-Argon Electrode
Negative/Straight Polarity

DC-Argon Electrode
Positive/Reverse Polarity

1-15

—

Pure Tungsten
(Green Band)
0.010 in. (0.25mm)
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

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

2% Thorium Alloyed Tungsten
(Red Band)
0.010 in. (0.25mm)

Table 3. Weld Cable Size
Maximum Total Cable Length in Weld Circuit

Duty Cycle

Under 100 ft.

150 ft.

200 ft.

250 ft.

300 ft.

350 ft.

400 ft.

(Under 30m)

(45m)

(60m)

(70m)

(90m)

(105m)

(120m)

100-60%

60-100%

1/0

2/0

3/0

Welding Amperes
100
150

10-100%

200

1/0

2/0

3/0

4/0

250

1/0

2/0

3/0

4/0

2-2/0

300

1/0

2/0

3/0

4/0

2-2/0

2-3/0

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

SETUP FOR OPERATION

MANUAL 0-2504

4.0 BASIC TROUBLESHOOTING

General

WARNING

Troubleshooting and repairing this unit is 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
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. Check/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.

MANUAL 0-2504

BASIC TROUBLESHOOTING

A. No Weld Output; Unit is Completely Inoperative
1. Line disconnect switch is in OFF position
a. Place line disconnect switch in ON 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
SELECTOR (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 28).
3. Improper input connections
a. Refer to Section 2.04 Electrical Input Requirements, page 17.
4. Poor electrode condition
a. Replace 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.

BASIC TROUBLESHOOTING

MANUAL 0-2504

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 28).
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.
5. Water in torch
a. Refer to torch parts list for part(s) requiring replacement
and repair torch as necessary.

NOTE

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; check primary supply breaker or fuses and
replace if necessary.
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.
F. 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. No Weld or Output; Fan Operating; WARNING Indicator OFF
1. Faulty Remote Control Device
a. Connect a jumper between pins 2 and 3 of the REMOTE 8
receptacle for contactor closure. If amperage and voltage
can be adjusted with front panel controls, repair or replace
remote control device.
2. Line voltage is too high
a. Verify that input voltage matches setting on rear panel
INPUT SELECTOR switch.
H. Low or Maximum Weld Output With No Control
1. Faulty remote control device
a. Connect a jumper between pins 2 and 3 of the REMOTE 8
receptacle for contactor closure. If amperage and voltage
can be adjusted with front panel controls, repair or replace
remote control device.

MANUAL 0-2504

BASIC TROUBLESHOOTING

I. Limited Weld Output
1. Poor primary input voltage
a. Check primary input voltage is within ±10% of nominal
voltage, i.e. 230VAC ±10%.
J. 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.
K. 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.

BASIC TROUBLESHOOTING

MANUAL 0-2504

4.03 REMOTE 8-Pin Connections
The REMOTE 8-Pin receptacle is used to connect any of the following
equipment to the welding power source circuitry:
•
•
•
•

Remote Hand Pendant
Remote Foot Control
Remote Contactor Control
Remote Amperage Control

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 8-Pin receptacle.

2
5

4
8

Socket
1
2

3
6

Function
Chassis common
Remote contactor control when
contact closure is provided between
sockets 2 and 3 (GND)
Remote contactor control when
contact closure is provided between
sockets 2 and 3 (+24 V DC)
Remote amperage control when
contact closure is provided between
sockets 4 and 8 (+12 V DC)
Amperage remote control (MINIMUM);
PC board common; use as return for
remote control inputs/outputs
Amperage remote control (MAXIMUM)
input command signal; +4 volts for maximum

3
4
5
6
7

Remote amperage reference signal (WIPER);
0 volts to +4 volts (peak current set by main
rheostat)
Remote amperage control when
contact closure is provided between
sockets 4 and 8 (SIGNAL)

Figure 7. REMOTE 8-Pin Connections

MANUAL 0-2504

BASIC TROUBLESHOOTING

APPENDIX A
ACCESSORIES

10-4006
10-4007
10-4008
10-4009
10-4010
10-4011
10-4012
10-4013
10-4014
10-4015
10-4016

Ext. Cable
Ext. Cable
Ext. Cable
Ext. Cable
Ext. Cable
Ext. Cable

10-4017
10-4018
10-4019
10-4020
10-4021
10-4022

LENGTH

CONNECTORS

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
3'/.9m
15'/4.6m
25'/7.6m
50'/15.2m
75'/22.8m
100'/30.4m

15'/4.6m
25'/7.6m
15'/4.6m
15'/4.6m
15'/4.6m
25'/7.6m
25'/7.6m
25'/7.6m
25'/7.6m
15'/4.6m
25'/7.6m
8-Pin (Male) & 8-Pin (Female)
8-Pin (Male) & 8-Pin (Female)
8-Pin (Male) & 8-Pin (Female)
8-Pin (Male) & 8-Pin (Female)
8-Pin (Male) & 8-Pin (Female)
8-Pin (Male) & 8-Pin (Female)

8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)
8-Pin (Male)

All

APPLICABLE
TORCH
HANDLE

N/A
N/A
N/A
N/A
N/A
N/A

N/A
N/A
5/ - 7/ "/16mm-22mm
8
8
7/ " - 11/ "/22mm-29mm
8
8
11/8" - 13/8"/29mm-35mm
5/ " -7/ "/16mm-22mm
8
8
7/ " - 11/ "/22mm-29mm
8
8
11/8" - 13/8"/29mm-35mm
N/A
N/A
N/A

Current and Voltage display with hold feature
X
X
6"/150cm
8-Pin (Male & 14-Pin (Female)
50mm Dinse-style plug - Male for additional torches/electrode holders

Extension Cables for Remote Controls

Torch Switch
Torch Switch
Torch Switch
Torch Switch
Torch Switch
Torch Switch
Torch Switch
Torch Switch
Hand Pendant
Foot Control
Foot Control

Remote Control

Digital Meter Kit 10-4000
Adapter
10-4003
Dinse Connector 10-2020

REMOTE
ARC CURRENT
CONTROL
CAT. NO ON/OFF CONTROL
Miscellaneous Acessories

APPENDIX A - ACCESSORIES

MANUAL 0-2504

APPENDIX A
ACCESSORIES

10-4080
10-4082
10-2023
10-2028
10-2027
10-4003

TIG Kit

STICK Kit

Dinse TIG Block
Dinse TIG Block
Dinse TIG Block
Adapter

Includes: Arcair BG-26V-12 TIGTorch w/ accessory kit, Victor HRF1425-580
regulator, Ground lapm w/ 12ft. cable and 50mm Dinse Connector attached
Includes: Electrode Holder w/ 15ft. cable and 50mm Dinse-style Connector attached
Ground Clamp w/ 12ft. cable and 50mm Dinse-style Connector attached
Air Cooled (#26 style) 7/8-14 R.H.
Air Coled (#17 style) 3//8-24 R.H.
Air Cooled (#18 style) 7/8-14 L.H.
8-Pin (Male) to 14-Pin (Female)

Miscellaneous Accessories (Kits are provided assembled ready to install)
Item
Cat. No.
Description

MANUAL 0-2504

APPENDIX B – INTERCONNECTION DIAGRAMS

The following pages contain the interconnection diagrams for all LS300,
models in current production, to aid in the identification of replacement
parts.

MANUAL 0-2504

APPENDIX B
INTERCONNECTION DIAGRAMS

LS300 - 230/460V Interconnection Diagram

IGBT
Inverter
(Q1)

PCB4

Line 3 White
Line 2

Red

C2E1
E2

PCB2

PCB3

1
2
4
5

Line 1 Black

Input Diode
Bridge (D1)
+
R

C21E1

1
2
4
5

MCB

IGBT
Inverter
(Q2)

C2E1
C1
G1

PCB5

C21E1

Black
G

White

R2 Orange

S
T
–

1
3
5

12
11
10
9
8
7
6
5
4
3
2
1

15
14
13
12
11
10
9
8
5
4
3
2
1

11
10
9
8
7
6
5
4
3
2
1

CN4

E2
(B)

1
2
3
4

CN21

C1
(B)

TB2

CN22

(Black)

E2
(A)

(Black)

C1
(A)

2
1

PCB1-2

CN9

5
4
2
1

(Black)

CN7

3
1

TB1

CN23

TB6

CN5

(Bus Bar)

TB5

CN1

(Bus Bar)

TB4

(Black)

(Bus Bar)

TB3

(Black)

(Bus Bar)

Thyristor Cathode (Black)
Thyristor Gate (White)
Thyristor Anode (Orange)

Output Voltage Detect (White)
Output Voltage Detect (Black)
IGBT Gate Drive - G3 (White)
IGBT Gate Drive - E3 (Orange)
IGBT Gate Drive - E4 (Black)
IGBT Gate Drive - G4 (White)
IGBT Gate Drive - G2 (White)
IGBT Gate Drive - E2 (Red)
IGBT Gate Drive - E1 (Black)
IGBT Gate Drive - G1(White)

(Bus Bar)
Ground

CN20

7
4
1

CN6

CN20

Main Circuit Board
(PCB1)

FAN1

2
1
4

CN14

(Red)
(Black)

CN8

Line 3 (Black)
Line 2 (White)
Line 1 (Red)

5
4
2
1

1
2
CN2

CN17

CN15

PCB1-1

2
1

TH1

CN16

2
3
1

CN16

Thermal Detect (Black)
Thermal Detect (Black)

CN10

230V

CN13

460V
Input Select

CN18

CN24

(Gray)
(Green)
(Blue)

TB12

APPENDIX B
INTERCONNECTION DIAGRAMS

MANUAL 0-2504

R2
A

K
D2

C6
1

E
T2

CT1

C
D

Output
Filter
R7
Network

C8
3

–

FCH

C
R3

D
B

E
A

1 2 3 4 5 6 7 8

CON1
(Front View)

Amperage Maximum (Violet)

Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)

5
4
3
2
1
7
6
CN3

CN2

CN1

Digital Panel Meter
(PCB7)
(Optional)

2
1

Front Panel
(PCB6)

MANUAL 0-2504

11
10
9
8
7
6
5
4
3
2
1

CN4

Torch Control (Pink)
Torch Control (Yellow)

15
14
13
12
11
10
9
8
5
4
3
2
1

CN7

Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC

CN6

CN8

Input 1/3 Phase Detect
Input Changeover Control
+12VDC
PWM Gate Drive
PWM Gate Drive
Input Changeover Control
Input Changeover Control
Torch Switch Control
Output Short Circuit Detect
PCB Common - 0V
Primary Current Detect
Primary Current Detect
Primary Current Detect

GND (Blue)

12
11
10
9
8
7
6
5
4
3
2
1

1
4

CN9

Tripping Relay Control
Input Changeover Switch
Input Changeover Switch
Thyristor Gate Drive
Pre-charge Control
PCB Common - 0V
Undervoltage
Overvoltage
Reset Signal
+12VDC
PCB Common - 0V
Input Voltage Detect

Amperage Control +12VDC (Yellow)
Contactor Control 2 / +24VDC (Orange)
Contactor Control 1 / GND (Red)

Case Ground (Brown)

Case Ground (Green)
Output Short Detect (Black)
Output Short Detect (White)

Ground (Yellow)
Output Current Detect - 0V to –12V (Orange)
–12VDC (Red)
+12VDC (Brown)

2
5

APPENDIX B
INTERCONNECTION DIAGRAMS

LS300 - 380-415V Interconnection Diagram

PCB3

1
2
4
5

CN5
CN23

CN22

CN21

CN4

(Bus Bar)

CN8

CN14

CN6

CN2

CN15

CN16

CN13

CN10

CN16

CN24

CN17

CN15

CN1

(Bus Bar)

CN9

2
1

(Bus Bar)

CN7

2
3
1

Thermal Detect (Black)
Thermal Detect (Black)

1
3

(Black)

2
1

TH1

CN17

11
10
9
8
7
6
5
4
3
2
1
1
2
(Red)
(Black)
FAN1

7
4
1

TB6

(Black)

15
14
13
12
11
10
9
8
5
4
3
2
1

2
1
4

Line 3 (Black)
Line 2 (White)
Line 1 (Red)

5
4
2
1

PCB1-1

12
11
10
9
8
7
6
5
4
3
2
1

5
4
2
1

Main Circuit Board
(PCB1)

1
3
5
3
1

TB5

(Bus Bar)

MANUAL 0-2504

APPENDIX B
INTERCONNECTION DIAGRAMS

1
2
3
4
TB2
TB4

TB1
TB3

E
Ground

T
Red
Line 2

L1
White
Line 1 Black

R2 Orange
Line 3 White

Black

Input Diode
Bridge (D1)
+
R
MCB

PCB2

E2
G2
E1
G1
E2
G2
E1
G1

C2E1
C2E1

PCB5
PCB4

E2
C1
IGBT
Inverter
(Q2)
E2
C1
IGBT
Inverter
(Q1)

E2
C21E1

C1
E2
C21E1

–

TB12

R2
A

K
D2

C6
1

E
T2

CT1

C
D

Output
Filter
R9
Network

C8
3

–

FCH

C
R3

D
B

E
A

1 2 3 4 5 6 7 8

CON1
(Front View)

Amperage Maximum (Violet)

Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)

5
4
2
3
1
7
6
CN3

CN2

CN1

Digital Panel Meter
(PCB7)
(Optional)

2
1

Front Panel
(PCB6)

MANUAL 0-2504

11
10
9
8
7
6
5
4
3
2
1

CN4

Torch Control (Pink)
Torch Control (Yellow)

15
14
13
12
11
10
9
8
5
4
3
2
1

CN7

Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC

CN6

CN8

GND (Blue)

12
11
10
9
8
7
6
5
4
3
2
1

1
4

CN9

Amperage Control +12VDC (Yellow)
Contactor Control 2 / +24VDC (Orange)
Contactor Control 1 / GND (Red)

Case Ground (Brown)

Case Ground (Green)
Output Short Detect (Black)
Output Short Detect (White)

Ground (Yellow)
Output Current Detect - 0V to –4V (Orange)
–12VDC (Red)
+12VDC (Brown)

2
5

APPENDIX B
INTERCONNECTION DIAGRAMS

LS300 - 460/575V Interconnection Diagram
PCB4

IGBT
Inverter
(Q1)

Line 3 White
Line 2

PCB2

PCB3

Black
G

White

R2 Orange

Red

C2E1
C1

1
2
4
5

Input Diode
Bridge (D1)
+
R

C21E1

1
2
4
5

MCB
Line 1 Black

IGBT
Inverter
(Q2)

C2E1
C1
G1

PCB5

C21E1

T
–
C1

1
3
5
12
11
10
9
8
7
6
5
4
3
2
1

15
14
13
12
11
10
9
8
5
4
3
2
1

11
10
9
8
7
6
5
4
3
2
1

CN4

E2
(B)

1
2
3
4

CN21

C1
(B)

TB2

CN22

(Black)

E2
(A)

(Black)

C1
(A)

2
1

PCB1-2

CN9

5
4
2
1

CN7

3
1

TB1

CN23

TB6

CN5

TB5

CN1

(Bus Bar)

TB4

(Black)

(Bus Bar)

TB3

(Black)

(Bus Bar)

Thyristor Cathode (Black)
Thyristor Gate (White)
Thyristor Anode (Orange)

Ground

(Bus Bar)

CN20

2
1
4

CN14

7
4
1

CN6

CN20

Main Circuit Board
(PCB1)

(Red)
(Black)

FAN1

CN8

Line 3 (Black)
Line 2 (White)
Line 1 (Red)

5
4
2
1

1
2
CN2

575V
T4
5
6

CR1

460V
CN17

CN17

CN24

PCB1-1

TH1

CN15

CN10

CN16

2
1

CN16

CN13

Thermal Detect (Black)
Thermal Detect (Black)

2
3
1

TB12
D4

1
4

APPENDIX B
INTERCONNECTION DIAGRAMS

1
4

CN25

PCB8

CN2

CN1

1
3

CN19

CR1

MANUAL 0-2504

R2
A

+
A

K
D2

C6
1

E
T2

CT1

C
D

Output
Filter
R7
Network

C8
3

–

FCH

C
R3

D
B

E
A

1 2 3 4 5 6 7 8

CON1
(Front View)

Amperage Maximum (Violet)

Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)

5
4
2
3
1
7
6
CN3

CN2

CN1

Digital Panel Meter
(PCB7)
(Optional)

2
1

Front Panel
(PCB6)

MANUAL 0-2504

11
10
9
8
7
6
5
4
3
2
1

CN4

Torch Control (Pink)
Torch Control (Yellow)

15
14
13
12
11
10
9
8
5
4
3
2
1

CN7

Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC

CN6

CN8

GND (Blue)

12
11
10
9
8
7
6
5
4
3
2
1

1
4

CN9

Amperage Control +12VDC (Yellow)
Contactor Control 2 / +24VDC (Orange)
Contactor Control 1 / GND (Red)

Case Ground (Brown)

Case Ground (Green)
Output Short Detect (Black)
Output Short Detect (White)

Ground (Yellow)
Output Current Detect - 0V to –4V (Orange)
–12VDC (Red)
+12VDC (Brown)

2
5

APPENDIX B
INTERCONNECTION DIAGRAMS

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : No
Create Date                     : 1997:06:02 15:44:27Z
Subject                         : 
Modify Date                     : 2003:07:08 15:08:11-05:00
Page Count                      : 45
Page Mode                       : UseOutlines
Page Layout                     : SinglePage
Creation Date                   : 1997:06:02 15:44:27Z
Producer                        : Acrobat Distiller 2.1 for Macintosh
Keywords                        : 
Author                          : PRODUCTION
Mod Date                        : 2003:07:08 15:08:11-05:00
Metadata Date                   : 2003:07:08 15:08:11-05:00
Title                           : APPXA&B.pm
Description                     : 
Creator                         : PRODUCTION

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APPXA&B.pm Thermal Arc LS300 Welder Manual

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