161 STL
®
THERMAL ARC
201 TS
INVERTER ARC WELDER
Service
Art # A-10144
Manual
Revision: AC Issue Date: Dec. 03, 2012 Manual No.: 0-5148
Operating Features:
50
Hz
60
50
Hz
60
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 worldwide service network. To locate your nearest distributor or service agency call
1-800-462-2782, or visit us on the web at www.Thermalarc.com.
This Service 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. We have made every effort to provide you with accurate
instructions, drawings, and photographs of the product(s) we used when
writing this manual. However errors do occur and we apologize if there are
any contained in this manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website or
contact our customer support for assistance.
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 Victor
Technologies International, 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 market-leading,
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 employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manu
facturer assumes no liability for its use.
Service Manual Number 0-5148 for:
Thermal Arc 161 STL Power Source Arc Welder Part No. W1003700
Thermal Arc 161 STL System with Stick/TIG Kit & Case Part No. W1003701
Thermal Arc 201 TS Power Source Arc Welder Part No. W1003800
Thermal Arc 201 TS System with Stick/TIG Kit & Case Part No. W1003801
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road,
Suite 300 St, Louis, Mo 63017
USA
www.thermalarc.com
Copyright
Victor Technologies International, Inc.
®
All rights reserved.
©
2011,2012 by
-
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: June 15, 2011
Revision AC Date: December 03, 2012
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 General Safety Information for Victor CS Regulator ........................................ 1-4
1.03 Principal Safety Standards .............................................................................. 1-5
1.04 Symbol Chart .................................................................................................. 1-6
1.05 Servicing Hazards ........................................................................................... 1-7
1.06 EMF Information ............................................................................................. 1-8
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How to Use This Manual ................................................................................. 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt of Equipment ...................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 Transportation Methods .................................................................................. 2-1
SECTION 3:
SAFETY AND INSTALLATION ....................................................................... 3-1
3.01 Duty Cycle ....................................................................................................... 3-1
3.02 Specifications - 161STL .................................................................................. 3-3
3.03 Specifications -201TS ..................................................................................... 3-4
3.04 Environment ................................................................................................... 3-5
3.05 Location .......................................................................................................... 3-5
3.06 Electrical Input Connections ........................................................................... 3-5
3.07 Electromagnetic Compatibility ........................................................................ 3-8
3.08 Volt-Ampere Curves ...................................................................................... 3-10
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 Setup for Welding ........................................................................................... 4-5
4.03 Stick (SMAW) Setup ....................................................................................... 4-6
4.04 LIFT TIG (GTAW) Setup................................................................................... 4-7
4.05 HF TIG (GTAW) Setup (201TS only) ................................................................ 4-9
4.06 Welding Current Control Explanation ............................................................ 4-10
4.07 Victor Regulator ............................................................................................ 4-11
4.08 Leak Testing the System ............................................................................... 4-12
4.09 Lift Start TIG with the Thermal Arc 161STL .................................................. 4-12
SECTION 5:
THEORY OF OPERATION ............................................................................ 5-1
5.01 Inverter Design ............................................................................................... 5-1
TABLE OF CONTENTS
SECTION 6:
TROUBLESHOOTING ................................................................................ 6-1
6.01 Basic Troubleshooting .................................................................................... 6-1
6.02 Checking Unit Before Applying Power ............................................................ 6-2
6.03 Tools Needed for Troubleshooting and Servicing ............................................ 6-2
6.04 Case Removal ................................................................................................. 6-3
6.05 Clear Cover Sheet Removal ............................................................................. 6-4
6.06 Pre-Power Check ............................................................................................ 6-5
6.07 DC Bus Voltage Check .................................................................................... 6-8
6.08 Installing Clear Cover Sheet ............................................................................ 6-9
6.09 Waveforms for Section 6-10 ......................................................................... 6-10
6.10 Troubleshooting Circuit Diagram - 161STL ................................................... 6-13
6.11 161STL Connector Diagram .......................................................................... 6-14
6.12 Troubleshooting Circuit Diagram - 201TS ..................................................... 6-15
6.13 201TS Connector Diagram ............................................................................ 6-16
SECTION 7:
DISASSEMBLY PROCEDURE ....................................................................... 7-1
7.01 Safety Precautions for Disassembly ............................................................... 7-1
7.02 Control Board Removal ................................................................................... 7-2
7.03 Front Panel Assembly Removal ...................................................................... 7-4
7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal ......................... 7-6
7.05 Back Panel Removal ....................................................................................... 7-8
7.06 Power Switch S1 and Power Cord Removal ................................................. 7-11
7.07 Base Panel Removal ..................................................................................... 7-13
SECTION 8:
ASSEMBLY PROCEDURES .......................................................................... 8-1
8.01 Installing Base Board ...................................................................................... 8-1
8.02 Installing Back Panel ....................................................................................... 8-2
8.03 Installing Front Panel ...................................................................................... 8-4
8.04 Installing Main Control Panel and Clear Cover Sheet ...................................... 8-8
8.05 Installing Case .............................................................................................. 8-10
SECTION 9:
REPLACEMENT PARTS .............................................................................. 9-1
9.01 Hardware List ................................................................................................ 9-1
9.02 Replacement Part List - 161STL ..................................................................... 9-2
9.03 Replacement Part List - 201TS ....................................................................... 9-4
SECTION 10:
ACCESSORIES ....................................................................................... 10-1
LIMITED WARRANTY
WARRANTY SCHEDULE
SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS
!
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
WARNING
ELECTRIC SHOCK can kill.
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 semi-automatic 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.
1. Do not touch live electrical parts.
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 Owner’s
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.
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.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
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.
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.
3. Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Manual 0-5148 1-1 Safety Instructions and Warnings
5. Use approved ear plugs or ear muffs if noise level is high.
THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
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 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.
WARNING
WELDING can cause fire or explosion.
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.
1. Protect yourself and others from flying sparks and hot metal.
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.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering 2
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding
(stick) electrodes
Safety Instructions and Warnings 1-2 Manual 0-5148
Electrode Size
Metal Thickness
or Welding Current
Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in.,
4 to 6.4 mm
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Filter
Shade
No.
12 Plasma arc cutting
Welding or Cutting
Operation
Gas metal-arc
welding (MIG)
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
No.
SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS
!
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
CYLINDERS can explode if damaged.
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.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
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.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
WARNING
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
Manual 0-5148 1-3 Safety Instructions and Warnings
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS
!
1.02 General Safety Information for
Victor CS Regulator
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.
3. Allow pressure to escape before completely removing cap.
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
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.
NOTE
A Fire Prevention
Welding and cutting operations use fire or combustion as a basic
tool. The process is very useful when properly controlled. However,
it can be extremely destructive if not performed cor rectly in the proper
environment.
1. The work area must have a fireproof floor.
2. Work benches or tables used during welding or cutting
operations must have fireproof tops.
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring from sparks and hot
metal.
4. Keep an approved fire extinguisher of the proper size and
type in the work area. Inspect it regularly to ensure that it
is in proper working order. Know how to use the fire extinguisher.
5. Move combustible materials away from the work site. If you
can not move them, protect them with fireproof covers.
WARNING
NEVER perform welding, heating, or cutting operations
on a container that has held toxic, combustible or
flammable liq uids, or vapors. NEVER perform welding,
heating, or cutting operations in an area containing combustible vapors, flam mable liquids, or explosive dust.
B Housekeeping
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.
!
WARNING
NEVER allow oxygen to contact grease, oil, or other
flam mable substances. Although oxygen by itself will not
burn, these substances become highly explosive. They
can ignite and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and other flammable
substances.
C Ventilation
!
WARNING
Ade quately ventilate welding, heating, and cutting work
areas to prevent accumulation of explosive or toxic
concen trations of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When
welding/brazing, read and understand the Material Safety
Data Sheet for the welding/brazing alloy.
Safety Instructions and Warnings 1-4 Manual 0-5148
SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS
!
D Personal Protection
Gas flames produce infrared radiation which may have a harm ful effect
on the skin and especially on the eyes. Select goggles or a mask with
tempered lenses, shaded 4 or darker, to protect your eyes from injury
and provide good visibility of the work.
Always wear protective gloves and flame-resistant clothing to protect skin
and clothing from sparks and slag. Keep collars, sleeves, and pockets
buttoned. DO NOT roll up sleeves or cuff pants.
3. Store empty cylinders away from full cylinders. Mark them
“EMPTY” and close the cylinder valve.
4. NEVER use compressed gas cylinders without a pressure
reducing regulator attached to the cylinder valve.
5. Inspect the cylinder valve for oil, grease, and damaged
parts.
When working in a non-welding or cutting environment, always wear
suitable eye protection or face shield.
WARNING
Practice the following safety and operation precautions
EVERY TIME you use pressure regulation equipment.
Deviation from the following safety and operation
instructions can result in fire, explosion, damage to
equipment, or injury to the operator.
E Compressed Gas Cylinders
The Department of Transportation (DOT) approves the design and
manufacture of cylinders that contain gases used for welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will use it. Keep
the cylinder in a vertical position. Secure it to a cart, wall, work
bench, post, etc.
!
WARNING
DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition
immediately.
6. Momentarily open and close (called “cracking”) the cylinder
valve to dislodge any dust or dirt that may be present in the
valve.
CAUTION
When cracking the cylinder valve, DO NOT stand directly
in front of the cylinder valve. Always perform cracking in
a well ventilated area. If an acetylene cylinder sprays a
mist when cracked, let it stand for 15 minutes. Then, try
to crack the cylinder valve again. If this problem persists,
contact your gas supplier.
1.03 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.
Figure 1-1: Gas Cylinders
!
WARNING
Cylinders are highly pressurized. Handle with care.
Serious accidents can result from improper handling
or mis use of compressed gas cylinders DO NOT drop
the cylinder, knock it over, or expose it to excessive
heat, flames or sparks. DO NOT strike it against other
cylinders. Contact your gas supplier or refer to CGA P-1
“Safe Handling of Compressed Gases in Containers”
publication.
NOTE
CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly,VA 20151-2923
2. Place the valve protection cap on the cylinder whenever
mov ing it, placing it in storage, or not using it. Never drag or
roll cylinders in any way. Use a suitable hand truck to move
cylin ders.
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.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
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.
Manual 0-5148 1-5 Safety Instructions and Warnings
THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
t1
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
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
t
IPM
MPM
S
Inches Per Minute
Meters Per Minute
See Note
See Note
115V 15A
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
Safety Instructions and Warnings 1-6 Manual 0-5148
Receptacle RatingAuxiliary Power
Voltage Input
V
Art # A-04130_AB
S
SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS
1.05 Servicing Hazards
WARNING
!
WARNING
The symbols shown below are used throughout this
manual to call attention to and identify possible hazards.
When you see the symbol, watch out, and follow the
related instructions to avoid the hazard.
Only qualified persons should test, maintain, and repair
this unit.
Only qualified persons should test, maintain, and repair
this unit.
WARNING
ELECTRIC SHOCK can kill.
• Donottouchliveelectricalparts.
• TurnOffweldingpowersourceandwirefeederanddisconnect
and lockout input power using line disconnect switch, circuit
breakers, or by removing plug from receptacle, or stop engine
before servicing unless the procedure specifically requires an
energized unit.
• Insulate yourselffrom ground by standing orworking on
dry insulating mats big enough to prevent contact with the
ground.
• Donotleaveliveunitunattended.
• Ifthisprocedurerequiresandenergizedunit,haveonlyperson-
nel familiar with and following standard safety practices do the
job.
• Whentestingaliveunit,usetheone-handmethod.Donotput
both hands inside unit. Keep one hand free.
• Disconnectinputpowerconductorsfromde-energizedsupply
line BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of input power
on inverters.
• TurnOffinverters,disconnectinputpower,anddischargeinput
capacitors according to instructions in Troubleshooting Section
before touching any parts.
FLYING METAL or DIRT can injure eyes.
• Wearsafety glasses withside shields orface shield during
servicing.
• Becareful not toshort metaltools,parts, or wirestogether
during testing and servicing.
WARNING
HOT PARTS can cause sever burns.
• Donottouchhotpartsbarehanded.
• Allowcoolingperiodbeforeworkingonequipment.
• Tohandlenotparts,usepropertoolsand/orwearheavy,insu-
lated welding gloves and clothing to prevent burns.
WARNING
EXPLODING PARTS can cause injury.
• Failedpartscanexplodeorcauseotherpartstoexplodewhen
power is applied to inverters.
• Alwayswear a faceshield and longsleeves when servicing
inverters.
WARNING
SHOCK HAZARD from testing.
• TurnOffweldingpowersourceandwirefeederorstopengine
before making or changing meter lead connections.
• Useatleastonemeterleadthathasaself-retainingspringclip
such as an alligator clip.
• Readinstructionsfortestequipment.
WARNING
WARNING
STATIC (ESD) can damage PC boards.
• PutongroundedwriststrapBEFOREhandlingboardsorparts.
• Useproperstatic-proofbagsandboxestostore,move,orship
PC boards.
WARNING
FIRE OR EXPLOSION hazard.
• Donotplaceuniton,over,ornearcombustiblesurfaces.
• Donotserviceunitnearammables.
Manual 0-5148 1-7 Safety Instructions and Warnings
FALLING UNIT can cause injury.
• Useliftingeyetoliftunitonly,NOTrunninggear,gascylinders,
or any other accessories.
• Useequipmentofadequatecapacitytoliftandsupportunit.
• Ifusingliftforkstomoveunit,besureforksarelongenough
to extend beyond opposite side of unit.
WARNING
MOVING PARTS can cause injury,
• Keepawayfrommovingpartssuchasfans.
• Keepawayfrompinchpointssuchasdriverolls.
THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS
• Haveonlyqualiedpersonsremovedoors,panels,covers,or
guards for maintenance as necessary.
• Keephands,hair,looseclothing,andtoolsawayfrommoving
parts.
• Reinstalldoors,panels,covers,orguardswhenmaintenance
is finished and before reconnecting input power.
WARNING
MAGNETIC FIELDS can affect Implanted Medical Devices.
• WearersofPacemakersandotherImplantedMedicalDevices
should keep away from servicing areas until consulting their
doctor and the device manufacturer.
1.06 EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about
such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: “The body of evidence,
in the committee’s judgment, has not demonstrated that exposure to
power-frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to
be examined. Until the final conclusions of the research are reached,
you may wish to minimize your exposure to electromagnetic fields
when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
WARNING
OVERUSE can cause OVERHEATING.
• Allowcoolingperiod;followrateddutycycle.
• Reducecurrentorreduce duty cycle beforestarting to weld
again.
• Donotblockorlterairowtounit.
WARNING
H.F. RADIATION can cause interference.
• High-frequency(H.F.)caninterferewithradionavigation,safety
services, computers, and communications equipment.
• Haveonlyqualiedpersonsfamiliarwithelectronicequipment
install, test, and service H.F. producing units.
• The useris responsiblefor having aqualified electrician
promptly correct any interference problem resulting from the
installation.
• IfnotiedbytheFCCaboutinterference,stopusingtheequipment at once.
• Havetheinstallationregularlycheckedandmaintained.
• Keephigh-frequencysourcedoorsandpanelstightlyshut,keep
spark gaps at correct setting, and use grounding and shielding
to minimize the possibility of interference.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and
the device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures
is recommended.
!
WARNING
READ INSTRUCTIONS.
• UseTestingBooklet(PartNo.150853)whenservicingthisunit.
• ConsulttheOwner’sManualforweldingsafetyprecautions.
• Useonlygenuinereplacementpartsfromthemanufacturer.
Safety Instructions and Warnings 1-8 Manual 0-5148
INTRODUCTION THERMAL ARC 161STL, 201TS
!
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual
This Manual usually applies to the part numbers listed on
page i. To ensure safe operation, read the entire manual,
including the chapter on safety instructions and warnings.
Throughout this manual, the word 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
Gives information regarding possible personal
injury. Warnings will be enclosed in a box
such as this.
CAUTION
Refers to possible equipment damage. Cau
tions will be shown in bold type.
NOTE
Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics
You will also notice icons from the safety section appearing throughout the manual. These are to advise you of
specific types of hazards or cautions related to the portion
of information that follows. Some may have multiple
hazards that apply and would look something like this:
-
2.02 Equipment Identification
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.
2.04 Description
The Thermal Arc 161STL is compact inverter welding
machine has infinitely adjustable welding current from 10
to 160 amps. It has a LIFT TIG (GTAW) welding mode that
offers stable TIG welding characteristics with an optimized
Lift Start TIG sequence to initiate the welding arc when
used with a suitable TIG torch and shielding gas.
The Thermal Arc 201TS is compact inverter welding
machine has infinitely adjustable welding current from
10 to 200 amps. It has a LIFT TIG (GTAW) and HF TIG
(GTAW) welding modes that offers stable TIG welding
characteristics with an optimized start TIG sequence to
initiate the welding arc when used with a suitable TIG
torch and shielding gas.
Both models have advanced TIG features including 8 Pin
Amp Plug for remote control devices, down slope, 2T /
4T controls, and gas solenoid operation. They also have
STICK (SMAW) welding mode which uses standard general purpose STICK (SMAW) 3/32” (2.5mm) electrodes
for light gauge work, generally less than 1/8” (3.2mm)
thick and STICK (SMAW) 1/8” (3.2mm) electrodes for
heavier material.
The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the machine. Equipment which
does not have a nameplate attached to the machine is
identified only by the specification or part number printed
on the shipping container. Record these numbers for
future reference.
Manual 0-5148 2-1 Introduction
2.05 Transportation Methods
Disconnect input power
conductors from de-energized supply line before moving
the welding power source.
Lift unit with handle on top of case. Use handcart or similar
device of adequate capacity. If using a fork lift vehicle,
secure the unit on a proper skid before transporting.
THERMAL ARC 161STL, 201TS INTRODUCTION
Notes
Introduction 2-2 Manual 0-5148
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
230VAC Input
AMPS
Duty Cycle (percentage)@40˚C
Lift TIG
Stick
Art # A-10193
Duty Cycle (percentage)@40ºC
SECTION 3:
SAFETY AND INSTALLATION
3.01 Duty Cycle
The rated duty cycle of a Welding Power Source, is the percentage of a ten minute time period that it may be operated
at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain
the 10 minute duty cycle period, suppose a Welding Power Source is designed to operate with a 30% duty cycle at
160 amperes and 26.4 volts. This means that it has been designed and built to provide the rated amperage (160A) for
3 minutes, i.e. arc welding time, out of every 10 minute period (30% of 10 minutes is 3 minutes). During the other 7
minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.
120
100
80
60
Manual 0-5148 3-1 Safety and Installation
40
20
0
020406080100 120140 160 180
115VAC Input
Lift TIG
Stick
AMPS
Art # A-10194
Figure 3-1: 161STL Duty Cycle
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
230VAC Input
0
20
40
60
80
100
120
050100 150 200250
AMPS
Duty Cycle (percentage)@ 40˚C
Lift TIG/HF TIG
Stick
Art # A-10145
115VAC Input
0
20
40
60
80
100
120
050 100 150 200250
AMPS
Duty Cycle (percentage)@40˚C
Stick
Lift TIG/HF TIG
Art # A-10157
Safety and Installation 3-2 Manual 0-5148
Figure 3-2: 201TS Duty Cycle
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
3.02 Specifications - 161STL
Power Source Part Number W1003700
Mains Power
Nominal Supply Voltage AC 115V AC 208/230V
Number of Phases Single Phase Single Phase
Input Voltage Range AC 104 - 127V AC 187- 253V
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Effective Input Current (l1eff) 20 Amps 16 Amps
Maximum Input Current (l1 max) ∆ 28.6 Amps ∆ 25 Amps
Single Phase Generator Requirements [Continuous rating
at nominal supply voltage with maximum output for STICK
(SMAW) welding]
Welding Output
Welding Current Range Stick: 10 - 125 Amps
5 KVA 6 KVA
Stick:/TIG:
TIG: 10 - 160 Amps
10 - 160 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min.
(Quoted figures refer to STICK (SMAW) output)
100A @ 45%, 24.0V
95A @ 60%, 23.8V
80A @ 100%, 23.2V
160A @ 30%, 26.4V
120A @ 60%, 24.8V
100A @ 100%, 24.0V
Rated Input Current (A) 28.6A 25A
for STICK (SMAW) Welding Io = 100A @ 24.0V Io = 160A @ 26.4V
Rated Input Current (A) 28.6A 15.5A
for LIFT TIG (GTAW) Welding Io = 150A @ 16.4V Io = 160A @ 16.4V
Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 45% 26.4V, 160A @ 30%
Rated Output for LIFT TIG (GTAW) Welding 16.0V, 150A @ 35% 16.4V, 160A @ 30%
Duty Cycle (%) 45% @ 100A 30% @ 160A
Welder Type Inverter Power Source
Output Terminal Type Heavy Duty Dinse
TM
50
Classification
Protection Class IP23S
Standards EN 60974-1
EN50199
Cooling Method Fan Cooled
Dimensions and Weight
Welding Power Source Mass 21.6 lb. (9.8 kg)
Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆
The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes
and protected by fuses or circuit breaker is recommended for this application. 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)
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously
sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications
due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location
and conditions and local power grid supply conditions.
Manual 0-5148 3-3 Safety and Installation
.
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
3.03 Specifications -201TS
Power Source Part Number W1003800
Mains Power
Nominal Supply Voltage AC 115V AC 208/230V
Number of Phases Single Phase Single Phase
Input Voltage Range AC 104- 127V AC 187- 253V
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Effective Input Current (l1eff) 20 Amps 16 Amps
Maximum Input Current (l1 max) ∆ 28.6 Amps ∆ 32 Amps
Single Phase Generator Requirements [Continuous rating at
nominal supply voltage with maximum output for STICK (SMAW)
welding]
Welding Output
Welding Current Range Stick: 10 - 125 Amps
5 KVA 6 KVA
Stick/TIG:
TIG: 10 - 160 Amps
10 - 200 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min.
(Quoted figures refer to STICK (SMAW) output)
100A @ 45%, 24.0V
95A @ 60%, 23.8V
80A @ 100%, 23.2V
200A @ 20%, 28V
120A @ 60%, 24.8V
100A @ 100%, 24.0V
Rated Input Current (A) 28.6A 32A
for STICK (SMAW) Welding Io = 100A @ 24.0V Io = 200A @ 28V
Rated Input Current (A) 28.6A 20.6A
for LIFT TIG/HF TIG (GTAW) Welding Io = 150A @ 16.0V Io = 200A @ 18V
Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 45% 28V, 200A @ 20%
Rated Output for LIFT TIG/HF TIG (GTAW) Welding 16.0V, 150A @ 35% 18V, 200A @ 25%
Duty Cycle (%) 45% @ 100A 20% @ 200A
Welder Type Inverter Power Source
Output Terminal Type Heavy Duty Dinse
TM
50
Classification
Protection Class IP23S
Standards EN 60974-1
EN50199
Cooling Method Fan Cooled
Dimensions and Weight
Welding Power Source Mass 22 lb. (10 kg)
Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆
The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes
and protected by fuses or circuit breaker is recommended for this application. 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)
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously
sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications
due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location
and conditions and local power grid supply conditions.
Safety and Installation 3-4 Manual 0-5148
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
3.04 Environment
These units are designed for use in environments with increased hazard of electric shock. Examples of environments
with increased hazard of electric shock are:
A. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
B. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable
or accidental contact by the operator.
C. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human
body and the insulation properties of accessories.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased hazard, have been insulated.
3.05 Location
Be sure to locate the welder according to the following guidelines:
• Inareas,freefrommoistureanddust.
• Ambienttemperaturebetween14°F(-10°C)to104°F(40°C).
• Inareas,freefromoil,steamandcorrosivegases.
• Inareas,notsubjectedtoabnormalvibrationorshock.
• Inareas,notexposedtodirectsunlightorrain.
• Placeatadistanceof12”(300mm)ormorefromwallsorsimilarthatcouldrestrictnaturalairowforcooling
!
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.06 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging
procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other disconnecting device.
• Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one
of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility
for information about the type of electrical service available, how proper connections should be made, and inspection
required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power
from the welding power supply whenever necessary to inspect or service the unit.
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Manual 0-5148 3-5 Safety and Installation
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
208-230V, 50A,1Ø
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3-3:
1. Connect end of ground (GREEN or GREEN/YELLOW) 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.
3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.
Input Voltage Circuit Breaker or Fuse Size
115V 30A
208-230V 50A
Table 3-1: Fuse Guide
CAUTION
The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.
Welding Power Supply
The Adapters enable
connection to all these
power outlets
120
120V,V,
20A,1Ø
15A,1Ø
Safety and Installation 3-6 Manual 0-5148
Art# A-09789
Primary Power Cable
Figure 3-3: Electrical Input Connections
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides
pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors
have charged to operating voltage (after approximately 5 seconds)
NOTE
Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.
Model Primary Supply Lead
Size (Factory Fitted)
Thermal Arc
161 STL
Thermal Arc
201 TS
12 AWG (3.3mm²)
12 AWG (3.3mm²)
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current
Minimum Primary
Current Circuit Size
(Vin/Amps)
LIFT TIG/ HF TIG
Current & Duty Cycle
STICK (SMAW)
(GTAW)
115V/30A - 100A @ 45%
115V/30A 150A @ 35% 208-230V/25A - 160A @ 30%
208-230V/15A 160A @ 30% -
115V/30A - 100A @ 45%
115V/30A 150A @ 35%
-
208-230V/25A - 200A @ 20%
208-230V/25A 200A @ 25%
-
Manual 0-5148 3-7 Safety and Installation
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
3.07 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the welding
equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of
the manufacturer. In some cases this remedial action
may be as simple as earthing the welding circuit, see
NOTE below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding Power
Source and the work, complete with associated input
filters. In all cases, electromagnetic disturbances shall be
reduced to the point where they are no longer Troublesome.
B. Assessment of Area
Before installing welding equipment, the user shall make
an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into
account.
1. Other supply cables, control cables, signaling and
telephone cables; above, below and adjacent to the
welding equipment.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic Emissions
1. Mains Supply
Welding equipment should be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may be
necessary to take additional precautions such as
filtering of the mains supply. Consideration should
be given to shielding the supply cable of permanently
installed welding equipment in metallic conduit or
equivalent. Shielding should be electrically continuous
throughout its length. The shielding should be
connected to the Welding Power Source so that good
electrical contact is maintained between the conduit
and the Welding Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the welding equipment
is in operation. The welding equipment should not
be modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted
and maintained according to the manufacturer’s
recommendation
3. Welding Cables
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial
equipment.
5. The health of people around, e.g. the use of pacemakers and hearing aids.
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to
be carried out.
8. The immunity of other equipment in the environment:
the user shall ensure that other equipment being used
in the environment is compatible: this may require
additional protection measures.
Safety and Installation 3-8 Manual 0-5148
The welding cables should be kept as short as possible
and should be positioned close together, running at or
close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the welding
installation and adjacent to it should be considered.
However, metallic components bonded to the work
piece will increase the risk that the operator could
receive a shock by touching the metallic components
and the electrode at the same time. The operator
should be insulated from all such bonded metallic
components.
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and
position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk
of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to
earth should be made by direct connection to the work piece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems
of interference. Screening the entire welding installation may be considered for special applications.
Manual 0-5148 3-9 Safety and Installation
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
A-09949
230VAC Input
0
10
20
30
40
50
60
70
80
050100 150 200
AMPS
VOLTS
Stick Max
Lift TIG Max
Art # A-10195
Lift TIG Max
3.08 Volt-Ampere Curves
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves
of other settings fall between curves shown.
115VAC Input
80
70
60
50
40
VOLTS
30
Stick Max
20
10
0
050 100 150 200
AMPS
Art # A-10196
Figure 3-4: 161STL Volt-Ampere Curves
Safety and Installation 3-10 Manual 0-5148
SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS
230VAC Input
80
70
60
50
40
Stick Max
VOLTS
30
Lift TIG Max
20
10
0
050 100 150 200 250
AMPS
115VAC Input
80
70
60
Lift Tig Max
50
Art # A-10158
40
VOLTS
30
20
10
0
050 100 150 200
Manual 0-5148 3-11 Safety and Installation
Stick Max
AMPS
Art # A-10159
Figure 3-4: 201TS Volt-Ampere Curves
THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION
Notes
Safety and Installation 3-12 Manual 0-5148
OPERATION THERMAL ARC 161STL, 201TS
SECTION 4:
OPERATION
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold the electrode. The welding current range values should be used as a
guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies
between different classes of electrode, welding current at any one setting would vary according to the type of electrode
in use. The operator should use the welding current range values as a guide then fine tune the welding current to suit
the specific application. Refer to the electrode manufacture's literature for further information.
4.01 Front Panel
(C) Trigger Mode Selection Switch
(A) Power On Indicator
(B) Fault Indicator
(E) Welding Current
Control
(G) Gas Outlet
Negative Output Terminal
(D) Process Selection Switch
(F) Arc Force/Down
Slope Control
(I) 8 Pin Control Socket
Positive Output Terminal
Manual 0-5148 4-1 Operation
Art # A-09786_AC
Figure 4-1: Thermal Arc 161STL Controls
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