Arc Master

LM-200
INVERTER ARC
WELDER
Operating Manual
Version No: 1
Operating Features:
Issue Date: November 30, 2005
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Manual No.: 0-4835
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WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate
your nearest distributor or service agency call
1-800-752-7621, or visit us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
WARNINGS
Read and understand this entire Manual and your employers safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
LM-200 Inverter Arc Welder

Operation Manual Number 0-4835 for:
Part Number 10-3092
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2005 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: November 30, 2005
Record the following information for Warranty purposes:

Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01
1.02
1.03
1.04
1.05
2.01
Arc Welding Hazards ...................................................................................... 1-1

Principal Safety Standards ............................................................................. 1-4
Precautions de Securite en Soudage lArc ................................................... 1-5
Dangers Relatifs au Soudage lArc ............................................................... 1-5
Principales Normes de Securite ..................................................................... 1-8
How To Use This Manual ................................................................................ 2-1
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
Equipment Identification................................................................................. 2-1

Receipt Of Equipment ..................................................................................... 2-1
Symbol Chart ................................................................................................. 2-2
Description ..................................................................................................... 2-3
Functional Block Diagram ............................................................................... 2-4
Transporting Methods .................................................................................... 2-5
Electrical Input Connections ........................................................................... 2-6
Specifications ................................................................................................. 2-9
Duty Cycle .................................................................................................... 2-10
SECTION 3:
OPERATION ........................................................................................... 3-1
3.01 LM-200 DC CC Views ..................................................................................... 3-1
3.02 Weld Parameter Descriptions for Pro-Plus LM-200 ....................................... 3-4
3.03 Weld Process selection for the LM-200 .......................................................... 3-6
3.04 Weld Parameter Descriptions ......................................................................... 3-7
3.05 Weld Parameters ............................................................................................ 3-9
3.06 Power Source Features ................................................................................. 3-10
SECTION 4:
SAVE/LOAD OPERATION ........................................................................... 4-1
4.01 SEQUENCE OF OPERATION ............................................................................ 4-1
4.02 Save / Load Operation .................................................................................... 4-2
4.03 LOAD Operation.............................................................................................. 4-2
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING ...................................... 5-1
5.01 Basic Maintenance ......................................................................................... 5-1
5.02 General Troubleshooting ................................................................................ 5-2
5.03 Common Welding Operation Faults ................................................................ 5-2
5.04 Solving MIG Problems Beyond the Welding Terminals ................................... 5-3
5.05 MIG Welding Problems .................................................................................. 5-5
5.06 TIG Welding Problems ................................................................................... 5-6
5.07 Stick Welding Problems ................................................................................. 5-8
5.08 Power Source Problems ............................................................................... 5-10
5.09 Error Codes .................................................................................................. 5-11
5.10 Voltage Reduction Device (VRD) .................................................................. 5-13
5.11 VRD Maintenance ......................................................................................... 5-13
5.12 Switching VRD On/Off .................................................................................. 5-14
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: SYSTEM SCHEMATIC ..................................................................... A-2
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
LM-200 INVERTER ARC WELDER
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01
Arc Welding Hazards
7. Use fully insulated electrode holders. Never dip holder in water to

cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
WARNING
9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
12. Use only well-maintained equipment. Repair or replace damaged

parts at once.
1. Do not touch live electrical parts.
13. In confined spaces or damp locations, do not use a welder with

AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its Owners
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
November 30, 2005
1-1

3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
1. Keep your head out of the fumes. Do not breath the fumes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator.
5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturers instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition

can cause fire on the hidden side.
5. Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Electrode Size
Filter
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm

1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Welding or cutting
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
November 30, 2005

WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
2. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged.
4. Do not overfill tank allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure.

If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
1. Protect compressed gas cylinders from excessive heat, mechanical

shocks, and arcs.
WARNING
MOVING PARTS can cause injury.
2. Install and secure cylinders in an upright position by chaining

them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and

securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for

maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect

negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in

use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing

is finished and before starting engine.
WARNING
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.

3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and ) on batteries.
November 30, 2005
1-3

1.02
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
3. Allow pressure to escape before completely removing cap.
WARNING
This product, when used for welding or cutting, produces

fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): ...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
November 30, 2005

1.03
Precautions de Securite en Soudage lArc
MISE EN GARDE
LE SOUDAGE A LARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
SAPPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QUILS NAIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL DOPERATION OU LES INSTRUCTIONS AVANT DINSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procds de soudage peuvent sauser des blessures graves ou la mort, de mme que des dommages au reste du matriel et la
proprit, si lutilisateur nadhre pas strictement toutes les rgles de scurit et ne prend pas les prcautions ncessaires.
En soudage et coupage, des pratiques scuritaires se sont dveloppes suite lexprience passe. Ces pratiques doivent tre apprises par
tude ou entranement avant dutiliser lequipement. Toute personne nayant pas suivi un entranement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les quipements raccords aux lignes dalimentation alors que dautres sadressent aux
groupes lectrognes.
La norme Z49.1 de lAmerican National Standard, intitule SAFETY IN WELDING AND CUTTING prsente les pratiques scuritaires suivre.
Ce document ainsi que dautres guides que vous devriez connatre avant dutiliser cet quipement sont prsents la fin de ces instructions de
scurit.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX DINSTALLATION, DE REPARATION, DENTRETIEN ET DESSAI.
1.04
Dangers Relatifs au Soudage lArc
AVERTISSEMENT
LELECTROCUTION PEUT ETRE MORTELLE.
6. Arrtez tout quipement aprs usage. Coupez lalimentation de

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

Llectrode et le circuit de soudage sont sous tension
ds la mise en circuit. Le circuit dalimentation et les
circuits internes de lquipement sont aussi sous tension ds la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets dentrainement
et toutes les pices mtalliques en contact avec le fil de
soudage sont sous tension. Un quipement
inadquatement install ou inadquatement mis la terre
est dangereux.
10. Nutilisez quune bonne prise de masse pour la mise la terre de

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

3
Isolez-vous de la pice souder et de la mise la terre au moyen

de tapis isolants ou autres.
4. Dconnectez la prise dalimentation de lquipement ou arrtez le

moteur avant de linstaller ou den faire lentretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
lalimentation afin dviter une mise en marche accidentelle.
5. Veuillez installer cet quipement et le mettre la terre selon le
manuel dutilisation et les codes nationaux, provinciaux et locaux
applicables.
November 30, 2005
1-5

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

POUR LA SANTE.
Larc de soudage produit une chaleur et des rayons

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

dangereuses respirer.
1. Eloignez la tte des fumes pour viter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance

approprie (consultez la norme ANSI Z49 indique ci-aprs) pour
vous protger le visage et les yeux lorsque vous soudez ou que
vous observez lexcution dune soudure.
2. A lintrieur, assurez-vous que laire de soudage est bien ventile

ou que les fumes et les vapeurs sont aspires larc.
2. Portez des lunettes de scurit approuves. Des crans latraux

sont recommands.
4. Lisez les fiches signaltiques et les consignes du fabricant relatives aux mtaux, aux produits consummables, aux revtements
et aux produits nettoyants.
3. Entourez laire de soudage de rideaux ou de cloisons pour protger

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

dair approuv.
5. Ne travaillez dans un espace confin que sil est bien ventil; sinon,
portez un respirateur adduction dair. Les gaz protecteurs de
soudage peuvent dplacer loxygne de lair et ainsi causer des
malaises ou la mort. Assurez-vous que lair est propre la respiration.
6. Ne soudez pas proximit doprations de dgraissage, de
nettoyage ou de pulvrisation. La chaleur et les rayons de larc
peuvent ragir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS 8.2-73)
Dimension d'lectrode ou
Epiasseur de mtal ou
Intensit de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opration de coupage
ou soudage
Soudage l'arc sous gaz

avec fil plein (GMAW)
mtaux non-ferreux
toutes conditions
11
mtaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 6 po. (25 150 mm)

pais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'lectrode ou
Nuance de
Epiasseur de mtal ou
filtre oculaire
Intensit de courant
Opration de coupage
ou soudage
Soudage l'arc sous gaz avec

lectrode de tungstne (GTAW)
Soudage l'hydrogne
atomique (AHW)
Soudage l'arc avec
lectrode de carbone (CAW)
Soudage l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 1/2 po. (3 12 mm)

pais
Soudage l'arc avec
lectrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec

lectrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
pais
14
moins de 5/32 po. (4 mm)
10
5/32 1/4 po. (4 6.4 mm)
12
mince
moins de 300 ampers
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 400 ampers
12
plus de 400 ampers
14
Coupage l'arc Plasma (PAC)
pais
1-6
November 30, 2005

7. Ne soudez des tles galvanises ou plaques au plomb ou au
cadmium que si les zones souder ont t grattes fond, que si
lespace est bien ventil; si ncessaire portez un respirateur adduction dair. Car ces revtements et tout mtal qui contient ces
lments peuvent dgager des fumes toxiques au moment du
soudage.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
mtalliques volantes. En refroidissant, la soudure peut
projeter du clats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE

EXPLOSION
1. Portez un cran facial ou des lunettes protectrices

approuves. Des crans latraux sont recommands.
Larc produit des tincellies et des projections. Les

particules volantes, le mtal chaud, les projections de
soudure et lquipement surchauff peuvent causer un
incendie et des brlures. Le contact accidentel de
llectrode ou du fil-lectrode avec un objet mtallique
peut provoquer des tincelles, un chauffement ou un
incendie.
2. Portez des vtements appropris pour protger la peau.
1. Protgez-vous, ainsi que les autres, contre les tincelles et du

mtal chaud.
2. Ne soudez pas dans un endroit o des particules volantes ou des
projections peuvent atteindre des matriaux inflammables.
3. Enlevez toutes matires inflammables dans un rayon de 10, 7
mtres autour de larc, ou couvrez-les soigneusement avec des
bches approuves.
4. Mfiez-vous des projections brulantes de soudage susceptibles
de pntrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Mfiez-vous des incendies et gardez un extincteur porte de la
main.
6. Noubliez pas quune soudure ralise sur un plafond, un plancher,
une cloison ou une paroi peut enflammer lautre ct.
7. Ne soudez pas un rcipient ferm, tel un rservoir ou un baril.
8. Connectez le cble de soudage le plus prs possible de la zone
de soudage pour empcher le courant de suivre un long parcours
inconnu, et prvenir ainsi les risques dlectrocution et dincendie.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommages peuvent
exploser. Comme les bouteilles font normalement partie
du procd de soudage, traitez-les avec soin.
1. Protgez les bouteilles de gaz comprim contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles un support ou un cadre
fixe pour les empcher de tomber ou dtre renverses.
3. Eloignez les bouteilles de tout circuit lectrique ou de tout soudage.
4. Empchez tout contact entre une bouteille et une lectrode de
soudage.
5. Nutilisez que des bouteilles de gaz protecteur, des dtendeurs,
des boyauxs et des raccords conus pour chaque application
spcifique; ces quipements et les pices connexes doivent tre
maintenus en bon tat.
6. Ne placez pas le visage face louverture du robinet de la bouteille
lors de son ouverture.
9. Ne dgelez pas les tuyaux avec un source de courant.

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

lorsque raccord pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprim et aux quipements connexes, ainsi que la publication
P-1 de la CGA, identifie dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ DECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz dchappement nocifs.
November 30, 2005
1-7

1. Utilisez lquipement lextrieur dans des aires ouvertes et bien
ventiles.
Les accumulateurs contiennent de llectrolyte acide et

dgagent des vapeurs explosives.
2. Si vous utilisez ces quipements dans un endroit confin, les

fumes dchappement doivent tre envoyes lextrieur, loin
des prises dair du btiment.
1. Portez toujours un cran facial en travaillant sur un accumu-lateur.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
2. Arrtez le moteur avant de connecter ou de dconnecter des cbles

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

faire le plein.
2. Ne faites pas le plein en fumant ou proche dune source dtincelles
ou dune flamme nue.
AVERTISSEMENT
3. Si cest possible, laissez le moteur refroidir avant de faire le plein

de carburant ou den vrifier le niveau au dbut du soudage.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT

BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant ras bord: prvoyez de lespace

pour son expansion.
Le liquide de refroidissement dun radiateur peut tre

brlant et sous pression.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout

carburant renvers avant de faire dmarrer le moteur.
1. Ntez pas le bouchon de radiateur tant que le moteur nest pas

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

ACCUMULATEUR; LELECTROLYTE DUN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8
2. Mettez des gants et posez un torchon sur le bouchon pour lter.

3. Laissez la pression schapper avant dter compltement le
bouchon.
1.05
Principales Normes de Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
November 30, 2005
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
2.02 Equipment Identification
This Owners Manual applies to just specification or part

numbers listed on page i.
The units identification number (specification or part

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

including the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as
follows:
WARNING
A WARNING gives information regarding

possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
2.03 Receipt Of Equipment

When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area listed
in the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
Additional copies of this manual may be purchased by

contacting Thermal Arc at the address and phone number
in your area listed in the inside back cover of this manual.
Include the Owners Manual number and equipment
identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
November 30, 2005
2-1

2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards

Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static

Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
2-2
Spot Time
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc

Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc

Welding (GTAW)
Frequency
Air Carbon Arc

Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
IPM
Inches Per Minute
Line Connection
Touch Start (GTAW)
MPM
Meters Per Minute
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
Voltage Input
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and

welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
Burnback Time
Disturbance In
Ground System
Art # A-04130
115V 15A
X
%
November 30, 2005

2.05 Description
The Thermal Arc Pro-Plus LM-200 is a single & three-phase DC arc welding power source with Constant Current
(CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage, lift arc
starter for use with Gas Tungsten Arc Welding (GTAW), Arc Control and Hot Start for Shielded Metal Arc Welding
(SMAW), Inductance Control for Gas Metal Arc Welding (GMAW) processes. The power source is totally enclosed in
an impact resistant, flame resistant and non-conductive plastic case
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power
source . Curves of other settings will fall between the curves shown.
(V)
OCV
Art # A-06919
18V
160A
1A
200A 220A(A)
(V)
(V)
OCV
OCV
28V
10V
10V
25A
200A
(A)
1A
200A 220A (A)
Figure 1: Model LM-200 volt-ampere curve
November 30, 2005
2-3

2.06 Functional Block Diagram
Input
Power
Main
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
Down
Transformers
AC115V,AC24V
(T3)
Over
Current
Protect
IGBT
Inverter
Themal
Detector
Hall Current
Output
Diodes
Themal
Detector
Main
Transformers
(T1)
Transformer
(HCT1)
Output
Inductor
To each control circuit

+/-15VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Thermal
Sensor
Circuit
Drive
Circuit
StickMode
VRD
Sensing
Circuit
Lift Tig Mode

Output Short
Sensing
Circuit
Primary
Circuit
Sensor
14PIN
Receptacle
(CON1)
Sequence
Control
Fan Control
Circuit
Fan
19PIN
Receptacle
(CON2)
Current
Adjustment
Circuit
Art # A-06920
Reference
Adjustment &
Mode select Switch
14PIN-19PIN
Select Switch
(S3)
Panel Circuit Boad
Figure 2: LM-200 Model functional block diagram
2-4
November 30, 2005

2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
Lift unit with handle or shoulder strap on top of case.

Use hand cart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
WARNING
ELECTRIC SHOCK can kill.
DO NOT TOUCH live electrical parts.

Disconnect input power conductors from deenergized supply line before moving welding power
source.
WARNING
FALLING EQUIPMENT can cause serious

personal injury and equipment damage.
November 30, 2005
2-5

2.08 Electrical Input Connections
3. Use Table 1 and Table 2 as a guide to select line fuses

for the disconnect switch.
NOTE
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC

VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input
power employing lockout/tagging procedures.
Lockout/tagging procedures consist of padlocking
line disconnect switch in open position, removing
fuses from fuse box, or shutting off and redtagging
circuit breaker or other disconnecting device.
Electrical Input Requirements: Operate the welding
power source from a single-phase 50/60 Hz, AC power
supply. The input voltage must match one of the electrical
input voltages shown on the input data label on the unit
nameplate. Contact the local electric utility for information
about the type of electrical service available, how proper
connections should be made, and inspection required.
For Single-Phase operation connect the

GREEN, BLACK and WHITE input conductors.
Insolate the RED Conductor, it is not used for
Single-phase operation.
Input Voltage
208 VAC
230 VAC
460 VAC
Fuse Size
60 Amps
50 Amps
30 Amps
Table 1: Electrical Input Connections
NOTE
Fuse size is based on not more than 200
percent of the rated input amperage of the
welding power source (Based on Article 630,
National Electrical Code).
The line disconnect switch provides a safe and convenient

means to completely remove all electrical power from
the welding power supply whenever necessary to inspect
or service the unit.
NOTE
These units are equipped with a threeconductor with earth power cable that is
connected at the welding power source end
for single-phase and three-phase electrical
input power.
To operate signal-phase, do not connect the RED
input conductor.
Do not connect an input (WHITE, RED or BLACK)
conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an
input line terminal.
1. Connect end of ground (GREEN) conductor to a
suitable ground. Use a grounding method that
complies with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE)
input conductors to a de-energized line disconnect
switch.
2-6
November 30, 2005

Welding Power Supply
Ground Conductor
Ground Terminal
Line Disconect Switch
Line Fuse
Primary Power Cable
Art # A-06923
Figure 3: Electrical input connections
Input Power: Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT
BREAKER is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCRs in the Power Control
Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5
seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
November 30, 2005
2-7

The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding current
and duty cycle from this welding equipment:
Model
Primary Supply
Lead Size
Minimum Primary
Current Circuit Size
(Vin/Amps)
208/39
230/35
Current & Duty Cycle

MIG
200A @ 60%
460/18
8/4 AWG minimum
(Factory Fitted)
3?
PRO-PLUS
LM-200
230/27
460/14
208/45
230/41
460/21
230/44
208/37
1?
STICK
208/29
208/51
8/3 AWG minimum
TIG
230/33
200A @ 60%
-
200A @ 60%
200A @ 60%
200A @ 60%
208/57
230/51
200A @ 60%
Table 2: Primary Current Circuit sizes to achieve maximum current
2-8
November 30, 2005

2.09 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
LM-200
TIG
STICK
MIG
200
28
60%
200A / 18V @ 60%
150A / 16V @ 100%
200A / 28V @ 60%
150A / 26V @ 100%
200A / 24V @ 60%
150A / 22V @ 100%
Output Current
Range
TIG
STICK
1 200A
Output Voltage
Range
MIG
10 28V
Open Circuit Voltage

Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
208V
230V
Input Volts Three Phase
208V
230V
460V
November 30, 2005
65V
8.27 (210mm)
16.89 (420mm)
17.72 (450mm)
59.5 lb. 27.0 kg
200A
28V
60%
9.3
7.0
0.5
0.13
Amperage Draw @ Rated Load
57
51
No Load
2.4
1.8
45
41
21
1.4
1.1
0.7
2-9

2.10 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a
given output without causing overheating and damage to
the unit. If the welding amperes decrease, the duty cycle
increases. If the welding amperes are increased beyond
the rated output, the duty cycle will decrease.
WARNING
Exceeding the duty cycle ratings will cause the

thermal overload protection circuit to become
energized and shut down the output until the
unit has cooled to normal operating
temperature. Continually exceeding the duty
cycle ratings can cause damage to the welding
power source.
To calculate duty cycle:
Art # A-05167
2
current
(rated current) x(rated duty cycle)

(desired duty cycle)
i.e. At 400A rated output current, and 25% rated duty

cycle, the operator wants to work on a 50% duty cycle.
The maximum allowable current draw is:
Art # A-05168
current
current
current
current
2-10
(400A) x(.25)
(.50)
160,000x(0.5)
80,000
282.8A
November 30, 2005
SECTION 3:
OPERATION
3.01 LM-200 DC CC Views
1
6
8
7
10
11
2
3
4
Art # A-06925
Figure 3-1: Pro-Plus LM-200 Power Source

1. Control Knob: This control sets the selected weld parameter, rotating it clockwise increases the parameter and is
indicated on the digital meter. Pushing the knob in previews the actual welding voltage while welding.
2. Remote Control Socket: The 14 pin Remote Control Socket is used to connect remote current control devices to
the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Socket Pin
A
24VAC auxiliary high side.
Input to energize solid state contactor

(Contact closure between pin A and pin B)
C
D
5k ohm (maximum) connection to 5k ohm remote control potentiometer

Zero ohm (minimum) connection to 5k ohm remote control potentiometer
Wiper arm connection to 5k ohm remote control potentiometer
Current feedback Ifb = 100Amps/Volt
24/115 VAC circuit common, also connected to chassis
Voltage Feedback Vfb = 10 Arc Volts/Volt
115 VAC auxiliary high side
115 VAC input to energize solid state contactor (Contact closure between pin I and
pin J)
Chassis ground
L,M,N
November 30, 2005
Function
Not used
3-1

3. Positive Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
4. Negative Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
bayonet terminal and /or melting of the housing (case).
5. Remote Control Socket: The 19 pin Remote Control Socket is used to connect remote current control devices to
the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Socket Pin
Function
Contactor circuit (+15 Volts)
Contactor circuit in, (closure between pin A and Pin B will energize output.)
C
D
Scaled output voltage signal: Vfb = 10 Arc Volts/Volt

24 VAC auxiliary power high side
Chassis ground
Remote control maximum
Remote control wiper (0 10 Volts)
Remote Control minimum
Remote control wiper (0 10 Volts)
Control circuit common
Arc Establish = +12 Volts
Control Circuit common
24/115 VAC neutral
N/C
N/C
Scaled output signal: Ifb = 100 Amps/Volt
N/C
6. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the ON position. This
enables the Power Supply.
WARNING!
When the welder is connected to the Primary supply voltage, the internal electrical components maybe at
500V potential with respect to earth.
3-2
Nvember 30, 2005

7. Input Cable: The input cable connects the Primary
supply voltage to the equipment.
8. Voltage Input Select Switch (Smart Logic Switch):
User selectable switch.
A manual slide switch selects the proper input voltage
range. If this slide switch is not set to the position
that matches the input line voltage, the Smart Logic
will inhibit the welding power source from turning on
and a warning indication will be displayed
WARNING!
Do not alter the position of the Voltage Input

Select Switch when the ON/OFF Switch is in
the ON position and the unit is powered up.
9. 14/19 Pin Remote Control Select Switch: User
selectable switch.
Position this switch for the remote control device
socket to be utilized. The unselected Remote Control
Socket is disabled at this time and cannot be utilized.
Do not alter the position of this switch while one of
the Remote Control Sockets is being utilized.
10. 24VAC Remote Device C/B: Push to reset. Controls
the 24VAC power source for the wire feeders controlled
through the Remote Control Sockets.
11. 115VAC Remote Device C/B: Push to reset. Controls
the 115VAC power source for the wire feeders
controlled through the Remote Control Sockets.
November 30, 2005
3-3

3.02 Weld Parameter Descriptions for Pro-Plus LM-200
Art # A-06930
Figure 3-2: Pro-Plus LM-200 Front Panel with Parameter Description
3-4
Nvember 30, 2005
Parameter
Description
This parameter provides a suitable short circuit current in STICK welding to improve
electrode sticking and arc stability.
ARC CONTROL
This parameter operates in STICK weld mode and is used to improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak
start current on top of the (WELD) current.
HOT START
DC (A)
DC (V)
Weld Current (Amperage)- when lit parameter knob sets the STICK and TIG WELD
current.
Weld Voltage (Volt) when lit parameter knob sets the MIG voltage.
Contactor operation in Stick Mode.
Contactor ON/OFF
Selects in operation Panel boad or Remote.
Operation
PANEL/REMOTE
INDUCTANCE
This parameter, similar to the ARC CONTROL in STICK mode, allows for the
adjustment of the dynamic property of the arc. As the inductance is increased the
output voltage may need to be adjusted to achieve the desired weld characteristics.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs
into the LM-200 memory.
Weld Parameter Descriptions for Pro-Plus LM-200
November 30, 2005
3-5

3.03 Weld Process selection for the LM-200
Weld Mode
Weld Parameter
LIFT TIG
STICK
WELD (V)
INDUCTANCE
HOT START
WELD (A)
ARC CONTROL
MIG
Description
Weld voltage MIG Mode.
Inductance control in MIG Mode.
Start current in amps is added to the WELD (A).
WELD (A) current for STICK or LIFT TIG.
Adjusts percentage increase in welding current
and is proportional to arc length (arc voltage).
Weld Process Selection Verses Weld Mode
3-6
Nvember 30, 2005

3.04 Weld Parameter Descriptions
1. WELD (V) - This parameter sets the MIG weld arc voltage in MIG mode.
2. INDUCTANCE - This parameter sets the INDUCTANCE when MIG welding. It controls the dynamic properties
of the arc in dip transfer welding mode. When this parameter is set to 0%, ie minimum inductance, the arc has
a fast response with a resulting crisp arc noise and coarse spatter. When this parameter is set to 100%, ie
maximum inductance, the arc has a slow response with a resulting soft arc and fine spatter.
NOTE
As the INDUCTANCE is increased, the WELD (V) may need to be adjusted to achieve the desired weld
characteristic.
3. HOT START - This parameter operates in STICK mode and improves the start characteristics for stick electrodes.
e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD current. e.g. HOT START
current = 150 amps when Weld Current = 100 amps & HOT START = 50A
4. WELD (A) - This parameter sets the STICK & Lift TIG weld current.
5. ARC CONTROL - This parameter operates in STICK mode only and is used to adjust percentage increase in
welding current and is proportional to arc length (arc voltage). This control provides an adjustable amount of
arc control (or dig). This feature can be particularly beneficial in providing the operator with the ability to
compensate for variability in joint fit up in certain situations with particular electrodes, eg cellulose and hydrogen
controlled electrodes. In all welding processes, the amount of penetration obtained is dependent on the
welding current; ie the greater the penetration, the greater the current.
Arc Force Position
Current Increase when Arc Voltage

is less than 18V
Effect on Welding Performance
Minimum (0)
0A
Soft arc, Low spatter, Low penetration
Medium (20%)
32A
Normal arc, Improved fusion

characteristics,
Normal penetration
Maximum (100%)
160A
Hard arc, Deep penetration
Weld Parameter Descriptions

In general, having the ARC CONTROL set at 100% (maximum) allows greater penetration control to be achieved.
With the ARC CONTROL set at 0% (minimum) the Power Source has a constant current characteristic. In
other words, varying the arc length does not significantly effect the welding current. When the ARC CONTROL
set to 100%, it is possible to control the welding current by varying the arc length. This is very useful for
controlling penetration on root runs and side wall wash on vertical up fillet welds.
November 30, 2005
3-7

Root runs
During root runs the weld pool forms a keyhole shape. If too much weld current is used, the hole blows
out and the weld collapses. If too little weld current is used, the hole closes up and penetration is lost. The
size of the hole also determines the arc length; ie as the hole gets bigger, the arc gets longer.
If arc force is used, the increase in the arc length causes the weld current to decrease until the hole starts
to close up but if the hole closes up to much then the arc length decreases which causes the weld current
to increase. Too little or too much arc force makes this process unstable. The operator must adjust the arc
force until a happy medium is reached.
Vertical up welding
When welding vertical up with arc force on, the operator can control the amount of current by changing arc
length, ie voltage. Weld metal is deposited by digging the electrode into the side of the base metal joint
and then increasing the arc length with a flicking motion, to allow the weld pool to freeze, before digging the
electrode into the other side of the base metal joint.
Without arc force, increasing the arc length does not decrease the weld current sufficiently and the operator
has to manually decrease the current via a remote current control to freeze the weld pool. This welding
current reduction also reduces the penetration.
The arc force allows the weld pool to freeze during the flick phase without decreasing the amount of weld
current available during the dig phase thus maximizing penetration.
3-8
Nvember 30, 2005

3.05 Weld Parameters
Weld Mode
Weld
Parameter
WELD (V)
MIG
INDUCTANCE
HOT START
WELD (A)
TIG or STICK
ARC CONTROL
November 30, 2005
Parameter Range
Factory
Setting
Incremental
Unit
10.0 to 28.0V DC
17.0V
0.1V
0 to 100%
10%
1%
0 to 70A
20A
1A
1 to 200A DC
80A
1A
0 to 100%
10%
1%
LIFT TIG
STICK
MIG
3-9

3.06 Power Source Features
Feature
New Digital Control
All welding parameters are adjustable
Touch Panel Switches
Touch switches eliminate mechanical damage
Front Control Cover
Protects front panel controls
Digital Meter Volt & Ammeter
Displays selected weld parameter value

Displays average weld current when welding
Displays average weld current for 20 seconds after weld has
been completed
A selected weld parameter value can be adjusted at any time
even while welding
Intelligent Fan Control
The intelligent cooling system is designed to reduce dust and

foreign material build-up, while providing optimum cooling.
Fan speed reduces approximately 30 seconds after machine is
turned on
Fan speed increases when internal components reaches
operating temperature
ON/OFF switch
Mains ON/OFF switch located on rear panel
Voltage Reduction Device (VRD)
VRD fully complies to IEC 60974-1

VRD light is ON and operational when in STICK mode.
Control Knob
For the selected weld parameter, rotating the knob clockwise

increases the parameter
Rotating the knob counterclockwise decreases the parameter
A selected weld parameter value can be adjusted at any time
even while welding
Pushing the knob in sets the selected parameter then displays
the next parameter
Self Diagnosis Using Error Codes
An error code is displayed on the Digital Meter when a problem

occurs with Mains supply voltage or internal component
problems.
Save/Load function
3-10
Description
A total number of 5 programs can be saved into the LM-200

memory
SAVE the Current Weld Parameters into Memory
Press the SAVE button
Select a memory location by rotating the control knob, 1 to 5 is
displayed on the meter
After selecting the desired memory location (ie 1 to 5), press the
parameter button and the machine give a beep to confirm the
weld parameters from the control panel are saved.
LOAD (retrieve) a Program to Control Panel
Press the LOAD button
Select a memory location by rotating the control knob, 1 to 5 is
displayed on the meter
After selecting the desired memory location (ie 1 to 5), press the
parameter button and the machine give a beep to confirm the
weld parameters are loaded onto the control panel
Nvember 30, 2005
SECTION 4:
SAVE/LOAD OPERATION
4.01 SEQUENCE OF OPERATION
NOTE
Parameter Buttons are used to select the parameters to be set. The LEDs show which function is being
adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for
Symbol descriptions.
2
4
Art # A-06931
Figure 4-1. - LM-200 Front Panel

1. Contactor function Pressing this buttons enables
Contactor functions.
2. Remote functions Pressing this buttons enables
remote current functions.
3. Digital LED displays Welding amperage, Voltage
and parameter values are displayed in this window.
Internal warnings such as over temperature, low or
high input voltage applied are signaled to the operator
by a warning sound and error message on the screen.
4. Save/Load Buttons By using the Save & Load
buttons the operator can easily save up to 5 welding
parameter programs.
5. Control knob Allows the operator to adjust the
output amperage/voltage within the entire range of
the power source, also used to set each parameter
value.
November 30, 2005
6. Process Button This button selects between

STICK, Lift TIG, and MIG modes. MIG modes include
MS for mild steel and SS for stainless steel.
7. Parameter Button. This button select between
HOT START, WELD CURRENT, and ARC CONTROL
while in STICK and Lift TIG modes and selects
between WELD VOLTAGE and INDUCTANCE
CONTROL while in MIG mode. This button is also
used in conjunction with the Save/Load buttons to
save and load welding programs.
NOTE
Use the Scroll Buttons to move to the
parameter to be set. The LED will show which
function is being adjusted on the weld
sequence graph. Use the control knob to
adjust each parameter.
4-1

4.02 Save / Load Operation
A total number of 5 programs can be saved into the LM200.
SAVE the Current Weld Parameters into Memory
1. Press the Save Button
2. Select a memory location by rotating the control
knob. 1to 5 will be displayed on the meter.
3. After selecting the desired memory location (i.e.
1 to 5), press the parameter button and the
machine will beep to confirm the weld parameters
from the control panel are saved.
LOAD (retrieve) a Saved Welding Parameter from
Memory
1. Press the LOAD button
2. Select the desired memory location, 1 to 5, by
rotating the control knob.
3. When the desired memory location has been
selected, press the parameter button and the
machine will beep to confirm the weld parameter
is loaded onto the control panel.
NOTE
If you have not previously saved any weld
parameters into the memory, the LOAD
function will not work.
4.03 LOAD Operation

The LOAD operation can be performed only when the
machine is idling. The machine can be in any mode of
operation to LOAD but no welding should be performed
during a LOAD operation.
4-2
November 30, 2005
SECTION 5: BASIC MAINTENANCE AND TROUBLESHOOTING

5.01 Basic Maintenance
Warning!
Disconnect input power before maintaining.
Maintain more often

if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch

body and consumables
Visually inspect the

cables and leads.
Replace as needed
Visually inspect the Wire

feed mechanisms
3 Months
Replace all
broken parts
Gas and
air lines
Clean
exterior
of power supply
6 Months
Visually check and

use a vacuum to carefully
clean the interior
Art # A-06950
November 30, 2005
5-1

5.02 General Troubleshooting
5.03 Common Welding Operation Faults
Troubleshooting and repairing this unit is a process which

should be undertaken only by those familiar with high
voltage, high power electronic equipment.
The following are some of the more common operating

faults that occur during welding operations:
1. Power:
Main power not connected
WARNING
There are extremely dangerous voltage and

power levels present inside this unit. Do not
attempt to diagnose or repair unless you have
had training in power electronics
measurement and troubleshooting
techniques.
Main power not turned on

MAIN CIRCUIT BRAKER set on OFF position
INPUT SELECTOR (Easy Link) Switch in wrong
position
2. Poor Weld:
Wrong polarity
Wrong electrode used
Electrode not properly prepared
Incorrect welding amperage setting
Speed too slow or too fast
Incorrect switch settings for intended operation
Poor weld output connection(s)
If the problem is not resolved after checking the above,
the following guide may suggest more specific items to
check given the faulty operating symptom(s) you are
experiencing.
5-2
November 30, 2005

5.04 Solving MIG Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through
to the MIG torch. There are two main areas where problems occur with GMAW.
A. Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some
contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by
checking the following points:
Porosity Problem
Solution
1 Gas cylinder contents and flow meter Ensure that the gas cylinder is not empty and the flow meter is correctly
adjusted to 25 cubic feet per hour.
2 Gas leaks
Check for gas leaks between the regulator/cylinder connection and in the
gas hose to the Wire Feeder.
3 Internal gas hose in the Wire Feeder
Ensure the hose from the solenoid valve to the MIG torch adapter has not
fractured and that it is connected to the MIG torch adapter.
4 Welding in a windy environment
Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted, oxidized or Clean contaminates off the plate
greasy plate
6 Distance between the MIG torch nozzle Keep the distance between the MIG torch nozzle and the work piece to a
and the work piece
minimum.
7 Maintain the MIG torch in good
working order
Ensure that the gas holes are not blocked and gas is exiting out of the
torch nozzle.
Do not restrict gas flow by allowing spatter to build up inside the MIG
torch nozzle.
Check that the MIG torch O-rings are not damaged.
WARNING!
Disengage the drive roll when testing for gas flow by ear.
November 30, 2005
5-3

B. Inconsistant Wire Feed
Checking the following points can reduce wire-feeding problems:
Wire Feed Problem
Solution
1 Wire spool brake is too tight
Feed roller driven by motor in the cabinet will slip.
2 Wire spool brake is too loose
Wire spool can unwind and tangle.
3 Worn or incorrect feed roller size
Use 'U' groove drive feed roller matched to the aluminum

wire size you are welding.
Use 'V' groove drive feed roller matched to the steel wire
size you are welding.
Use knurled V groove drive feed roller matched to the flux
cored wire size you are welding.
Wire will rub against the misaligned guides and reduces
wire feedability.
4 Misalignment of inlet/outlet guides

5 Liner blocked with wire debris
Wire debris is produced by the wire passing through the

feed roller, if excessive pressure is applied to the pressure
roller adjuster.
Wire debris can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
Wire debris is fed into the liner where it accumulates thus
reducing wire feedability.
6 Incorrect or worn contact tip
The contact tip transfers the weld current to the electrode

wire. If the hole in the contact tip is to large then arcing
may occur inside the contact tip resulting in the electrode
wire jamming in the contact tip.
When using soft electrode wire such as aluminum it may
become jammed in the contact tip due to expansion of the
wire when heated. A contact tip designed for soft electrode
wires should be used.
5-4
7 Poor work lead contact to work piece
If the work lead has a poor electrical contact to the work

piece then the connection point will heat up and result in a
reduction of power at the arc.
8 Bent liner
This will cause friction between the wire and the liner thus
reducing wire feedability
November 30, 2005

5.05 MIG Welding Problems
Possible Cause
Description
1
Undercut
Lack of penetration
Lack of fusion
Excessive spatter
Irregular weld shape
Weld cracking
Cold weld puddle
Arc does not have a

crisp sound, that short
arc exhibits, when the
wirefeed speed and
voltage are adjusted
correctly
November 30, 2005
Reduce WELD (V) control or increase the wire

feed speed.
Adjust angle
Increase the torch travel speed and/or reduce
welding current by reducing the WELD (V)
control or reducing the wire feed speed.
Welding arc voltage too high.
B
C
Incorrect torch angle

Excessive heat input
B
C
Welding current too low
Joint preparation too narrow or gap

too tight
Shielding gas incorrect
Increase welding current by increasing wire

feed speed and increasing WELD (V) control.
Increase joint angle or gap
Change to a gas which gives higher penetration
C
3
Remedy
Increase WELD (V) control.
Voltage too low

A
Voltage too high
Voltage too low
B
C
D
Incorrect voltage and current settings.

Convex, voltage too low. Concave,
voltage too high.
Wire is wandering
Incorrect shielding gas
Insufficient or excessive heat input
A
B
Weld beads too small

Weld penetration narrow and deep
C
D
Excessive weld stresses

Excessive voltage
Cooling rate too fast
Faulty rectifier unit
B
C
Loose welding cable connection.

Low Primary Voltage
B
C
The MIG torch has been connected to

the wrong voltage polarity on the front
panel.
Lower the voltage by reducing the WELD (V)

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

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

Reduce current and voltage and increase MIG
torch travel speed or select a lower penetration
shielding gas.
C Increase weld metal strength or revise design
D Decrease voltage by reducing the WELD (V)
control.
E Slow the cooling rate by preheating part to be
welded or cool slowly.
Have an Accredited Thermal Arc Service Agent
to test then replace the faulty component.
Check all welding cable connections.
Contact supply authority
Connect the MIG torch to the positive (+)
welding terminal for solid wires and gas
shielded flux cored wires. Refer to the
electrode wire manufacturer for the correct
polarity.
5-5

5.06 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumalbes, maintenance of equipment and proper welding
technique.
Description
Remedy
Excessive beard buildup or poor penetration

or poor fusion at edges
of weld.
Welding current is too low
Increase weld current and/or faulty

joint preparation
Weld bead too wide

and flat or undercut at
edges of weld or
excessive burn through
Welding current is too high
Decrease weld current
Weld bead too small or

insufficient penetration
or ripples in bead are
widely spaced apart
Travel speed too fast
Reduce travel speed
Weld bead too wide or

excessive bead build up
or excessive penetration in butt joint
Travel speed too slow
Increase travel speed
Uneven leg length in

fillet joint
Wrong placement of filler rod
Re-position filler rod
Electrode melts when

arc is struck.
A Electrode is connected to the +

terminal.
A Connect the electrode to the

terminal.
Dirty weld pool.
A Electrode contaminated through

contact with work piece or filler rod
material.
A Clean the electrode by grinding off

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

fitting or change gas cylinder.
5-6
Possible Cause
Electrode melts or
A No gas flowing to welding region.
oxidizes when an arc is
struck.
A Check the gas lines for kinks or

breaks and gas cylinder contents.
B Torch is clogged with dust.
B Clean torch
C Gas hose is cut.
C Replace gas hose.
D Gas passage contains impurities.
D Disconnect gas hose from torch

then raise gas pressure and blow
out impurities.
E Gas regulator turned off.
E Turn on.
F Torch valve is turned off.
F Turn on.
G The electrode is too small for the

welding current.
G Increase electrode diameter or

reduce the welding current.
November 30, 2005
Description
Possible Cause
Poor weld finish
Inadequate shielding gas.
10 Arc flutters during TIG

welding
11 Welding arc can not be

established
12 Arc start is not smooth
November 30, 2005
Remedy
Increase gas flow or check gas line
for gas flow problems.
A Tungsten electrode is too large for

the welding current.
A Select the right size electrode. Refer

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

ways to reduce arc flutter.
A Work clamp is not connected to the

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

piece or connect the work/torch
leads to the right welding terminals.
B Torch lead is disconnected.
B Connect it to the terminal.
C Gas flow incorrectly set, cylinder

empty or the torch valve is off.
C Select the right flow rate, change

cylinders or turn torch valve on.
A Tungsten electrode is too large for

the welding current.
A Select the right size electrode. Refer

to Basic TIG Welding Guide.
B The wrong electrode is being used

for the welding job
B Select the right electrode type.

Refer to Basic TIG Welding Guide
C Gas flow rate is too high.
C Select the correct rate for the

welding job.
Refer to Basic TIG Welding Guide.
D Incorrect shielding gas is being

used.
D Select the right shielding gas. Refer

to Basic TIG Welding Guide.
E Poor work clamp connection to

work piece.
E Improve connection to work piece.
5-7

5.07 Stick Welding Problems
Description
Possible Cause
Remedy
1 Gas pockets or voids in

weld metal (Porosity)
A Electrodes are damp

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

of the weld metal to fill
the root of the weld
C Insufficient gap
D Incorrect sequence
A Dry electrodes before use

B Reduce welding current
C Clean joint before welding
A Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes
B Travel slightly slower to allow greater
build up in throat
C Preheat plate and cool slowly
A Increase welding current
B Use smaller diameter
electrode
C Allow wider gap
D Use correct build-up sequence
Art # A-04991
Incorrect sequence
Insufficient
gap
Figure 5-1 - Example of insufficient gap or incorrect sequence
4 Portions of the weld run A Small electrodes used on heavy cold A Use larger electrodes and pre-heat
do not fuse to the
plate
the plate
surface of the metal or B Welding current is too low
B Increase welding current
edge of the joint
C Wrong electrode angle
C Adjust angle so the welding arc is
directed more into the base metal
D Travel speed of electrode is too high D Reduce travel speed of electrode
E Scale or dirt on joint surface
E Clean surface before welding
Lack of fusion caused by dirt,

electrode angle incorrect,
rate of travel too high
Art # A-04992
Lack of inter-run
fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of root fusion
Figure 5-2 - Example of Lack of Fusion

5-8
November 30, 2005

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

trapped in undercut from previous
run
B Joint preparation too restricted
C Irregular deposits allow slag to be
trapped
D Lack of penetration with slag
trapped beneath weld bead
E Rust or mill scale is preventing full

fusion
F Wrong electrode for position in
which welding is done
A If bad undercut is present, clean slag

out and cover with a run from a
smaller diameter electrode.
B Allow for adequate penetration and
room for cleaning out the slag
C If very bad, chip or grind out
irregularities
D Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners
E Clean joint before welding
F
Use electrodes designed for position

in which welding is done, otherwise
proper control of slag is difficult
Art # A-04993
Not cleaned, or
incorrect
electrode
Slag trapped in
undercut
Slag trapped in root
Figure 5-3 - Eamples of Slag
November 30, 2005
5-9

5.08 Power Source Problems
Description
1 The welding arc cannot
be established
Possible Cause
A The Primary supply voltage has not A Switch ON the Primary supply
voltage.
been switched ON.
B The Welding Power Source switch is B Switch ON the Welding Power
Source.
switched OFF.
C Loose connections internally.
C Have an Accredited Thermal Arc

Service Agent repair the connection.
2 Maximum output
welding current can not
be achieved with
nominal Mains supply
voltage.
Defective control circuit
Have an Accredited Thermal Arc

Service Agent inspect then repair the
welder.
3 Welding current
reduces when welding
Poor work lead connection to the

work piece.
Ensure that the work lead has a

positive electrical connection to the
work piece.
4 No gas flow when the

torch trigger switch is
depressed.
A Gas hose is cut.

B Gas passage contains impurities.
C Gas regulator turned off.

D Torch trigger switch lead is
disconnected or switch/cable is
faulty.
5 Gas flow wont shut off A Weld Mode (STD, SLOPE, REPEAT
or SPOT) was changed before
POST-FLOW gas time had finished.
5-10
Remedy
A Replace gas hose.

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

cycle.
OR
Switch machine off then on to reset
solenoid valve sequence.
B Gas valve is faulty.
B Have an Accredited Thermal Arc
Service Agent replace gas valve.
C Gas valve jammed open.
C Have an Accredited Thermal Arc
Service Agent repair or replace gas
valve.
D POST-FLOW control is set to 60 sec. D Reduce POST-FLOW time.
The Weld Process Mode (STICK, HF
The TIG electrode has
Do not change Weld Process Mode
TIG or LIFT TIG) was changed
been contaminated due
before the POST-FLOW gas time had
before POST-FLOW gas time had
to the gas flow shutting
finished.
off before the profinished.
grammed POST-FLOW
time has elapsed
November 30, 2005

5.09 Error Codes
Description
Possible Cause
1 E01 error code

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

Sources duty cycle has
been exceeded.
B Fan ceases to operate.
C Air flow is restricted by

vents being blocked
2 E02 error code

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

Sources duty cycle has
been exceeded.
B Fan ceases to operate.
3 E03 error code

displayed
Primary (input) current
too high
A Primary current is too

high because welding arc
is too long.
B Mains supply voltage is
more than 10% below
nominal voltage
C Air flow is restricted by

vents being blocked
Remedy
C
A
Remarks
Let Power Source cool

down then keep within its
duty cycle.
Have an Accredited Thermal
Arc Service Agent
investigate
Unblock vents then let
Power Source cool down.
Weld current ceases.

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

down then keep within its
duty cycle.
Arc Service Agent
investigate
Unblock vents then let
Power Source cool down.

Fan operates at max speed.
E02 resets when TH1 decreases
to 70C for about 30 seconds.
Reduce length of welding

arc.

Switch machine off then on to
Have an Accredited Thermal reset E03 error.
Arc Service Agent or a
qualified electrician check
for low Mains voltage.
4 E11 error code

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

greater than the nominal
voltage plus 10%.

the Primary voltage.

Error code E11 automatically will
reset when the voltage reduces.
5 E14 error code

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

less than the nominal
operating voltage less
10%.

the Mains voltage.
Weld current available.

Buzzer sounds intermittently.
reset when the voltage increases.
6 E12 error code

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

down to a dangerously
low level.

the Mains voltage.

reset when the voltage increases.
November 30, 2005
5-11
Description
Possible Cause
Remedy
Remarks
7 E81 error code

displayed
Wrong Primary supply
(input) voltage
connected
When 3 phase machine is

first turned on with the
wrong Primary supply
(input) voltage connected
Have an Accredited Thermal No weld current is available.

Switch machine off.
the Mains voltage
8 E82 error code

displayed
Link switch plug not
connected
Link switch plug not

connected
Have an Accredited Thermal No weld current is available.

Arc Service Agent check
connector plug on input
Switch machine off.
PCB
9 E83 error code

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

(input) voltage fluctuates
and is not stable.

Arc Service Agent check
connector plug on input
PCB and the Mains voltage
10 E93 error code

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

error
Have an Accredited Thermal Weld current ceases.

Arc Service Agent check the Buzzer sounds constantly.
control PCB
Switch machine off.
11 E94 error code

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

Sources temperature
sensors have
malfunctioned.
Have an Accredited Thermal Weld current ceases.

Arc Service Agent check or Buzzer sounds constantly.
replace the temperature
Switch machine off.
sensors.
12 E99 error code

displayed
Mains supply (input)
voltage has been turned
off but control circuit
has power from the
primary capacitors
A Main on/off switch on

machine has been turned
B off
Mains supply (input)
voltage has been turned
off
5-12
A
B
No weld current is available.

Switch machine off then on to
reset E83 error.
Turn on/off switch on.

Have an Accredited Thermal Must switch machine off then on
to reset E99 error.
the Mains voltage and fuses
November 30, 2005

5.10 Voltage Reduction Device (VRD)
VRD Specification:
Description
VRD Open Circuit Voltage
Notes
15.3 to 19.8V
Open circuit voltage between welding terminals
VRD Resistance
148 to 193 ohms
The required resistance between welding terminals

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

the welding current has stopped
5.11 VRD Maintenance

Routine inspection and testing (power source):
An inspection of the power source, an insulation resistance
test and an earth resistance test shall be carried out.
A) For transportable equipment, at least once every 3
months; and
In addition to the above tests and specifically in relation

to the VRD fitted to this machine, the following periodic
tests should also be conducted by an accredited Thermal
Arc service agent.
B) For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record
of the periodic tests.
NOTE
A transportable power source is any
equipment that is not permanently connected
and fixed in the position in which it is operated.
Description
VRD Open
Circuit Voltage
VRD Turn ON
Resistance
VRD Turn OFF
Time
IEC 60974-1 Requirements

Less than 20V; at Vin=460V
Less than 200 ohms
Less than 0.3 seconds
Periodic Tests
If this equipment is used in a hazardous location or

environments with a high risk of electrocution then the
above tests should be carried out prior to entering this
location.
November 30, 2005
5-13

5.12 Switching VRD On/Off
Switch the machine Off.
A) Remove the clear plastic cover from the control panel (see Figure 5-4).
Lift up the cover so it rests on the top of the unit
Place a small flat bladed screw driver between the cover hinge on the front panel
Gently lift the cover hinge out of the front cover mounting hole
Remove the control's clear plastic cover
3
1
Art # A-07079
Figure 5-4: VRD ON/OFF Step A

B) Remove the four mounting screws from the the control panel (see Figure 5-5).
Art # A-07080
1
1
2
Figure 5-5: VRD ON/OFF Step B
5-14
November 30, 2005

C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see
Figure 5-6).
CAUTION
DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control
PCB back into the front panel controls can only be achieved by removing the side covers.
VR1
Art # A-07081
Figure 5-6: VRD ON/OFF Step C and D

D) Turning the VRD ON/OFF (see Figure 5-6)
To turn VRD ON: rotate the trim potentiometer on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 5-13.
To turn VRD OFF: rotate the trim potentiometer on the display PCB fully counter clockwise.
WARNING
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise
as the VRD function will be unknown for every other position.
November 30, 2005
5-15
5-16
November 30, 2005
APPENDIX 1: OPTIONS AND ACCESSORIES
ACCESSORIES
Stick Kit
TIG Kit
PART NO.
10-4082A
10-4080
Dinse Connector
Hand Held Pendant
10-2020
10-2005
Foot Control
10-2008
10-2007
Extension Cable
Torch Switch On/Off

Torch Switch On/Off
w/current control
10-2030
10-2031
10-4032
10-4033
10-4034
10-2001
10-2002
10-2003
10-2004
Rack Systems
WIRE FEEDERS
A2000
VA2000
VA4000
VS212
November 30, 2005
10-4029
10-4031
10-4033
W3200001
W3300001
W3400001
W3512002
DESCRIPTION
Work clamp with 10 cable, and stick electrode with 25 #1 cable
Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with
valve, accessory kit includes 1 ea of 0040x7, 1/16x7,
3/32x7 2% Tungsten with collet & collet bodies, 1 ea 1/4,
5/16, 3/8 alumina cup
T50mm Dinse style male plug
Includes contactor On/Off switch and current control
with 25ft cable and 14-pin male plug
Contactor On/Off and current control with 15ft cable
and 14-pin male plug
Contactor On/Off and current control with 25ft cable
and 14-pin male plug
3ft with 14-pin male plug and 14-pin female cable receptacle
25ft torch mounted with 14-pin male plug
- adapts to 5/8-7/8 torch
- adapts to 7/8-1-1/8 torch handle
- adapts to 1-1/8-1-3/8 torch handle
4 pack w/electrical
6 pack w/electrical
8 pack w/electrical
UltraFeed 2 Roll
UltraFeed 2 Roll
UltraFeed 4 Roll
PortaFeed 2 Roll
A-1
APPENDIX 2: SYSTEM SCHEMATIC
P
TB1
G1
E1
R2
1
2
3
R2
CN11
CN4
1 2 3
1 2
TB4
CN18
1
2
3
1
2
3
G3
E3
19P
CN1
CN5
CN6
CN4
CN31
CN32
CN30
CN31
CN32
CN30
A-2
CE
TB7
G
E
CN131
CN132
CN130
CN131
CN132
CN130
G7
Q10 E7
1
2
3
Q21
G
E
Q22
C
G
E
G8
E8
Q12
Q23
1
2
3
4
CN2
Q11
G
E
Q24
G
E
G
E
1 2 3 4 5 6
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN20
CN21
CN22
CN23
PCB6
Control
Circuit Bord
[WK-5688]
CN27
CN18
CN27
CN18
CN1
CN3
PCB7
Filter Circuit Bord
[WK-5689]
PCB17
Socket Receptacle Circuit Bord
[WK-5689]
CN1
CN3
CN7
1 2 3 4 5 6 7 8
CN3
CN13
CN15
CN16
CN2
CN19
1 2 3
1 2 3 4 5
1 2 3 4
1 2 3 4 5 6
1 2 3
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3
CN4
CN2
CN15
CN6
CN5
CN10
CN9
CN8
1 2 3
1 2 3 4 5 6
1 2 3 4 5 6 7
1 2 3 4
1 2 3 4 5 6
TB1
EC
CON2 S T V C U J H N K
Q20
Q9
G
E
CT1
CT2
CT3
CT4
Q19
PCB11 G
IGBT Gate E
Circuit Bord C
[WK-5479]
G
E
1
2
3
4
1
2
3
4
PCB3
Control Souce
Circuit Bord
[WK-5548]
S3
14P
1
2
3
TB6
E8
G8
CN6
1 2 3 4 5
115V
Q8
TB5
E3
G3
CN10
1 2 3 4 5 6 7
24V
UB1
CN20
1
2
3
4
Q7
PCB9 G
IGBT Gate E
Circuit Bord C
[WK-5479]
CN2
1 2
CN7
CN5
CN20
CN33
1
2
3
CN2
CN5
CN1
1 2 3
PCB5
Conect Circuit Bord
[WK-5696]
Q18
G
E
PCB4
Detect
Circuit Bord
[WK-4819]
FAN1
+
1
2
3
4
5
6
E5
G5
230V
0V
TB20
G
E
G4
E4
S2
1
2
3
4
CE
CN3
1
2
3
4
G
E
G
E
E2
G2
CN2
460V
TB19
E1
G1
R2
TB4
CN7
TB18
1 2 3 4 5
CN4
1
2
3
4
5
6
Q6
Q17
1
2
3
4
G
E
CN1
G3
E3
E7
G7
1 2 3
Q5
CN2
REAR
PANEL
Q16
TB3
115V
24V
0V
1 2
1
2
3
G4
E4
Q15
G
E
G
E
TB2
Q14
G
E
TB3
1
2
3
4
5
115V
SIDE CHASSIS 1
Q13
PCB10 G
IGBT Gate E
Circuit Bord
C
[WK-5479]
Q4
1
2
3
4
PCB2
Link
Circuit Bord
[WK-5597]
MCB1
MCB2
G2
E2
TB2
T1
CN1
TB12
G
E
G
E
1
2
3
4
5
CE
Q3
CN1
PCB21
Filter
Circuit Bord
[WK-4917]
24V
(2)
460V
230V
0V
Ground
0V
T(5)
TB11
G
E
G
E
N
Line3
Q2
TB10
E4
G4
(0)
S(4)
Line2
Q1
E6
G6
Line1
TB15
G
E
CN2
G(6)
R(3)
CE
PCB1
Main
PCB8
Circuit Bord IGBT Gate
[WK-5493] Circuit Bord
[WK-5479]
TB1
K(7)
S1
TB14
CN1
+
(1)
TB13
CN1
UB3
CN1
Art # A-06951
CN3
1
2
D1
A
L
B M G R F D P
EC
CON1 M N C D E H F N J
K
B
November 30, 2005
AC1
PCB14
TRANS Bord
[WK-5594]
SH.DET+
PCB15
DIODE Snubber
Circuit Bord
[WK-5606]
D5
+15
-15
IS
GND
4
1 2 3
TO1
TB35
+Output
Terminal
AC2
TB33
CT2
CT1
TB7
HCT1
TB21
TB34
CT2
D7
TB8
UB2
1 2 3 4 5
L1
D2
UB4
CN3
1
2
3
TB30
TB16
Ground
CN1
PCB18
Filter Circuit Bord
[WK-5499]
SIDE CHASSIS 3
TB32
TB22
TB31
-Output
Terminal
FRONT
PANEL
SH.DET-
CT4
CT3
TO2
D4
AC4
CT3
TB17
FCH1
EB
R2
TH2
TH1
UB1
UB2
CN8
CN9
CN8
CN1
A M L
B
C
N
V
P
D
R
E
T
S
CON2
November 30, 2005
A
K
B
J
H
G
PCB12
Panel
Circuit Board
[WK-5527]
1
2
3
4
1
2
3
4
1
2
3
4
5
6
+15
-15
IS
GND
PCB13
Encorder Board
[WK-5528]
CN1
CN1
1 2 3 4
1 2 3 4
I
N
M
E
1
2
3
4
5
6
7
J
K
UB4
CN2
1 2 3 4 5 6 7 8 9
CN9
SIDE CHASSIS 2
UB3
CN21
1 2 3 4 5
1 2 3 4
CN17
SH.DET+
SH.DET-
AC2
AC4
EB
R3
1 2 3
Ground
H
G
Art # A-06951
CON1
A-3
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
LIMITED WARRANTY: Thermal Arc, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of

merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether
arising out of contract, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermals obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchasers rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc is a Registered
Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS
WARRANTY PERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
1 year
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer .............................................................
See the Engines Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
WARRANTY PERIOD
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
WARRANTY PERIOD
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
PLASMA WELDING EQUIPMENT
WARRANTY PERIOD
Ultima 150
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
SMAW (Stick) WELDING EQUIPMENT
WARRANTY PERIOD
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
160S, 300S, 400S
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
GENERAL ARC EQUIPMENT
WARRANTY PERIOD
Water Recirculators ....................................................................................................................... 1 year
Plasma Welding Torches.............................................................................................................180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
LABOR
1 year
LABOR
1 year
180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days

Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items...................................................................Nil
Nil
3 years
3 years
1 year
LABOR
3 years
3 years
1 year
LABOR
3 years
3 years
3 years
1 year
LABOR
1 year
1 year
1 year
3 years
3 years
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road

Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Lot 151, Jalan Industri 3/5A

Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road

Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road

Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com

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LM-200

Issue Date: November 30, 2005

Manual No.: 0-4835

WE APPRECIATE YOUR BUSINESS!

YOU ARE IN GOOD COMPANY!

LM-200 Inverter Arc Welder

Publication Date: November 30, 2005

Record the following information for Warranty purposes:

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

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

LM-200 INVERTER ARC WELDER

Arc Welding Hazards

7. Use fully insulated electrode holders. Never dip holder in water to

9. Do not wrap cables around your body.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or

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

1. Do not touch live electrical parts.

13. In confined spaces or damp locations, do not use a welder with

2. Wear dry, hole-free insulating gloves and body protection.

November 30, 2005

LM-200 INVERTER ARC WELDER

WELDING can cause fire or explosion.

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

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these

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

3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

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

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

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

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

5. Work in a confined space only if it is well ventilated, or while

7. Do not weld on closed containers such as tanks or drums.

7. Do not weld on coated metals, such as galvanized, lead, or

Eye protection filter shade selector for welding or cutting

Under 1/8 in., 3 mm

November 30, 2005

LM-200 INVERTER ARC WELDER

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

CYLINDERS can explode if damaged.

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

Shielding gas cylinders contain gas under high pressure.

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

1. Protect compressed gas cylinders from excessive heat, mechanical

2. Install and secure cylinders in an upright position by chaining

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

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

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

2. Stop engine before installing or connecting unit.

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

3. Have only qualified people remove guards or covers for

4. To prevent accidental starting during servicing, disconnect

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

8. Read and follow instructions on compressed gas cylinders,

6. Reinstall panels or guards and close doors when servicing

Engines can be dangerous.

SPARKS can cause BATTERY GASES TO EXPLODE;

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

ENGINE EXHAUST GASES can kill.

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

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

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

November 30, 2005