Thermal Arc 201 TS User manual

Art # A-10139

32AOUTLET

STICK

TIG

230V

110V

TIG/STICK

32AOUTLET

16AOUTLET

201 TS

Operating Manual

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

Operating Features:

THERMAL ARC

INVERTER ARC WELDER

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as

our customer and will strive to provide you with the best service and reliability

in the industry. This product is backed by our extensive warranty and world-

wide service network. To locate your nearest distributor or service agency call

+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then check for a newer version of the manual on our website or contact our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 sec-

tors 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

Thermadyne Industries, Inc.

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

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

Art # A-10140

THERMAL ARC 201 TS SAFE INSTRUCTION

Manual 0-5149 1-1 General Information

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 when-

ever the output is on. The input power cir-

cuit 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.

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 acciden-

tally.

5. Properly install and ground this equipment accord-

ing to its Owner’s Manual and national, state, and

local codes.

6. Turn off all equipment when not in use. Disconnect

power to equipment if it will be left unattended or

out of service.

7. Use fully insulated electrode holders. Never dip

holder in water to cool it or lay it down on the

ground or the work surface. Do not touch holders

connected to two welding machines at the same

time or touch other people with the holder or

electrode.

8. Do not use worn, damaged, undersized, or poorly

spliced cables.

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth)

ground.

11.Do not touch electrode while in contact with the

work (ground) circuit.

12.Use only well-maintained equipment. Repair or

replace damaged parts at once.

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

welder with AC output unless it is equipped with a

voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working

above ﬂoor level.

15.Keep all panels and covers securely in place.

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE

INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or

property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be

learned through study and training before using this equipment. Some of these practices apply to equipment

connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive

training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the 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.

SAFE INSTRUCTION THERMAL ARC 201 TS

General Information 1-2 Manual 0-5149

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 recom-

mended.

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.

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 venti-

lated, 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.

Eye protection ﬁlter shade selector for welding or cutting

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

Welding or Cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Welding or Cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Torch soldering 2 Gas metal-arc

welding (MIG)

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

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in.,

4 to 6.4 mm 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

THERMAL ARC 201 TS SAFE INSTRUCTION

Manual 0-5149 1-3 General Information

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

lead, or cadmium plated steel, unless the coating

is removed from the weld area, the area is well

ventilated, and if necessary, while wearing an air-

supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes

if welded.

WARNING

WELDING can cause ﬁre or explosion.

Sparks and spatter ﬂy off from the welding

arc. The ﬂying sparks and hot metal, weld

spatter, hot workpiece, and hot equipment

can cause ﬁres and burns. Accidental con-

tact of electrode or welding wire to metal

objects can cause sparks, overheating,

or ﬁre.

1. Protect yourself and others from ﬂying sparks and

hot metal.

2. Do not weld where ﬂying sparks can strike ﬂam-

mable 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 cur-

rent from traveling long, possibly unknown paths

and causing electric shock and ﬁre hazards.

9. Do not use welder to thaw frozen pipes.

10.Remove stick electrode from holder or cut off

welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can

cause injury.

Chipping and grinding cause ﬂying metal.

As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side

shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under

high pressure. If damaged, a cylinder can

explode. Since gas cylinders are normally

part of the welding process, be sure to

treat them carefully.

1. Protect compressed gas cylinders from excessive

heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position

by chaining them to a stationary support or equip-

ment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other

electrical circuits.

4. Never allow a welding electrode to touch any

cylinder.

5. Use only correct shielding gas cylinders, regulators,

hoses, and fittings designed for the specific

application; maintain them and associated parts

in good condition.

6. Turn face away from valve outlet when opening

cylinder valve.

7. Keep protective cap in place over valve except

when cylinder is in use or connected for use.

8. Read and follow instructions on compressed

gas cylinders, associated equipment, and CGA

publication P-1 listed in Safety Standards.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated

areas.

2. If used in a closed area, vent engine exhaust out-

side and away from any building air intakes.

SAFE INSTRUCTION THERMAL ARC 201 TS

General Information 1-4 Manual 0-5149

WARNING

ENGINE FUEL can cause ﬁre or explosion.

Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near

any sparks or open ﬂames.

3. Allow engine to cool before fueling. If possible,

check and add fuel to cold engine before beginning

job.

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

expand.

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

starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut

ﬁngers and hands and catch loose clothing.

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

and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or

covers for maintenance and troubleshooting as

necessary.

4. To prevent accidental starting during servicing,

disconnect negative (-) battery cable from bat-

tery.

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 bat-

tery.

2. Stop engine before disconnecting or connecting

battery cables.

3. Do not allow tools to cause sparks when

working on a battery.

4. Do not use welder to charge batteries or jump

start vehicles.

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

WARNING

STEAM AND PRESSURIZED HOT COOL-

ANT 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 re-

moving cap.

LEAD WARNING

This product contains chemicals, includ-

ing lead, or otherwise produces chemicals

known to the State of California to cause

cancer, birth defects and other reproduc-

tive harm. Wash hands after handling.

(California Health & Safety Code § 25249.5

et seq.)

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 Conclu-

sions Section of the U.S. Congress, Ofﬁce of Tech-

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