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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

1GENERALMANUAL 0-2504

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

Thermal Dynamics Corporation

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

GENERAL MANUAL 0-2504

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 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.

3GENERALMANUAL 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 Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium 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.

GENERAL MANUAL 0-2504

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.

5GENERALMANUAL 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.

6GENERAL MANUAL 0-2504

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

7GENERALMANUAL 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 oute opération, procédure ou renseignement général sur lequel il

importe d’insister davantage ou qui contribue à l’efficacité de

fonctionnement du système.

ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas

de non-respect de la procédure en question.

AVERTISSEMENT 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 MANUAL 0-2504

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 cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse 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.

9GENERALMANUAL 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.

GENERAL MANUAL 0-2504

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.

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

12GENERAL MANUAL 0-2504

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 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.

13 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

14 MANUAL 0-2504

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.

19V

3005 AMPS

VOLTS

Arc Characteristics

"AMPERAGE" Control

310145

Figure 1. LS300 model Volt-Ampere curve

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.

INTRODUCTION

16 MANUAL 0-2504

2.02 Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the LS300 power supply.

Main

Circuit

Breaker

DC Power

Supply for

Control Circuit

Voltage Sensor

Drive Circuit Primary

Current

Sensor

Lift Tig Mode

Output Short

Sensing Circuit

Input

Diode Output

Diodes

Output

Inductor

Input



Power

Inrush Current 

Suppresor IGBT Inverter

Module

Thermal

Sensor

Output

Transformers

Current

Transformer

(CT-1)

Capacitor

Thermal

Sensor

Circuit

Current

Adjustment

Circuit

Reference

Adjustments &

Control Switches

Torch Control

Connection

(CON1)

Control

Transformer

(-c Config.)

+–

–

Trouble

Sensing

Circuit

Sequence

Control

To each control circuit

+12VDC +20VDC

+24VDC +5VDC

Coupling

Coil

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 ELECTRIC SHOCK can kill.

• DO NOT TOUCH live electrical parts.

• Disconnect input power conductors from de-energized supply line

before moving welding power source.

WARNING 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 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.

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 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 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

18 MANUAL 0-2504

• 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.

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 a guide to select line fuses for the disconnect

switch.

Table 1. Fuse Size Selection Input Power/Input Voltage Fuse Size (Amperes)

Three-Phase 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).

THERMADYNE

OFF ON

208-230V 460V

INPUT SELECT

SWITCH

PRIMARY POWER

PRIMARY CABLE

TURN OFF YOUR MAIN POWER SOURCE AND

CIRCUIT BREAKER OF THIS WELDER BEFORE

MAINTENANCE OR INSPECTION

5A/10V - 400A/36V

400/ 300/ 230/

60%

25% 100%

280A 210A 160A

31V

36/ 32/ 28/

28V 26V

208V

3/1

230V

460V

60/80 Hz

61/78A 40/63A

66/70A 37/48A

27/36A 18/24A

28/37A

26/34A

13/17A

21.9/

16.2kVA 14.6/

10.9kVA 10/

8.0kVA

IP 23S

f1f2

IEC974

400S

Thermal Dynamics

WEST LEBANON, NEW HAMPSHIRE USA 03784

MADE IN JAPAN

Primary Power Cable

Line Fuse

Line

Disconnect

Switch

Welding Power Supply

Ground

Conductor

Ground

Terminal

Figure 3. Electrical input connections

INTRODUCTION

MANUAL 0-2504

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

INTRODUCTION

20 MANUAL 0-2504

2.05 Specifications

LS300 Models

Parameter

Rated Output

40% duty cycle

Three-phase

Amperes 250

Volts 30

Single-phase

Amperes 170

Volts 27

25% duty cycle

Three-phase

Amperes 300

Volts 32

Single-phase

Amperes 210

Volts 28

Output Range (Min. - Max.) STICK/LIFT TIG

Amperes 5-300

Volts10-32

Open Circuit Voltage

230 V/460 V 64 V

Dimensions/Weight

Width 8.3 in (210 mm)

Height 16.9 in (430 mm)

Length 16.5 in (420 mm)

Weight 40.7 lb (18.5 kg)

Output at No Load

Three-phase Input Single-phase Input

208 V 1.4A 2.4 A

230 V 1.3 A 2.2 A

380 V 0.8 A

400 V 0.7 A

415 V 0.7 A

460 V 0.6 A 1.1 A

575 V 0.5 A

KVA 0.5

KW 0.3

Output at Rated Load

25% Duty Cycle Three-phase Input Single-phase Input

208 V 40 A 53 A

230 V 37 A 48 A

380 V 22 A

400 V 21 A

415 V 20 A

460 V 18 A 24 A

575 V 15 A

KVA 14.6 10.9

KW 11.3 6.9

40% Duty Cycle Three-phase Input Single -phase Input

208 V 32 A 41 A

230 V 29 A 37 A

380 V 17 A

400 V 16 A

415 V 15 A

460 V 14 A 19A

575 V 11 A

KVA 11.4 8.5

KW 8.8 5.7

INTRODUCTION

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:

(rated current)2 x (rated duty cycle)

(desired duty cycle)

current =

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:

(300A)2 x (.25)

(.50)

current =

90,000 x (0.5)

current =

45,000

current =

212.1A

current =

INTRODUCTION

22 MANUAL 0-2504

3.0 OPERATOR CONTROLS

3.01 LS Front & Rear Panels

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.

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.





287 1

Figure 4. Front panel operator controls

OPERATOR CONTROLS

2323

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

OPERATOR CONTROLS

24 MANUAL 0-2504

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.

300A

75%

145A

Main Knob Arc Control

100%25% 50%

19V 10V/100A Droop

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.

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 per

the following:

a. PROCESS SELECTOR switch [2] to STICK position.

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

desired.

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

Z49.1.

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

9. Begin welding.

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

SETUP FOR OPERATION

26 MANUAL 0-2504

3.02 Setup for Operation

Gas Tungsten Arc Welding (GTAW) Lift Start

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 28).

3. Prepare tungsten electrode and insert into torch. For the majority of

electrodes in use, the electrode is connected to the NEGATIVE

output terminal.

4. Wear dry insulating gloves and clothing.

5. Connect shielding gas supply to gas fitting on back panel.

6. Connect remote control device to 8-pin receptacle.

NOTE 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.

8. 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].

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

Z49.1.

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

11. Activate remote control device.

NOTES a. In LIFT TIG mode, touch electrode to work and lift to start arc.

12. Begin welding.

WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill.

Shut off gas supply when not in use.

LIFT START

(GTAW WITHOUT HIGH

FREQUENCY)

SETUP FOR OPERATION

28 MANUAL 0-2504

3.02 Setup for Operation

Table 2. Electrode Selection Table

Electrode/Diameter Amperage Range

DC-Argon Electrode DC-Argon Electrode

Negative/Straight Polarity Positive/Reverse Polarity

Pure Tungsten

(Green Band)

0.010 in. (0.25mm) 1-15 —

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

2% 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. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.

(Under 30m) (45m) (60m) (70m) (90m) (105m) (120m)

Duty Cycle 100-60% 60-100% 10-100%

Welding Amperes

100 4 4 43211/01/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

SETUP FOR OPERATION

MANUAL 0-2504

4.0 BASIC TROUBLESHOOTING

General Troubleshooting and repairing this unit is a process which should be

undertaken only by those familiar with high voltage, high power electronic

equipment.

WARNING There are extremely dangerous voltage and power levels present inside

this unit. Do not attempt to diagnose or repair unless you have had 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.

BASIC TROUBLESHOOTING

30 MANUAL 0-2504

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.

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.

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.

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.

BASIC TROUBLESHOOTING

32 MANUAL 0-2504

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.

Socket

Chassis common

Remote contactor control when

contact closure is provided between

sockets 2 and 3 (GND)

Function

345

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)

Remote amperage control when

contact closure is provided between

sockets 4 and 8 (SIGNAL)

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

Remote amperage reference signal (WIPER);

0 volts to +4 volts (peak current set by main

rheostat)

Figure 7. REMOTE 8-Pin Connections

BASIC TROUBLESHOOTING

34 MANUAL 0-2504

APPENDIX A - ACCESSORIES

APPENDIX A

ACCESSORIES

APPLICABLE

REMOTE ARC CURRENT TORCH

CONTROL CAT. NO ON/OFF CONTROL LENGTH CONNECTORS HANDLE

Miscellaneous Acessories

Digital Meter Kit 10-4000 Current and Voltage display with hold feature

Adapter 10-4003 X X 6"/150cm 8-Pin (Male & 14-Pin (Female) All

Dinse Connector 10-2020 50mm Dinse-style plug - Male for additional torches/electrode holders

Remote Control

Torch Switch 10-4006 X 15'/4.6m 8-Pin (Male) N/A

Torch Switch 10-4007 X 25'/7.6m 8-Pin (Male) N/A

Torch Switch 10-4008 X X 15'/4.6m 8-Pin (Male) 5/8 - 7/8"/16mm-22mm

Torch Switch 10-4009 X X 15'/4.6m 8-Pin (Male) 7/8" - 11/8"/22mm-29mm

Torch Switch 10-4010 X X 15'/4.6m 8-Pin (Male) 11/8" - 13/8"/29mm-35mm

Torch Switch 10-4011 X X 25'/7.6m 8-Pin (Male) 5/8" -7/8"/16mm-22mm

Torch Switch 10-4012 X X 25'/7.6m 8-Pin (Male) 7/8" - 11/8"/22mm-29mm

Torch Switch 10-4013 X X 25'/7.6m 8-Pin (Male) 11/8" - 13/8"/29mm-35mm

Hand Pendant 10-4014 X X 25'/7.6m 8-Pin (Male) N/A

Foot Control 10-4015 X X 15'/4.6m 8-Pin (Male) N/A

Foot Control 10-4016 X X 25'/7.6m 8-Pin (Male) N/A

Extension Cables for Remote Controls

Ext. Cable 10-4017 X X 3'/.9m 8-Pin (Male) & 8-Pin (Female) N/A

Ext. Cable 10-4018 X X 15'/4.6m 8-Pin (Male) & 8-Pin (Female) N/A

Ext. Cable 10-4019 X X 25'/7.6m 8-Pin (Male) & 8-Pin (Female) N/A

Ext. Cable 10-4020 X X 50'/15.2m 8-Pin (Male) & 8-Pin (Female) N/A

Ext. Cable 10-4021 X X 75'/22.8m 8-Pin (Male) & 8-Pin (Female) N/A

Ext. Cable 10-4022 X X 100'/30.4m 8-Pin (Male) & 8-Pin (Female) N/A

MANUAL 0-2504

Miscellaneous Accessories (Kits are provided assembled ready to install)

Item Cat. No. Description

TIG Kit 10-4080 Includes: Arcair BG-26V-12 TIGTorch w/ accessory kit, Victor HRF1425-580

regulator, Ground lapm w/ 12ft. cable and 50mm Dinse Connector attached

STICK Kit 10-4082 Includes: Electrode Holder w/ 15ft. cable and 50mm Dinse-style Connector attached

Ground Clamp w/ 12ft. cable and 50mm Dinse-style Connector attached

Dinse TIG Block 10-2023 Air Cooled (#26 style) 7/8-14 R.H.

Dinse TIG Block 10-2028 Air Coled (#17 style) 3//8-24 R.H.

Dinse TIG Block 10-2027 Air Cooled (#18 style) 7/8-14 L.H.

Adapter 10-4003 8-Pin (Male) to 14-Pin (Female)

APPENDIX A

ACCESSORIES

36 MANUAL 0-2504

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.

APPENDIX B

INTERCONNECTION DIAGRAMS

38 MANUAL 0-2504

LS300 - 230/460V Interconnection Diagram

APPENDIX B

INTERCONNECTION DIAGRAMS

1



1



CN18

CN24

Orange

Black

White

(Bus Bar)

–

2

3

CN13

CN2

Ground

PCB1-1

PCB1-2

Main Circuit Board

(PCB1)

TB3 TB4 TB5 TB6 TB1

TB12

TB2

E2

(A)

C1

(A)

C1

(B)

E2

(B)

7

4

CN16

CN17

CN20

CN15

CN6

2

1

CN14

5

4

2

CN8

Line 3 (Black)

Line 2 (White)

Line 1 (Red)

Thyristor Cathode (Black)

Thyristor Gate (White)

Thyristor Anode (Orange)

IGBT Gate Drive - G2 (White)

IGBT Gate Drive - E2 (Red)

IGBT Gate Drive - E1 (Black)

IGBT Gate Drive - G1(White)

IGBT Gate Drive - G3 (White)

IGBT Gate Drive - E3 (Orange)

IGBT Gate Drive - E4 (Black)

IGBT Gate Drive - G4 (White)

Output Voltage Detect (White)

Output Voltage Detect (Black)

Thermal Detect (Black)

Thermal Detect (Black)

(Bus Bar)



(Bus Bar)



(Bus Bar)



(Bus Bar)

(Black)



(Black)



(Black)



(Black)

(Black)



(Black)

FAN1

5

4

2

CN9

1

2

3

CN1

1

3

CN5

3

CN7

2

TH1

CN10

MCB

Input Diode

Bridge (D1)

1

2

4

PCB2

PCB4 E2

C2E1

G1 E1 G2 E2

1

2

4

PCB3

PCB5 E2

C2E1

IGBT

Inverter

(Q2)

IGBT

Inverter

(Q1)

G1 E1 G2 E2

C1 C21E1C21E1

Black



White



Red

Line 1



Line 3



Line 2

CN22 CN21

2

CN4

15

14

13

12

11

10

9

8

5

4

3

2

CN23

1

(Red)

(Black)



230V

Input Select

460V (Gray)

(Green)

(Blue)

12

11

10

9

8

7

6

5

4

3

2

11

10

9

8

7

6

5

4

3

2

MANUAL 0-2504

CON1

(Front View)

12345678

Case Ground (Brown)

Contactor Control 1 / GND (Red)

Contactor Control 2 / +24VDC (Orange)

Amperage Control +12VDC (Yellow)

GND (Blue)

Amperage Maximum (Violet)

Amperage Control Wiper 0-4VDC (Gray)

Case Ground (Green)

CN3

876

354

CN6

Digital Panel Meter

(PCB7)

(Optional)

Front Panel

(PCB6)

CN2

CN1

Tripping Relay Control

Input Changeover Switch

Thyristor Gate Drive

Pre-charge Control

PCB Common - 0V

Undervoltage

Overvoltage

Reset Signal

+12VDC

PCB Common - 0V

Input Voltage Detect

12

11

10

9

8

7

6

5

4

3

2

CN9

Thermal Control

Output Voltage Detect

Output Current Detect

PCB Common - 0V

–12VDC

+5VDC

PCB Common - 0V

+12VDC

11

10

9

8

7

6

5

4

3

2

CN7

Torch Control (Pink)

Torch Control (Yellow) 2

CN4

Case Ground (Green)

Output Short Detect (Black)

Output Short Detect (White)

Ground (Yellow)

Output Current Detect - 0V to –12V (Orange)

–12VDC (Red)

+12VDC (Brown)

1 2 3 4

R2 C2 CT1

FCH

Output

Filter

Network

–

R3 C3

Input 1/3 Phase Detect

Input Changeover Control

+12VDC

PWM Gate Drive

Input Changeover Control

Torch Switch Control

Output Short Circuit Detect

PCB Common - 0V

Primary Current Detect

Primary Current Detect

15

14

13

12

11

10

9

8

5

4

3

2

CN8

APPENDIX B

INTERCONNECTION DIAGRAMS

40 MANUAL 0-2504

LS300 - 380-415V Interconnection Diagram

APPENDIX B

INTERCONNECTION DIAGRAMS

Orange

Black

White

(Bus Bar)

–

2

3

CN13

CN2

Ground

PCB1-1

Main Circuit Board

(PCB1)

TB3 TB4 TB5 TB6 TB1

TB12

TB2

7

4

CN16

CN17

CN17 CN15

CN15

CN6

2

1

CN14

5

4

2

CN8

Line 3 (Black)

Line 2 (White)

Line 1 (Red)

Thyristor Cathode (Black)

Thyristor Gate (White)

Thyristor Anode (Orange)

IGBT Gate Drive - G2 (White)

IGBT Gate Drive - E2 (Red)

IGBT Gate Drive - E1 (Black)

IGBT Gate Drive - G1(White)

IGBT Gate Drive - G3 (White)

IGBT Gate Drive - E3 (Orange)

IGBT Gate Drive - E4 (Black)

IGBT Gate Drive - G4 (White)

Output Voltage Detect (White)

Output Voltage Detect (Black)

Thermal Detect (Black)

Thermal Detect (Black)

(Bus Bar)



(Bus Bar)



(Bus Bar)



(Bus Bar)

(Black)



(Black)

FAN1

5

4

2

CN9

1

2

3

CN1

1

3

CN5

3

CN7

2

TH1

CN10

1

CN24

MCB

Input Diode

Bridge (D1)

1

2

4

PCB2

PCB4 E2

C2E1

G1 E1 G2 E2

1

2

4

PCB3

PCB5 E2

C2E1

IGBT

Inverter

(Q2)

IGBT

Inverter

(Q1)

G1 E1 G2 E2

C1 C21E1C21E1

Black



White



Red

Line 1



Line 3



Line 2

CN22 CN21

2

CN4

15

14

13

12

11

10

9

8

5

4

3

2

CN23

1

(Red)

(Black)



12

11

10

9

8

7

6

5

4

3

2

11

10

9

8

7

6

5

4

3

2

MANUAL 0-2504

CON1

(Front View)

12345678

Case Ground (Brown)

Contactor Control 1 / GND (Red)

Contactor Control 2 / +24VDC (Orange)

Amperage Control +12VDC (Yellow)

GND (Blue)

Amperage Maximum (Violet)

Amperage Control Wiper 0-4VDC (Gray)

Case Ground (Green)

CN3

876

354

CN6

Digital Panel Meter

(PCB7)

(Optional)

Front Panel

(PCB6)

CN2

CN1

Tripping Relay Control

Input Changeover Switch

Thyristor Gate Drive

Pre-charge Control

PCB Common - 0V

Undervoltage

Overvoltage

Reset Signal

+12VDC

PCB Common - 0V

Input Voltage Detect

12

11

10

9

8

7

6

5

4

3

2

CN9

Thermal Control

Output Voltage Detect

Output Current Detect

PCB Common - 0V

–12VDC

+5VDC

PCB Common - 0V

+12VDC

11

10

9

8

7

6

5

4

3

2

CN7

Torch Control (Pink)

Torch Control (Yellow) 2

CN4

Case Ground (Green)

Output Short Detect (Black)

Output Short Detect (White)

Ground (Yellow)

Output Current Detect - 0V to –4V (Orange)

–12VDC (Red)

+12VDC (Brown)

1 2 3 4

R2 C2 CT1

FCH

Output

Filter

Network

–

R3 C3

Input 1/3 Phase Detect

Input Changeover Control

+12VDC

PWM Gate Drive

Input Changeover Control

Torch Switch Control

Output Short Circuit Detect

PCB Common - 0V

Primary Current Detect

Primary Current Detect

15

14

13

12

11

10

9

8

5

4

3

2

CN8

APPENDIX B

INTERCONNECTION DIAGRAMS

42 MANUAL 0-2504

LS300 - 460/575V Interconnection Diagram

APPENDIX B

INTERCONNECTION DIAGRAMS

1



CN24

Orange

Black

White

(Bus Bar)

–

2

3

CN13

CN2

Ground

PCB1-1

PCB1-2

Main Circuit Board

(PCB1)

TB3 TB4 TB5 TB6 TB1

TB12

PCB8

TB2

E2

(A)

C1

(A)

C1

(B)

E2

(B)

7

4

CN16

CN17

CN20

CN15

CN6

2

1

CN14

5

4

2

CN8

Line 3 (Black)

Line 2 (White)

Line 1 (Red)

Thyristor Cathode (Black)

Thyristor Gate (White)

Thyristor Anode (Orange)

IGBT Gate Drive - G2 (White)

IGBT Gate Drive - E2 (Red)

IGBT Gate Drive - E1 (Black)

IGBT Gate Drive - G1(White)

IGBT Gate Drive - G3 (White)

IGBT Gate Drive - E3 (Orange)

IGBT Gate Drive - E4 (Black)

IGBT Gate Drive - G4 (White)

Output Voltage Detect (White)

Output Voltage Detect (Black)

Thermal Detect (Black)

Thermal Detect (Black)

(Bus Bar)



(Bus Bar)



(Bus Bar)



(Bus Bar)

(Black)



(Black)



(Black)



(Black)

(Black)



(Black)

FAN1

5

4

2

CN9

1

2

3

CN1

1

3

CN5

3

CN7

2

TH1

CN10

1

CN25

1

CN1

MCB

Input Diode

Bridge (D1)

1

2

4

PCB2

PCB4 E2

C2E1

G1 E1 G2 E2

1

2

4

PCB3

PCB5 E2

C2E1

IGBT

Inverter

(Q2)

IGBT

Inverter

(Q1)

G1 E1 G2 E2

C1 C21E1C21E1

460V

575V

CR1

Black



White



Red

Line 1



Line 3



Line 2

1



CN19

CN22 CN21

2

CN4

1

CN2

15

14

13

12

11

10

9

8

5

4

3

2

CN23

1

2



5

(Red)

(Black)



CR1

12

11

10

9

8

7

6

5

4

3

2

11

10

9

8

7

6

5

4

3

2

MANUAL 0-2504

CON1

(Front View)

12345678

Case Ground (Brown)

Contactor Control 1 / GND (Red)

Contactor Control 2 / +24VDC (Orange)

Amperage Control +12VDC (Yellow)

GND (Blue)

Amperage Maximum (Violet)

Amperage Control Wiper 0-4VDC (Gray)

Case Ground (Green)

CN3

876

354

CN6

Digital Panel Meter

(PCB7)

(Optional)

Front Panel

(PCB6)

CN2

CN1

Tripping Relay Control

Input Changeover Switch

Thyristor Gate Drive

Pre-charge Control

PCB Common - 0V

Undervoltage

Overvoltage

Reset Signal

+12VDC

PCB Common - 0V

Input Voltage Detect

12

11

10

9

8

7

6

5

4

3

2

CN9

Thermal Control

Output Voltage Detect

Output Current Detect

PCB Common - 0V

–12VDC

+5VDC

PCB Common - 0V

+12VDC

11

10

9

8

7

6

5

4

3

2

CN7

Torch Control (Pink)

Torch Control (Yellow) 2

CN4

Case Ground (Green)

Output Short Detect (Black)

Output Short Detect (White)

Ground (Yellow)

Output Current Detect - 0V to –4V (Orange)

–12VDC (Red)

+12VDC (Brown)

1 2 3 4

C2 CT1

FCH

Output

Filter

Network

–

R3 C3

Input 1/3 Phase Detect

Input Changeover Control

+12VDC

PWM Gate Drive

Input Changeover Control

Torch Switch Control

Output Short Circuit Detect

PCB Common - 0V

Primary Current Detect

Primary Current Detect

15

14

13

12

11

10

9

8

5

4

3

2

CN8

APPENDIX B

INTERCONNECTION DIAGRAMS

APPXA&B.pm Thermal Arc LS300 Welder Manual

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