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
Hz
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then check for a newer version of the manual on our website or contact our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
Copyright 2011 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: 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
• ThermalArc201TSpowersupplyintoolbox
• 26TIGtorch,3.8m(12.5ft)withIntegratedControls&accessoryKit
• Electrodeholder,5m(16.4ft)
• Worklead,5m(16.4ft)
• 4GP3.2mm(1/8")diastickelectrodes
• ThermalArc201TSGasHoselead4m(13ft)
• Operatingmanual
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:
• CENELECEN50199EMCProductStandardforArcWeldingEquipment.
• ISO/IEC60974-1(BS638-PT10)(EN60974-1)(EN50192)(EN50078)applicabletoweldingequipment
and associated accessories.
• For environmentswith increasedhazard ofelectrical shock,PowerSupplies bearingthe Smark
conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if
equipped with properly installed standoff guides.
• Extensiveproductdesignverificationisconductedatthemanufacturingfacilityas partoftheroutine
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
withthedistributionnetworkoperatorifnecessary,thattheequipmentmaybeconnected.
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
OperationsDirector
Thermadyne Europe
Europa Building
ChorleyNIndustrialPark
Chorley, Lancashire,
EnglandPR67BX
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
On
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
t
t1
t2
%
X
IPM
MPM
t
V
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
Loading...