Tweco 201-ts User Manual

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201 TS

THERMAL ARC

INVERTER ARC WELDER

STICK

32AOU TLET

TIG

32AOU TLET

110V

TIG/STICK

16AOU TLET

230V

Operating Manual

Revision: AB Issue Date: May 20, 2011 Manual No.: 0-5149 Operating Features:

Art # A-10139

50 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 +44 (0) 1257 261 755, 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. 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 If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.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 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 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 judgement, the Manufacturer assumes no liability for its use.

Operating Manual Number 0-5149 for: Thermal Arc 201 TS Power Source Arc Welder Part Number W1003802 Thermal Arc 201 TS System with Stick/TIG Kit & Case Part Number W1003803

Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermadyne.com

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: April 20, 2011 Revision AB date: May 20, 2011

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ..................................... 1-1

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

1.02 Principal Safety Standards .............................................................................. 1-5

1.03 Declaration Of Conformity .............................................................................. 1-6

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 Transportation Methods .................................................................................. 2-1

2.05 Symbol Chart .................................................................................................. 2-2

2.06 Description ..................................................................................................... 2-3

2.07 User Responsibility ......................................................................................... 2-3

2.08 Duty Cycle ....................................................................................................... 2-4

2.09 Speciﬁcations ................................................................................................. 2-5

SECTION 3:

INSTALLATION, OPERATION AND SETUP ........................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Electromagnetic Compatibility ........................................................................ 3-3

3.05 Setup for Welding ........................................................................................... 3-4

3.06 STICK (MMA) Setup ....................................................................................... 3-5

3.07 LIFT TIG / HF TIG (GTAW) Setup ..................................................................... 3-7

3.08 Leak Testing the System ................................................................................. 3-8

3.09 When You Finish Using the Regulator ............................................................. 3-8

3.10 Storage of the Regulator ................................................................................. 3-8

TABLE OF CONTENTS

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 Front Panel ..................................................................................................... 4-1

4.02 Welding Current Control Explanation .............................................................. 4-3

4.03 STICK (MMA) Electrode Polarity ..................................................................... 4-3

4.04 Effects of Stick Welding Various Materials ...................................................... 4-3

4.05 GTAW Electrode Polarity ................................................................................. 4-4

4.06 Guide for Selecting Filler Wire ........................................................................ 4-4

4.07 Tungsten Electrode Current Ranges ................................................................ 4-4

4.08 Shielding Gas Selection .................................................................................. 4-4

4.09 Tungsten Electrode Types ............................................................................... 4-5

4.10 TIG Welding Parameters for Steel ................................................................... 4-5

4.11 Arc Welding Practice ....................................................................................... 4-5

4.12 Welding Position ............................................................................................. 4-6

4.13 Joint Preparations ........................................................................................... 4-7

4.14 Arc Welding Technique ................................................................................... 4-8

4.15 The Welder ...................................................................................................... 4-8

4.16 Striking the Arc ............................................................................................... 4-8

4.17 Arc Length ...................................................................................................... 4-8

4.18 Rate of Travel .................................................................................................. 4-8

4.19 Making Welded Joints ..................................................................................... 4-9

4.20 Distortion ...................................................................................................... 4-11

4.21 The Cause of Distortion ................................................................................ 4-11

4.22 Overcoming Distortion Effects ...................................................................... 4-12

SECTION 5:

SERVICE ............................................................................................... 5-1

5.01 Maintenance and Inspection ........................................................................... 5-1

5.02 STICK (MMA) Welding Problems ................................................................... 5-2

5.03 TIG Welding Problems ................................................................................... 5-3

5.04 Power Source Problems ................................................................................ 5-4

APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1

APPENDIX 2: REPLACEMENT PARTS .................................................................... A-2

APPENDIX 3: 201 TS SYSTEM SCHEMATIC ............................................................ A-4

LIMITED WARRANTY & WARRANTY SCHEDULE

TABLE OF CONTENTS

Art # A-10140

Thermal Arc 201 TS Stick/TIG System

Part Number W1003803

• ThermalArc201TSpowersupplyintoolbox

• 26TIGtorch,3.8m(12.5ft)withIntegratedControls&accessoryKit

• Electrodeholder,5m(16.4ft)

• Worklead,5m(16.4ft)

• 4GP3.2mm(1/8")diastickelectrodes

• ThermalArc201TSGasHoselead4m(13ft)

• Operatingmanual

THERMAL ARC 201 TS SAFE INSTRUCTION

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

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 European Standard EN60974-1 entitled: Safety in welding and allied processes Part 2: Electrical. 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 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.

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.

WARNING

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.

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.

Manual 0-5149 1-1 General Information

14. Wear a safety harness to prevent falling if working above ﬂoor level.

15. Keep all panels and covers securely in place.

SAFE INSTRUCTION THERMAL ARC 201 TS

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. Use a Welding Helmet or Welding Faceshield ﬁtted with a proper shade of ﬁlter (see ANSI Z49.1 and EN 60974-1 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.

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

6. Never wear contact lenses while welding.

Eye protection ﬁlter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

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 breath 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.

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

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

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Heavy Over 400 Amp 14

General Information 1-2 Manual 0-5149

THERMAL ARC 201 TS SAFE INSTRUCTION

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 airsupplied 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 con

tact of electrode or welding wire to metal objects can cause sparks, overheating, or ﬁre.

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.

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 10.7 m (35 ft) 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.

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

Engines can be dangerous.

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.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

Chipping and grinding cause ﬂying metal. As welds cool, they can throw off slag.

Manual 0-5149 1-3 General Information

SAFE INSTRUCTION THERMAL ARC 201 TS

4. Do not use welder to charge batteries or jump

WARNING

ENGINE FUEL can cause ﬁre or explosion.

Engine fuel is highly ﬂammable.

start vehicles.

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

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.

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.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.)

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

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.

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

The following is a quotation from the General Conclusions Section of the U.S. Congress, Ofﬁce of Tech-

General Information 1-4 Manual 0-5149

THERMAL ARC 201 TS SAFE INSTRUCTION

nology 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 and 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.

1.02 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.

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.

Safety in welding and allied processes Part 1: Fire Precautions, EN 60974-1 from SAI Global Limited, www. saiglobal.com.

Safety in welding and allied processes Part 2: Electrical, EN 60974-1 from SAI Global Limited, www.saiglobal. com.

Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations AS/NZS 1338.1:1992 from SAI Global Limited, www.saiglobal.com.

Manual 0-5149 1-5 General Information

SAFE INSTRUCTION THERMAL ARC 201 TS

1.03 Declaration of conformity

Manufacturer: Thermadyne Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CENELECEN50199EMCProductStandardforArcWeldingEquipment.

• ISO/IEC60974-1(BS638-PT10)(EN60974-1)(EN50192)(EN50078)applicabletoweldingequipment

and associated accessories.

• For environmentswith increasedhazard ofelectrical shock,PowerSupplies bearingthe Smark

conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

• Extensiveproductdesignverificationisconductedatthemanufacturingfacilityas partoftheroutine

design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

This equipment does not comply with IEC 61000-3-12. If it is connected to a public low voltage system, it is the responsibility of the installer or user of the equipment to ensure, by consultation

withthedistributionnetworkoperatorifnecessary,thattheequipmentmaybeconnected.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

WarninG

Steve Ward OperationsDirector Thermadyne Europe Europa Building ChorleyNIndustrialPark Chorley, Lancashire,

EnglandPR67BX

General Information 1-6 Manual 0-5149

INTRODUCTION THERMAL ARC 201 TS

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. Cautions 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

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.

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 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.

Manual 0-5149 2-1 Introduction

THERMAL ARC 201 TS INTRODUCTION

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Te mperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04937

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance In Ground System

Welding Gun

Burnback Time

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

4 Step Trigger Operation

2 Step Trigger Operation

2.05 Symbol Chart

Note that only some of these symbols will appear on your model.

Introduction 2-2 Manual 0-5149

INTRODUCTION THERMAL ARC 201 TS

2.06 Description

This compact inverter welding machine has infinitely adjustable welding current from 10 to 200 amps. The 201TS has a LIFT TIG (GTAW) and HF TIG (GTAW) welding mode 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. Advanced TIG features include 8 Pin Amp Plug for remote control devices, down slope, 2T / 4T controls, and gas solenoid operation. It also has STICK (MMA) welding mode which uses standard general purpose STICK (MMA)

2.5mm (3/32”) electrodes for light gauge work, generally less than 3.2mm (1/8”) thick and STICK (MMA) 3.2mm (1/8”) electrodes for heavier material.

2.07 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualiﬁed persons approved by Thermal Arc. Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor.

This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of Thermal Arc. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by Thermal Arc.

Manual 0-5149 2-3 Introduction

THERMAL ARC 201 TS INTRODUCTION

110VAC INPUT

100

020406080100 120 140 160

Welding Current (amps)

Duty Cycle (percentage)@40°C

Safe

Operating

Region

TIG (GTAW)

Stick (MMA)

Art # A-10141

2.08 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 200 amperes at 18 volts. This means that it has been designed and built to provide the rated amperage (200A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.

Introduction 2-4 Manual 0-5149

100

Duty Cycle (percentage)@40°C

020406080 100 120 140 160 180 200

Safe

Operating

Region

230VAC INPUT

TIG (GTAW)

Welding Current (amps)

Figure 2-1: Thermal Arc 201 TS Duty Cycle

Art # A-10142

INTRODUCTION THERMAL ARC 201 TS

2.09 Speciﬁcations

Power Source Part Number W1003802

Mains Power

Nominal Supply Voltage AC 110V AC 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) ∆ 39 Amps ∆ 32 Amps

Single Phase Generator Requirements

5 KVA 8 KVA [Continuous rating at nominal supply voltage with maximum output for STICK (MMA) welding]

Welding Output

Welding Current Range Stick: 10 - 125 Amps

TIG: 10 - 160 Amps

Stick/TIG:

10 - 200 Amps

Nominal DC Open Circuit Voltage (OCV) 71V 71V

Welding Output, 104º F (40º C), 10 min. (Quoted figures refer to STICK (MMA) output)

125A @ 25%, 25.0V

95A @ 60%, 23.8V

80A @ 100%, 23.2V

200A @ 20%, 28V

120A @ 60%, 24.8V

100A @ 100%, 24.0V

Rated Input Current (A) 39A 32A

for STICK (MMA) Welding Io = 125A @ 25.0V Io = 200A @ 28V

Rated Input Current (A) 30A 20.6A

for LIFT TIG/HF TIG (GTAW) Welding Io = 160A @ 16.4V Io = 200A @ 18V

Rated Output for STICK (MMA) Welding 25.0V, 125A @ 25% 28V, 200A @ 20%

Rated Output for LIFT TIG/HF TIG (GTAW)

16.4V, 160A @ 30% 18V, 200A @ 25%

Welding

Duty Cycle (%) 25% @ 125A 20% @ 200A

Welder Type Inverter Power Source

Output Terminal Type Heavy Duty Dinse

Classification

Protection Class IP23S

Standards EN 60974-1 EN50199

Cooling Method Fan Cooled

Dimensions and Weight

Welding Power Source Mass 10 kg (22 lb.)

Welding Power Source Dimensions (Height x Width x Depth)

∆

The recommended time delay fuse or circuit breaker size is 32 amp for 110V and 32 amp for 230V.

H230mm x W135mm x D450mm

( H 9.0” x W 5.3” x D 17.7”)

Manual 0-5149 2-5 Introduction

THERMAL ARC 201 TS INTRODUCTION

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.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

Introduction 2-6 Manual 0-5149

INSTALLATION THERMAL ARC 201 TS

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 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 considerable 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.

3.02 LOCATION

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C.

C. In areas, free from oil, steam and corrosive

gases.

D. In areas, not subjected to abnormal vibration or

shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 300mm or more from walls

or similar that could restrict natural air flow for cooling.

G. The enclosure design of this power source

meets the requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects (greater than 12mm), and direct protection from vertical drops. Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions. For further information please refer to EN 60529.

H. Precautions must be taken against the power

source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

WARNING

Thermal Arc advises that this equipment be electrically connected by a qualified electrician.

3.03 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. Lockout/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 (BROWN or BLUE) conductor to the ground terminal.

Do not connect the ground (GREEN or GREEN/ YELLOW) conductor to an input line terminal.

Refer to Figure 3-1:

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.

Manual 0-5149 3-1 Installation, Operation And Setup

THERMAL ARC 201 TS INSTALLATION

2. Connect ends of line Active (BROWN) and Neutral (BLUE) input conductors to a suitable power suply system that complies with all applicable local electrical codes.

3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.

Input Voltage Circuit Breaker or Fuse Size

110V 32A

230V 32A

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

Art# A-10143

Primary Power Cable

Figure 3-1 Electrical Input Connections

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)

Installation, Operation And Setup 3-2 Manual 0-5149

INSTALLATION THERMAL ARC 201 TS

NOTE

Damage to the PCA could occur if 265 VAC or higher is applied to the Primary Power Cable.

Model Primary Supply Lead

Size (Factory Fitted)

Thermal Arc

201 TS

H07RN-F 2.5mm²

Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

Minimum Primary

Current Circuit Size

(Vin/Amps)

110V/39A - 125A @ 25%

110V/30A 160A @ 30% -

230V/32A - 200A @ 25%

230V/21A 200A @ 25% -

LIFT TIG/HF TIG

Current & Duty Cycle

STICK (MMA)

(GTAW)

3.04 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.

NOTE

The welding circuit may or may nor be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 60974-13 Arc Welding Equipment - Installation and use (under preparation).

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, signalling and telephone cables; above, below and adjacent to the welding equipment.

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.

Manual 0-5149 3-3 Installation, Operation And Setup

THERMAL ARC 201 TS INSTALLATION

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 it’s 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 stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

3. Welding Cables

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.

5. Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of it’s

size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, 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.

3.05 SETUP FOR WELDING

NOTE

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 electrode. Wide safety margins provided by the design ensure that the Welding Power Source will withstand short-term overload without adverse effects. 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 electrodes, 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 application.

Installation, Operation And Setup 3-4 Manual 0-5149

INSTALLATION THERMAL ARC 201 TS

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

3.06 STICK (MMA) SETUP

Set Welding Current as speciﬁed by the Electrode Manufacturer.

Negative Output Terminal (Dinse™ 50)

Set Process Selection Switch to STICK.

Set ARC Force

Positive Output Terminal (Dinse™ 50)

200A

Art#: A-09784

Figure 3-2 Setup for STICK (MMA) Welding

Manual 0-5149 3-5 Installation, Operation And Setup

THERMAL ARC 201 TS INSTALLATION

STICK (MMA) Mode Sequence of Operation

CAUTION

Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the ground (work) clamp cable to the negative output terminal, and the electrode holder cable to the positive output terminal. It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection.

NOTE

This set up is known as DC Electrode Positive or reverse polarity. Please consult with the stick electrode manufacturer for speciﬁc polarity recommendations.

3. Connect the ground (work) clamp to your workpiece.

4. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D light should illuminate.

5. Set the “Process Selection Switch” to STICK.

6. Set the weld current control knob to the desired amperage.

7. Set the ARC FORCE control knob to 2.

Minimum (0) provides a soft arc, low spatter & low penetration.

Medium (2) provides a normal arc, improved fusion & normal penetration.

Maximum (10) provides a hard arc & deep penetration.

8. Install a stick electrode in the electrode holder.

9. You are now ready to begin STICK Welding

NOTE

Gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work piece while holding a consistent arc length above base metal.

Installation, Operation And Setup 3-6 Manual 0-5149

INSTALLATION THERMAL ARC 201 TS

3.07 LIFT TIG / HF TIG (GTAW) SETUP

Set Process Selection Switch to LIFT TIG or HF TIG.

Switch to 2T/4T

Set Welding Current as speciﬁed by the Electrode Manufacturer.

Set DOWN Slope

Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

Negative Output Terminal (Dinse™ 50)

Figure 3-3: Setup for LIFT TIG / HF TIG (GTAW) Welding

LIFT TIG / HF TIG (GTAW) Sequence of Operation

Positive Output Terminal (Dinse™ 50)

Art # A-10100_AB

CAUTION

Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the ground (work) clamp cable to positive output terminal. It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection.

3. Connect the TIG torch as follows:

a) Place the power cable into the negative output terminal. It is essential that the male plug is inserted

and turned fully clockwise until connector locks in place to achieve reliable electrical connection;

b) Place the 8 pin plug into the 8 pin socket. To make connections, align keyway, insert plug, and rotate

threaded collar fully clockwise.

c) Place the TIG torch gas hose to the gas outlet and tighten with a wrench. Caution: DO NOT over tighten.

4. Using a secured Argon cylinder, slowly crack open then close the cylinder valve while standing off to the side of the valve. This will remove any debris that may be around the valve & regulator seat area.

5. Install the regulator (for details of VICTOR regulator, please refer to 3.08 ) and tighten with a wrench.

6. Connect one end of the supplied gas hose to the outlet of the Argon regulator and tighten with a wrench. Caution: DO NOT over tighten.

Manual 0-5149 3-7 Installation, Operation And Setup

THERMAL ARC 201 TS INSTALLATION

7. Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and tighten with a wrench. Caution: DO NOT over tighten.

8. Open the Argon Cylinder Valve to the fully open position.

9. Connect the ground (work) clamp to your work piece.

10. Set the DOWN SLOPE control knob to the desire weld current ramp down time. Refer to Section

4.01.

gauge. Check for leaks using an approved leak detector solution.

c) If the high-pressure gauge drops and the

low-pressure gauge increases at the same time, there is a leak in the regulator seat.

d) If the regulator requires service or repair,

take it to a qualiﬁed repair technician.

5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.

11. Set the weld current control knob to the desired amperage.

12. The tungsten must be ground to a blunt point in order to achieve optimum welding results. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning.

13. Install the tungsten with approximately 1/8” to ¼” sticking out from the gas cup, ensuring you have correct sized collet.

14. Tighten the back cap then open the valve on the torch.

15. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D. light should illuminate. Set the “Process Selection Switch” to LIFT TIG and HF TIG

16. You are now ready to begin TIG Welding.

3.08 LEAK TESTING THE SYSTEM

Leak test the system before putting into operation.

1. Be sure that there is a valve in the downstream equipment to turn off the gas ﬂow.

WARNING

If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure.

3.09 WHEN YOU FINISH USING THE REGULATOR

1. Close the cylinder valve.

2. Open the valve on the downstream equipment. This drains all pressure from the system.

3. Close the valve on the downstream equipment.

4. Turn the adjusting screw counterclockwise to release the ten sion on the adjusting spring.

5. Check the gauges after a few minutes for veriﬁcation that the cylinder valve is closed completely.

3.10 STORAGE OF THE REGULATOR

2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure.

3. Close the cylinder valve.

4. Turn the adjusting screw/knob counterclockwise one turn.

a) If the high-pressure gauge reading drops,

there is a leak in the cylinder valve, inlet ﬁtting, or high-pressure gauge.

b) If the low-pressure gauge drops, there is a

leak in the down stream equipment, hose, hose ﬁtting, outlet ﬁtting or low-pressure

Installation, Operation And Setup 3-8 Manual 0-5149

When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro tected from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting.

OPERATION THERMAL ARC 201 TS

Art # A-10146

(A) Power On Indicator

(B) Fault Indicator

(E) Welding Current Control

(G) Gas Outlet

Negative Output Terminal

Positive Output Terminal

(I) 8 Pin Control Socket

(F) Arc Force/Down Slope Control

(D) Process Selection Switch

32AOUTLET

STICK

TIG

230V

110V

TIG/STICK

32AOUTLET 16AOUTLET

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

Front Panel

The welding power source is protected by a self re-setting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. If the FAULT light illuminates wait for the FAULT light to extinguish before resuming welding.

A. POWER Indicator

The POWER Indicator illuminates when the ON/OFF switch is in the ON position and the correct mains voltage is present.

B. FAULT Indicator

If Fault indicator lights up continuously then that is an Overcurrent Condition and needs to be serviced by an Authorized Thermalarc Technician.

Figure 4-1: Thermal Arc 201 TS Controls

Manual 0-5149 4-1 Operation

THERMAL ARC 201 TS OPERATION

C. TRIGGER Mode Switch (LIFT TIG Mode Only)

2T (Normal) Mode

Press the TIG Torch Trigger Switch or Foot Control and hold depressed to weld. Release the TIG Torch Trigger Switch or Foot Control to stop welding. Down Slope operates in LIFT TIG (GTAW) mode only. While welding if the TIG Torch Trigger Switch is released, the welding current ramps down to zero current over a deﬁned period of time. The time period is determined by the Down Slope Control Knob (F).

4T (Latch) Mode

This mode of welding is mainly used for long weld runs. The operator need only to press the TIG Torch Trigger Switch to activate and then release the TIG Torch Trigger Switch to continue to weld, then press the TIG Torch Trigger Switch again and release the TIG Torch Trigger Switch to stop welding. This eliminates the need for the operator to depress the TIG Torch Trigger Switch for the complete length of the weld. The 4T mode incorporates a current slope function which includes a ﬁxed current up slope of 1 second and an adjustable current down slope. Current slope operates in TIG Mode only. Up slope is not adjustable and activates automatically in 4T mode when the TIG torch trigger is depressed. To activate the Down Slope function in 4T mode while welding, the TIG Torch Trigger Switch must be depressed and held while welding which will ramp the Welding Current down to zero over a deﬁned period of time. The time period is determined by the Down Slope Control Knob (F). At any time while welding if the TIG Torch Trigger Switch is depressed and released the arc will extinguish immediately.

greater penetration control to be achieved. Down Slope operates in TIG mode only. It is used to set the time for weld current to ramp down. Refer to Item C (Trigger Mode Selection Switch) for further information regarding Downslope operation.

G. Gas Outlet

The Gas Outlet is a 5/8”-18 UNF female gas ﬁtting and is utilized for the connection of a suitable TIG Torch.

H. Post Gas Flow (weld current dependant)

Post Gas Flow is the time Gas ﬂows after the arc has extinguished. The gas ﬂow time is proportional to weld current. This is used to cool and reduce oxidization of the Tungsten Electrode. For example if the Welding Current is set to 10 amps the Post Gas Flow time will be approximately 3 seconds. For a Welding Current set to 160 Amps the Post Gas Flow time will be approximately 10 seconds. The Post Gas Flow time cannot be adjusted independently of the Welding Current.

I. 8 Pin Remote Socket

The 8 pin remote socket is used to connect the TIG Torch Trigger Switch to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

12345 678

5k Ohms

Front View of 8 Pin Socket

543

876

D. Process Selection Switch

Switches between STICK (MMA), LIFT TIG (GTAW) and HF TIG (GTAW) modes. Refer to Section 3.06 Setup for STICK (MMA) Welding and 3.07 Setup for TIG / HF TIG Welding.

E. Welding Current Control

The welding current is increased by turning the Weld Current Control Knob clockwise or decreased by turning the Weld Current Control Knob counterclockwise. The welding current should be set according to the speciﬁc application. Refer to application notes in this section for further information.

F. Arc Force/Down Slope Control

Plug Pin Function

1 2 Torch Switch Input (24V) to energize

3 Torch Switch Input (0V) to energize weld

4 5 5k ohm (maximum) connection to 5k ohm

6 Zero ohm (minimum) connection to 5k

Art # A-09815_AB

weld current. (connect pin 2&3 to turn on welding current)

current. (connect pin 2&3 to turn on welding current)

remote control potentiometer

ohm remote control potentiometer

Arc Force is effective when in STICK (MMA) Mode only. Arc Force control provides an adjustable amount of Arc Force (or “dig”) control. This feature can be particularly beneﬁcial in providing the operator the ability to compensate for variability in joint ﬁt-up in certain situations with particular electrodes. In general increasing the Arc Force control toward ‘10’ (maximum Arc Force) allows

Operation 4-2 Manual 0-5149

7 Wiper arm connection to 5k ohm remote

control potentiometer

NOTE

Remote Welding Current Control is not available on this model.

OPERATION THERMAL ARC 201 TS

Art # A-10147

32 Amp Outlet

Output Scale for 110V

Output Scale for 230V

32AOUTLET

STICK

TIG

230V

110V

TIG/STICK

32AOUTLET 16AOUTLET

J. ON/OFF Switch (located on rear panel not shown)

This switch controls the Mains Supply Voltage to the

Power Source.

4.02 Welding Current Control

4.03 STICK (MMA) Electrode Polarity

Stick electrodes are generally connected to the "+" Positive Output Terminal and the work lead to the "−" Negative Output Terminal but if in doubt consult the electrode manufacturers literature for further information.

Explanation

32 Amp Outlet

The mains power 32 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding.

The environmental conditions that may cause the mains power 32 Amp circuit breaker or fuse to trip are:

a) High ambient temperature

b) Worn parts in circuit breaker

c) Using an extension cable

d) Low line mains power voltage

Output Scale for 110V

The inside number scale identiﬁes the available

output weld current for STICK or LIFT TIG weld modes.

STICK Mode:

Exceeding these points will cause nui-

Nuisance tripping should not occur on a 16 Amp outlet.

Output Scale for 230V

The outside number scale identiﬁes the available output weld current for STICK or LIFT TIG/HF TIG weld modes.

Nuisance tripping should not occur on a 32A 230V outlet for both STICK & LIFT TIG/HF TIG Modes.

Identiﬁes the STICK weld point for

32 Amp outlet.

sance tripping of the circuit breaker or fuse.

4.04 Effects of Stick Welding Various Materials

High Tensile and Alloy Steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Manganese Steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

Copper and Alloys

The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections necessary to give proper fusion of weld and base metal.

Types of Electrodes

Arc Welding electrodes are classiﬁed into a number of groups depending on their applications. There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc The range of electrodes dealt

Figure 4-2: Current Control

with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use.

Manual 0-5149 4-3 Operation

THERMAL ARC 201 TS OPERATION

Metal Being Joined Electrode Comments

Mild Steel E6011 This electrode is used for all-position welding or for welding on

rusty, dirty, less-than-new metal. It has a deep, penetrating arc and is often the ﬁrst choice for repair or maintenance work.

Mild Steel E6013 This all-position, electrode is used for welding clean, new sheet

metal. Its soft arc has minimal spatter, moderate penetration and an easy-to-clean slag.

Mild Steel E7014 All positional, ease to use electrode for use on thicker steel than

E6013. Especially suitable sheet metal lap joints and ﬁllet welds, general purpose plate welding.

Mild Steel E7018 A low-hydrogen, all-position electrode used when quality is an

issue or for hard-to-weld metals. It has the capability of producing more uniform weld metal, which has better impact properties at low temperatures.

Cast Iron Eni-Cl Suitable for joining all cast irons except white cast iron.

Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.

4.05 GTAW Electrode Polarity

Connect the TIG torch to the "-" Negative Output Terminal and the work lead to the "+" Positive Output Terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece.

4.06 Guide for Selecting Filler Wire

Filler Wire Diameter DC Current (Amps)

1.6mm (1/16") 20 - 90

2.4mm (3/32") 65 - 115

3.2mm (1/8") 100 - 165

4.07 Tungsten Electrode Current Ranges

Electrode Diameter DC Current

1.0mm (.040”) 25 - 85

1.6mm (1/16”) 50 - 160

2.4mm (3/32”) 135 - 235

4.08 Shielding Gas Selection

Alloy Shielding Gas

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Nickel Alloy Welding Argon

Copper Welding Argon

Titanium Welding Argon

Operation 4-4 Manual 0-5149

OPERATION THERMAL ARC 201 Ts

4.08 Shielding Gas Selection

Alloy Shielding Gas

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Nickel Alloy Welding Argon

Copper Welding Argon

Titanium Welding Argon

4.09 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Ceriated 2%

DC welding of mild steel, stainless steel and copper.

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys.

Welding Application Features Color Code

4.10 TIG Welding Parameters for Steel

DC Current

Base Metal

Thickness

1.0mm

(0.040")

1.2mm

(0.045")

1.6mm (1/16")

3.2mm (1/8")

4.8mm

(3/16")

6.4mm (1/4")

Mild Steel

35-45 20-30

40-50 25-35 Lap/Filler

45-55 30-45

50-60 35-50 Lap/Filler

60-70 40-60

70-90 50-70 Lap/Filler

80-100 65-85

90-115 90-110 Lap/Filler

115-135 100-125

140-165 125-150 Lap/Filler

160-175 135-160

170-200 160-180 Lap/Filler

Stainless

Steel

Electrode Diameter

1.0mm

(0.040")

1.0mm

(0.040")

1.6mm (1/16")

2.4mm (3/32")

3.2mm

(1/8")

Excellent arc starting, long life, high current carrying capacity.

Longer life, more stable arc, easier starting, wider current range, narrower & more concentrated arc.

Filler Rod

Diameter

1.6mm

(1/16" )

1.6mm (1/16")

2.4mm (3/32")

3.2mm

(1/8")

4.0mm (5/32")

Argon Gas Flow

Rate Joint / Type

10 CFH

(5 LPM)

13 CFH

(6 LPM)

15 CFH

(7 LPM)

15CFH

(7 LPM)

21CFH

(10 LPM)

21CFH

(10 LPM)

Red

Grey

Butt/Corner

4.11 Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

Manual 0-5149 4-5 Operation

THERMAL ARC 201 TS OPERATION

4.12 Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in ﬂat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-3 through 4-10.

Art # A-07687

Figure 4-3: Flat position, down hand butt weld

Art A-07691

Figure 4-7: Vertical position, butt weld

Art # A-07688

Figure 4-4: Flat position, gravity ﬁllet weld

Art # A-07689

Figure 4-5: Horizontal position, butt weld

Art # A-07690

Figure 4-6: Horizontal - Vertical (HV) position

Art # A-07692

Figure 4-8: Vertical position, ﬁllet weld

Art# A-07693

Figure 4-9: Overhead position, butt weld

Art # A-07694

Figure 4-10: Overhead position, fillet weld

Operation 4-6 Manual 0-5149

OPERATION THERMAL ARC 201 TS

4.13 Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-11.

Open Square Butt

Joint

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”) depending on plate thickness

Single Vee Butt Joint

Lap Joint

Fillet Joint

Corner Weld

Not less than

45°

Single Vee Butt Joint

Double Vee Butt Joint

Tee Joints

(Fillet both sides of the

joint)

Edge Joint

1.6mm (1/16”)

Not less than

70°

Not less than

70°

1.6mm (1/16” ) max

1.6mm (1/16”) max

Art # A-07695_AE

Plug Weld Plug Weld

Figure 4-11: Typical joint designs for arc welding

Manual 0-5149 4-7 Operation

THERMAL ARC 201 TS OPERATION

4.14 Arc Welding Technique

A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.4mm (1/4") thick and a 3.2mm (1/8") electrode. Clean any paint, loose scale or grease off the plate and set it ﬁrmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job,

otherwise a poor circuit will probably result.

4.15 The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don’t hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will ﬁnd that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won’t be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

4.16 Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at ﬁrst experience difﬁculty due to the tip of the electrode “sticking” to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain a 1.6mm (1/16") to 3.2mm (1/8") gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Art # A-07696

Figure 4-12: Striking an arc

4.17 Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or “touch-weld” electrodes such as E7014 electrode do not stick in this way, and make welding much easier.

4.18 Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20° from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Operation 4-8 Manual 0-5149

OPERATION THERMAL ARC 201 TS

4.19 Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-12, allowing 1.6mm (1/16") to 2.4mm (3/32") gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 6.4mm (1/4") should have their mating edges beveled to form a 70° to 90° included angle. This allows full penetration of the weld metal to the root. Using a

3.2mm (1/8") E7014 electrode at 120 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufﬁcient to produce a well-formed bead. At ﬁrst you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20° from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

Art # A-07697

Figure 4-13: Butt weld

Heavy plate will require several runs to complete the joint. After completing the ﬁrst run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-13. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely ﬁlled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-5.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm (1/8") E7014 electrode at 120 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) ﬁllet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the ﬁllet and about 45° from the vertical. Some electrodes require to be sloped about 20° away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-14. Do not attempt to build up much larger than 6.4mm (1/4") width with a 3.2mm (1/8") electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-15. Weaving in HV ﬁllet welds is undesirable.

Art # A-07698

Figure 4-14: Weld build up sequence

Art # A-07699

Figure 4-15: Electrode position for HV ﬁllet weld

Manual 0-5149 4-9 Operation

THERMAL ARC 201 TS OPERATION

Art # A-07702

Art # A-07700

Figure 4-16: Multi-runs in HV ﬁllet weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your

work bench in an upright position. Use a 3.2mm (1/8") E7014 electrode and set the current at 120 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the ﬁllet. The electrode needs to be about 10° from the horizontal to enable a good bead to be deposited. Refer Figure 4-16. Use a short arc, and do not attempt to weave on the ﬁrst run. When the ﬁrst run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the ﬁrst run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-17 illustrates multi-run technique and Figure 4-18 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Art # A-07701

Figure 4-17: Single run vertical ﬁllet weld

Figure 4-18: Multi run vertical ﬁllet weld

Art # A-07703

Figure 4-19: Examples of vertical ﬁllet welds

2. Vertical Down

The E7014 electrode makes welding in this

position particularly easy. Use a 3.2mm (1/8") electrode at 120 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45°.

3. Overhead Welds

Apart from the rather awkward position neces-

sary, overhead welding is not much more difﬁcult that downhand welding. Set up a specimen for overhead welding by ﬁrst tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45° to the horizontal and tilted 10° in the line of travel (Figure 4-19). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead ﬁllet welds. Use a 3.2mm (1/8") E6012 electrode at 120 amps, and deposit the ﬁrst run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Operation 4-10 Manual 0-5149

OPERATION THERMAL ARC 201 TS

Upsetting

Art # A-07704

Figure 4-20: Overhead ﬁllet weld

4.20 Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do his freely at right angles to the surface of the plate (i.e., “through the weld”), but when it attempts to expand “across the weld” or “along the weld”, it meets considerable resistance, and to fulﬁll the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is “upset”). When the weld area begins to cool, the “upset” metal attempts to contract as much as it expanded, but, because it has been “upset”, it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

4.21 The Cause of Distortion

Distortion is cause by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately

2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses “locked-up” in the structure. If the joint material is relatively weak, for example, a butt joint in 2.0mm (5/64") sheet, the contracting weld metal may cause the sheet to become distorted.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain “locked-up” stresses in the job. Figures 4-20 and 4- 21 illustrate how distortion is created.

Hot

Weld

Hot

Expansion with compression

Cool

Art # A-07705_AB

Figure 4-21: Parent metal expansion

Art # A-07706_AB

Weld

Permanent Upset

Contraction with tension

Figure 4-22: Parent metal contraction

Manual 0-5149 4-11 Operation

THERMAL ARC 201 TS OPERATION

Dotted lines show effect if no preheat is used

4.22 Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is ﬂattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-25 through 4-28 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

Art # A-07708

Weld

PreheatPreheat

Figure 4-24: Reduction of distortion by preheating

Art # A-07709

Figure 4-25: Examples of distortion

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to ﬁnd by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-22.

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-23 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

Art # A-07710

Figure 4-26: Welding sequence

Art # A-07711

Figure 4-27: Step back sequence

Art # A-07428_AB

Art # A-07707

Figure 4-23: Principle of presetting

Figure 4-28: Chain intermittent welding

Art # A-07713_AB

Figure 4-29: Staggered intermittent welding

Operation 4-12 Manual 0-5149

SERVICE THERMAL ARC 201 TS

SECTION 5:

SERVICE

5.01 Maintenance and Inspection

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

There are extremely dangerous voltages and power levels present inside this product. Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

Warning! Disconnect input power before maintaining.

Each Use

To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

Maintain more often if used under severe conditions

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Replace all broken parts

Art # A-10002

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Bring the unit to an authorized Thermal Arc Service Centre to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

Manual 0-5149 5-1 Service

THERMAL ARC 201 TS SERVICE

Insufﬁcient Gap

Incorrect Sequence

Art # A-05866_AC

Art # A-05867_AC

Lack of inter-run fusion

Lack of side fusion, scale dirt, small electrode, amperage too low

Lack of root fusion

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

Art # A-05868_AB

5.02 STICK (MMA) 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.

A. Dry electrodes before use.

B. Reduce welding current.

2. Crack occurring in weld metal soon after solidiﬁcation commences.

3. A gap is left by failure of the weld metal to ﬁll the root of the weld.

4. Portions of the weld run do not fuse to the surface of the metal or edge of the joint

C. Surface impurities such as oil,

grease, paint, etc.

A. Rigidity of joint.

B. Insufficient throat thickness.

C. Cooling rate is too high. A. Welding current is too low.

B. Electrode too large for joint.

C. Insufﬁcient gap.

D. Incorrect sequence.

A. Small electrodes used on

heavy cold plate.

B. Welding current is too low.

C. Wrong electrode angle.

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.

Use larger electrodes and preheat the plate.

B. Increase welding current

C. Adjust angle so the welding arc is

directed more into the base metal

5. Non-metallic particles are trapped in the weld metal (slag inclusion).

D. Travel speed of electrode is too

high.

E. Scale or dirt on joint surface.

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.

D. Reduce travel speed of electrode

E. Clean surface before welding.

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.

Service 5-2 Manual 0-5149

SERVICE THERMAL ARC 201 TS

5.03 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description Possible Cause Remedy

1. Excessive bead build-up or poor penetration or poor fusion at edges of weld.

2. Weld bead too wide and ﬂat or undercut at edges of weld or excessive burn through.

3. Weld bead too small or insufﬁcient penetration or ripples in bead are widely spaced apart.

4. Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

5. Uneven leg length in ﬁllet joint. Wrong placement of ﬁller rod. Re-position ﬁller rod.

6. Electrode melts when arc is struck.

7. Dirty weld pool. A. Electrode contaminated through

8. Poor weld ﬁnish. Inadequate shielding gas. Increase gas ﬂow or check gas line

9. Arc ﬂutters during TIG welding. Tungsten electrode is too large

10. Welding arc cannot be established.

11. Electrode melts or oxidizes when an arc is struck.

Welding current is too low Increase weld current and/or

change joint preparation.

Welding current is too high. Decrease welding current.

Travel speed too fast. Reduce travel speed.

Travel speed is too slow. Increase travel speed.

 Electrodeisconnectedtothe"+"

Positive Output Terminal.

contact with work piece or ﬁller rod material.

B. Gas contaminated with air.

for the welding current.

A. Work clamp is not connected to

the work piece or the work/torch leads are not connected to the correct welding terminals.

B. Torch lead is disconnected.

C. Gas ﬂow incorrectly set, cylinder

empty or the torch valve is off.

A. No gas is flowing to welding

region. B. Torch is clogged with dust. C. Gas hose is cut. D. Gas passage contains impurities.

E. Gas regulator turned off. F. Torch valve is turned off. G. The electrode is too small for the

welding current.

Connect the electrode to the

"-"NegativeOutputTerminal.

A. Clean the electrode by grinding

contaminates off.

B. Check gas lines for cuts and loose

ﬁtting or change gas cylinder.

for problems

Select the right size electrode.

Refer to section Tungsten Electrode Current Ranges.

A. Connect the work clamp to the

work piece or connect the work/ torch leads to the correct welding terminals.

B. Connect it to the"-" Negative

Output Terminal.

C. Select the right ﬂow rate, change

cylinder or turn torch valve on.

A. Check the gas lines for kinks or

breaks or cylinder contains gas. B. Clean torch. C. Replace gas hose. D. Disconnect gas hose from torch

then raise gas pressure and blow

out impurities. E. Turn on. F. Turn on. G. Increase electrode diameter or

reduce the welding current.

Manual 0-5149 5-3 Service

THERMAL ARC 201 TS SERVICE

TIG Welding Problems (Continued)

Description Possible Cause Remedy

12. Arc start is not smooth. A. Tungsten electrode is too large for the welding current.

B. The wrong electrode is being

used for the welding job.

C. Gas ﬂow rate is too high.

D. Incorrect shield gas is being

used.

E. Poor work clamp connection

to work piece.

A. Refer to section Tungsten Electrode

Current Ranges for the correct size.

B. Refer to section Tungsten Electrode

Types for the correct electrode type.

C. Select the correct ﬂow rate for the

welding job.

D. Use 100% argon for TIG welding.

E. Improve connection to work piece.

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair.

5.04 Power Source Problems

Description Possible Cause Remedy

1. The welding arc cannot be established.

2. The welding arc cannot be established when the Warning Indicator lights up continuously

A. The Primary supply voltage

has not been switched ON.

B. The Welding Power Source

switch is switched OFF.

C. Loose connections internally.

The machines duty cycle has been exceeded

A. Switch ON the Primary

supply voltage.

B. Switch ON the Welding

Power Source.

C. Have an Accredited Thermal

Arc Service Provider repair the connection.

Wait for the Warning Indicator to extinguish before resuming welding

3. Maximum output welding current cannot be achieved with nominal Mains supply voltage.

4. Welding current reduces when welding.

5. Circuit breaker (or fuse) trips during welding.

6. The welding arc cannot be established when Fault Indicator is flashing.

Service 5-4 Manual 0-5149

Defective control circuit Have an Accredited Thermal Arc

Service Provider inspect then repair the welder.

Poor work lead connection to the work piece.

The circuit breaker (or fuse) is under size.

The input current to the main transformer has been exceeded.

Ensure that the work lead has a positive electrical connection to the work piece.

The recommended circuit breaker (or fuse) size is 32 amp. An individual branch circuit capable of carrying 32 amperes and protected by fuses or circuit breaker is recommended for this application. Have an Accredited Thermal Arc Service Provider inspect then repair the welder.

APPENDIX THERMAL ARC 201 Ts

APPENDIX 1: OPTIONS AND ACCESSORIES

Description Part Number

26 TIG Torch with 12.5ft lead, finger remote control, 50mm dinse connection and accessory kit

Foot Control, 8 pin amphenol, 15ft 600285 Slider Current Control with Torch Switch, 15ft, suits 1-1/8" dia. 26 TIG Torch Handle 10-4010 USA Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4011700 Canadian Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4011800 Claret Color Auto-Darkening welding helmet, spare cover lens and operating manual W4011900 Black Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4012000

W4013601

Manual 0-5149 A-1 Appendix

THERMAL ARC 201 Ts APPENDIX

APPENDIX 2: REPLACEMENT PARTS

Item

1 Handle W7003040

2 Panel, Cover W7003200

3 Rectiﬁer 1000V,50A W7003010

4 PCB, Control, 201 TS W7003222 PCB2

5 Thermostat W7003016 THC1, THC2

6 Resistor,4 ohm,60W W7003055 R1

7 PCB, Power, 201 TS W7003216 PCB1

8 Insulation Sheet W7003214

9 Points, HF Starter, 201 TS W7003034

10 Output Inductor Ferrite Core W7003210

11 Front Control PCB3 W7003218 PCB3

12 Front Panel W7003205

13 Front Panel Label W7003219

14 Rubber Boot W7003064

15 Knob, control, Red, 21 ODx6 ID W7003079

Connector, Gas Outlet, 161 STL-201

Description Part No. Reference Designator

W7003212

17 Output Terminal, 50mm dinse W7003020

18 Socket, 8 Pin, cable, 161 STL-201 TS W7003220

19 Gas Solenoid W7003033

20 Current Sensor, 161-201TS W7003076 Current Sensor

21 Base Panel W7003209

22 Fan,24V DC W7003090

23 Rear Panel W7003201

24 Connector, Gas Inlet, 161 STL-201 TS W7003215

25 ON/OFF Switch W7003053 SW1

26 PCB, Remote, 161 STL-201 TS W7003221 PCB4

WARNING

Appendix A-2 Manual 0-5149

APPENDIX THERMAL ARC 201 TS

Art # A-10148

Manual 0-5149 A-3 Appendix

THERMAL ARC 201 TS APPENDIX

54321

APPENDIX 3: 201 TS SYSTEM SCHEMATIC

INPUT 230VAC/110VAC

PCB MOUNTED HARNESS CONNECTORS PIN OUT

VIEWED FROM COMPONENT SIDE OF BOARD

123

82J,71J,41J,11J,2J72J,62J,21J,9J

J3,J4,J23,J15,J16,J21,J25

2141

J6,

,J22,J18

J7,J19

J30

J8,J24

610

50/60Hz

SHEETMETAL COVER

60W4Ω

ACOUT

J22-1

J22-2

J1,J10

+15V

J21-1

J21-2

GND

JC1

110VAC --155VDC

230VAC --325VDC

J29

J20

J5,J13

J14-1

J14-2

J14-3

WHITE

RED

Main Power PCB1

J20-1

J20-2

J20-3

J20-4

J20-5

J20-6

Over Current Signal

J23-2

J23-1

OC1JC2JC3

Over Current Signal

J15-1

J15-2

OC2

HFOUT

J30-1

J30-2

J30-3

J30-4

PFC CIRCUIT

J19

SWOUT

SWIN

J17J18

OC1IN

J21

RX24

JC1

J22

DY2

J11

FJ/QFDY1 JC3

J20

WVOUT

JC2

OC2

J15

HFOUT

41J31J21J01J32J

J16

J30

DSGDS

BLACK

RED

J19-1

J19-2

J19-3

RX24

ACOUT

DC -

DC +

FJ/QF

CONNECTOR LAYOUT DIAGRAM

J12-1

GND

J12-2

+24V

J12-3

+24V

J12-4

DY1

+24V

J13-1

J13-2

J13-3

J13-4

GND

J13-5

J10-1

J10-2

J10-3

J10-4

J10-5

J10-6

J10-7

DY2SWO UT

J11-1

-24V

J11-2

GND

J11-3

+24V

J18-1

+24V

J18-2

JC SWIN

J16-1

J16-2

J17-1

J17-2

J17-3

WVOUT

BLACK

RED

FAN

SOLENOID

GAS

J5-1

J5-2

J5-3

J5-4

SOU/HF/QF

J5-5

GND

J1-1

Over Current Signal

J1-2

IGBT Driver A

J1-3

J1-4

IGBT Driver B

J1-5

IGBT Driver B

J1-6

IGBT Driver A

+15V

J1-7

Control PCB2

J2-1

J2-2

J2-3

J6-1

J6-2

J7-1

J7-2

J7-3

+15V

J9-4

GUNPOWER

Current Feedback

GND

-15V

J9-1

J9-2

J9-3

THC2

THC1

J3-2

J4-1

J4-2

J3-1

OT2

OT1

J1 J2

CONNECTOR LAYOUT DIAGRAM

POWER

OT1

J3 J4

SOU/HF/QF

J7J8J9

OT2

GUN

VWBMWA

J8-10

J8-9

J8-8

J8-7

J8-6

J8-5

J8-4

J8-3

J8-2

J8-1

Current Sensor

NEG

POS

GRAY

YELLOW

WHITE

RED

J25-1

J25-2

J24-10

J26-1

J26-2

J26-3

J29-5

568

Remote PCB4

J29-7

J29-6

J26-4

R-G

J29-8

J-RC

J27-1

J27-2

J27-3

J27-4

GUN1

TIG Torch

Switch Signal

J28-1

J28-3

J29-2

J29-1

J29-4

J29-3

J24-9

110VAC --4.5VDC

230VAC --0.05VDC

J-MB

DOWN SLOPE/

ARC FORCE CONTROL

CONTROL

Front Panel PCB3

J24-2

J24-8

SELECTION SWITCH

WELD

CURRENT

J24-1

J24-4

J24-3

J24-7

J24-6

J24-5

TRIGGER MODE

PROCESS SELECTION

SWITCH

POWER ON INDICATOR

FAULT INDICATOR

Art # A-10149_AB

Appendix A-4 Manual 0-5149

LIMITED WARRANTY & WARRANTY SCHEDULE

In accordance with the warranty periods stated below, Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as deﬁned in this operating manual.

Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.

Welding Equipment - Limited Warranty Period

Product Period

ermal Arc 201TS

2 Years

TIG torch, electrode holder and work lead 30 Days

If warranty is being sought Thermadyne must be notiﬁed in writing within 30 days of the failure and at such time we will make arrangements to fulﬁl the warranty claim. Please contact your Thermadyne product supplier for the warranty repair procedure.

Thermadyne warranty will not apply to:

• EquipmentthathasbeenmodiedbyanyotherpartyotherthanThermadyne’sownservicepersonnelor

with prior written consent obtained from Thermadyne service department (UK).

• Equipmentthathasbeenusedbeyondthespecicationsestablishedintheoperatingmanual.

• Installationnotinaccordancewiththeinstallation/operatingmanual.

• Anyproductthathasbeensubjectedtoabuse,misuse,negligence,accident,impropercareand/ormain-

tenance including lack of lubrication, maintenance and protection, will be refused warranty.

• Failuretocleanandmaintainthemachineassetforthintheoperating,installationorservicemanual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation. This manual also offers basic troubleshooting, operational and technical details including application usage.

Using this manual correctly will ensure the quickest time possible for resolving any technical questions, application issues or defects with your Thermadyne product.

You may also wish to visit our web site www.thermadyne.com select your product class and then select literature. Here you will ﬁnd documentation including:

• Operatormanuals

• Servicemanuals

• Productguides

Alternatively please contact your Thermadyne distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne distributor or an Authorised Service Agent approved by the Company.

Customer Care UK: +44 (0)1257 261 755 / Fax: +44 (0)1257 224 800

Customer Care Italy +39 02 36546801 / Fax: +39 02 36546480

www.thermadyne.com

A Global Cutting & Welding Market Leader

WORLD HEADQUARTERS: 16052 Swingley R idge Road, Suite 300 • St. Louis, Missouri 63017 U.S.A.

THE AMERICAS EUROPE ASIA/PACIFIC

Denton, TX USA U.S. Customer Care

Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph: 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph: 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

Chorley, United Kingdom Customer Care

Ph: +44 1257-261755 Fax: +44 1257-224800

Milan, Italy Customer Care

Ph: +39 0236546801 Fax: +39 0236546840

Cikarang, Indonesia Customer Care

Ph: 6221-8990-6095 Fax: 6221-8990-6096

Rawang, Malaysia Customer Care

Ph: +603 6092-2988 Fax: +603 6092-1085

Melbourne, Australia Australia Customer Care

Ph: 1300-654-674 (tollfree) Ph: 61-3-9474-7400 Fax: 61-3-9474-7391

International

Ph: 61-3-9474-7508 Fax: 61-3-9474-7488

Shanghai, China Sales Office

Ph: +86 21-64072626 Fax: +86 21-64483032

Singapore Sales Office

Ph: +65 6832-8066 Fax: +65 6763-5812

™

Tweco 201-ts User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 ARC WELDING HAZARDS

1.02 PRINCIPAL SAFETY STANDARDS

1.03 Declaration of conformity

2.01 How to Use This Manual

2.03 Receipt of Equipment

2.04 Transportation Methods

2.05 Symbol Chart

2.06 Description

2.07 User Responsibility

2.08 Duty Cycle

3.01 ENVIRONMENT

3.02 LOCATION

3.03 ELECTRICAL INPUT CONNECTIONS

3.04 ELECTROMAGNETIC COMPATIBILITY

3.05 SETUP FOR WELDING

3.06 STICK (MMA) SETUP

3.07 LIFT TIG / HF TIG (GTAW) SETUP

3.08 LEAK TESTING THE SYSTEM

3.09 WHEN YOU FINISH USING THE REGULATOR

3.10 STORAGE OF THE REGULATOR

4.01 Front Panel

4.03 STICK (MMA) Electrode Polarity

4.04 Effects of Stick Welding Various Materials

4.05 GTAW Electrode Polarity

4.06 Guide for Selecting Filler Wire

4.07 Tungsten Electrode Current Ranges

4.08 Shielding Gas Selection

4.09 Tungsten Electrode Types

4.10 TIG Welding Parameters for Steel

4.11 Arc Welding Practice

4.12 Welding Position

4.13 Joint Preparations

4.14 Arc Welding Technique

4.15 The Welder

4.16 Striking the Arc

4.17 Arc Length

4.18 Rate of Travel

4.19 Making Welded Joints

4.20 Distortion

4.21 The Cause of Distortion

4.22 Overcoming Distortion Effects

5.01 Maintenance and Inspection

5.02 STICK (MMA) Welding Problems

5.03 TIG Welding Problems

5.04 Power Source Problems

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: REPLACEMENT PARTS

APPENDIX 3: 201 TS SYSTEM SCHEMATIC

LIMITED WARRANTY & WARRANTY SCHEDULE