201 Ts Manual

201 TS
tHERMAL aRC
inverter ARC weldER
STICK 32A OUTLET

TIG 32A OUTLET 110V
TIG/STICK 16A OUTLET
230V
Art # A-10139
Operating Manual
Revision: AB Issue Date: May 20, 2011 Manual No.: 0-5149
Operating Features:
50Hz
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 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then check for a newer version of the manual on our website or contact our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
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
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
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.
1.01 Arc Welding Hazards 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
WARNING holder in water to cool it or lay it down on the
ELECTRIC SHOCK can kill. ground or the work surface. Do not touch holders
connected to two welding machines at the same
Touching live electrical parts can cause time or touch other people with the holder or
fatal shocks or severe burns. The electrode electrode.
and work circuit is electrically live when-
ever the output is on. The input power cir- 8. Do not use worn, damaged, undersized, or poorly
cuit and machine internal circuits are also spliced cables.
live when power is on. In semiautomatic 9. Do not wrap cables around your body.
or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts 10. Ground the workpiece to a good electrical (earth)
touching the welding wire are electrically ground.
live. Incorrectly installed or improperly 11. Do not touch electrode while in contact with the
grounded equipment is a hazard. work (ground) circuit.
1. Do not touch live electrical parts.
12. Use only well-maintained equipment. Repair or
2. Wear dry, hole-free insulating gloves and body replace damaged parts at once.
protection.
13. In confined spaces or damp locations, do not use a
3. Insulate yourself from work and ground using dry welder with AC output unless it is equipped with a
insulating mats or covers. voltage reducer. Use equipment with DC output.
4. Disconnect input power or stop engine before 14. Wear a safety harness to prevent falling if working
installing or servicing this equipment. Lock input above floor level.
power disconnect switch open, or remove line
15. Keep all panels and covers securely in place.
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.
Manual 0-5149 1-1 General Information
SAFE INSTRUCTION THERMAL ARC 201 TS
WARNING
WARNING
FUMES AND GASES can be hazardous to
ARC RAYS can burn eyes and skin; NOISE your health.
can damage hearing.
Welding produces fumes and gases.
Arc rays from the welding process produce Breathing these fumes and gases can be
intense heat and strong ultraviolet rays hazardous to your health.
that can burn eyes and skin. Noise from
some processes can damage hearing. 1. Keep your head out of the fumes. Do not breath
the fumes.
1. Use a Welding Helmet or Welding Faceshield fitted
with a proper shade of filter (see ANSI Z49.1 and 2. If inside, ventilate the area and/or use exhaust at
EN 60974-1 listed in Safety Standards) to protect the arc to remove welding fumes and gases.
your face and eyes when welding or watching.
3. If ventilation is poor, use an approved air-supplied
2. Wear approved safety glasses. Side shields recom- respirator.
mended.
4. Read the Material Safety Data Sheets (MSDSs)
3. Use protective screens or barriers to protect others and the manufacturer’s instruction for metals,
from flash and glare; warn others not to watch the consumables, coatings, and cleaners.
arc.
5. Work in a confined space only if it is well venti-
4. Wear protective clothing made from durable, lated, or while wearing an air-supplied respirator.
flame-resistant material (wool and leather) and Shielding gases used for welding can displace air
foot protection. causing injury or death. Be sure the breathing air
is safe.
5. Use approved ear plugs or ear muffs if noise level
is high. 6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
6. Never wear contact lenses while welding. 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.
Electrode Size Filter Electrode Size Filter

Welding or Cutting Welding or Cutting
Metal Thickness Shade Metal Thickness Shade
Operation Operation
or Welding Current No. or Welding Current No.
Gas metal-arc
Torch soldering 2
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 Under 5/32 in., 4 mm 10 Heavy 14
(stick) electrodes
5/32 to 1/4 in.,
12 Plasma arc cutting
4 to 6.4 mm
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
General Information 1-2 Manual 0-5149

7. Do not weld on coated metals, such as galvanized, 1. Wear approved face shield or safety goggles. Side
lead, or cadmium plated steel, unless the coating shields recommended.
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air- 2. Wear proper body protection to protect skin.
supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded. WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
WARNING high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
WELDING can cause fire or explosion.
part of the welding process, be sure to
Sparks and spatter fly off from the welding treat them carefully.
arc. The flying sparks and hot metal, weld
1. Protect compressed gas cylinders from excessive
spatter, hot workpiece, and hot equipment
heat, mechanical shocks, and arcs.
can cause fires and burns. Accidental con-
tact of electrode or welding wire to metal 2. Install and secure cylinders in an upright position
objects can cause sparks, overheating, by chaining them to a stationary support or equip-
or fire. ment cylinder rack to prevent falling or tipping.
1. Protect yourself and others from flying sparks and 3. Keep cylinders away from any welding or other
hot metal. electrical circuits.
2. Do not weld where flying sparks can strike flam- 4. Never allow a welding electrode to touch any
mable material. cylinder.
3. Remove all flammables within 10.7 m (35 ft) of the 5. Use only correct shielding gas cylinders, regulators,
welding arc. If this is not possible, tightly cover hoses, and fittings designed for the specific
them with approved covers. application; maintain them and associated parts
in good condition.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and 6. Turn face away from valve outlet when opening
openings to adjacent areas. cylinder valve.
5. Watch for fire, and keep a fire extinguisher 7. Keep protective cap in place over valve except
nearby. when cylinder is in use or connected for use.
6. Be aware that welding on a ceiling, floor, bulkhead, 8. Read and follow instructions on compressed
or partition can cause fire on the hidden side. gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
! WARNING
welding area as practical to prevent welding cur-
Engines can be dangerous.
rent from traveling long, possibly unknown paths
and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
WARNING
10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use. ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
WARNING 1. Use equipment outside in open, well-ventilated

areas.
FLYING SPARKS AND HOT METAL can
cause injury. 2. If used in a closed area, vent engine exhaust out-
side and away from any building air intakes.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.

4. Do not use welder to charge batteries or jump
WARNING start vehicles.
ENGINE FUEL can cause fire or explosion. 5. Observe correct polarity (+ and –) on batteries.
Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel. WARNING
2. Do not add fuel while smoking or if unit is near STEAM AND PRESSURIZED HOT COOL-
any sparks or open flames. ANT can burn face, eyes, and skin.
3. Allow engine to cool before fueling. If possible, The coolant in the radiator can be very hot
check and add fuel to cold engine before beginning and under pressure.
job.
1. Do not remove radiator cap when engine is hot.
4. Do not overfill tank — allow room for fuel to Allow engine to cool.
expand.
2. Wear gloves and put a rag over cap area when
5. Do not spill fuel. If fuel is spilled, clean up before removing cap.
starting engine.
3. Allow pressure to escape before completely re-
moving cap.
WARNING
MOVING PARTS can cause injury.
LEAD WARNING
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing. This product contains chemicals, includ-
ing lead, or otherwise produces chemicals
1. Keep all doors, panels, covers, and guards closed
known to the State of California to cause
and securely in place.
cancer, birth defects and other reproduc-
2. Stop engine before installing or connecting unit. tive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5
3. Have only qualified people remove guards or et seq.)
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from bat-
tery. WARNING
5. Keep hands, hair, loose clothing, and tools away This product, when used for welding or
from moving parts. cutting, produces fumes or gases which
contain chemicals know to the State of
6. Reinstall panels or guards and close doors when California to cause birth defects and, in
servicing is finished and before starting engine. some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
NOTE
WARNING
SPARKS can cause BATTERY GASES TO Considerations About Welding And The
EXPLODE; BATTERY ACID can burn eyes Effects of Low Frequency Electric and
and skin. Magnetic Fields
The following is a quotation from the General Conclu-
Batteries contain acid and generate explosive gases. sions Section of the U.S. Congress, Office of Tech-
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.
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, Stan-
dards 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.

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.
! WARNING
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:
Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

INTRODUCTION THERMAL ARC 201 TS
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual 2.02 Equipment Identification
This Manual usually applies to the part numbers listed The unit’s identification number (specification or part
on page i. To ensure safe operation, read the entire number), model, and serial number usually appear
manual, including the chapter on safety instructions on a nameplate attached to the machine. Equipment
and warnings. Throughout this manual, the word which does not have a nameplate attached to the
WARNING, CAUTION and NOTE may appear. Pay machine is identified only by the specification or part
particular attention to the information provided under number printed on the shipping container. Record
these headings. These special annotations are easily these numbers for future reference.
recognized as follows:
2.03 Receipt of Equipment
! WARNING When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
Gives information regarding possible per- the equipment for possible damage due to shipping.
sonal injury. Warnings will be enclosed in If there is any damage, notify the carrier immediately
a box such as this. to file a claim. Furnish complete information concern-
ing damage claims or shipping errors to the location
in your area listed in the inside back cover of this
CAUTION
manual. Include all equipment identification numbers
Refers to possible equipment damage. as described above along with a full description of
Cautions will be shown in bold type. the parts in error.
NOTE
2.04 Transportation Methods
Offers helpful information concerning
certain operating procedures. Notes will
be shown in italics ! Disconnect input power
You will also notice icons from the safety section ap-
conductors from de-energized supply line before
pearing throughout the manual. These are to advise
moving the welding power source.
you of specific types of hazards or cautions related
to the portion of information that follows. Some Lift unit with handle on top of case. Use handcart or
may have multiple hazards that apply and would look similar device of adequate capacity. If using a fork
something like this: lift vehicle, secure the unit on a proper skid before
transporting.
Manual 0-5149 2-1 Introduction

THERMAL ARC 201 TS INTRODUCTION
2.05 Symbol Chart
Note that only some of these symbols will appear on your model.
On Single Phase Wire Feed Function
Wire Feed Towards

Off Three Phase Workpiece With
Output Voltage Off.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier
Increase/Decrease Remote Purging Of Gas
X
Continuous Weld
Circuit Breaker Duty Cycle
Mode
AC Auxiliary Power % Percentage Spot Weld Mode
Fuse Panel/Local Spot Time

t
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
Gas Metal Arc

Voltage t2
Postflow Time
Welding (GMAW)
Gas Tungsten Arc 2 Step Trigger

Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)
Negative Constant Current 4 Step Trigger

Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive hold for preflow.
Or Constant Potential
Direct Current (DC) High Temperature t Burnback Time
Protective Earth Disturbance In

(Ground) Fault Indication Ground System
Line Arc Force IPM Inches Per Minute
Line Connection Touch Start (GTAW) MPM Meters Per Minute
Auxiliary Power Variable Inductance

Art # A-04937
115V 15A Receptacle Rating-

V Voltage Input
Auxiliary Power
Introduction 2-2 Manual 0-5149

2.06 Description 2.07 User Responsibility
This compact inverter welding machine has infinitely This equipment will perform as per the information
adjustable welding current from 10 to 200 amps. contained herein when installed, operated, maintained
The 201TS has a LIFT TIG (GTAW) and HF TIG and repaired in accordance with the instructions pro-
(GTAW) welding mode that offers stable TIG welding vided. This equipment must be checked periodically.
characteristics with an optimized start TIG sequence Defective equipment (including welding leads) should
to initiate the welding arc when used with a suitable not be used. Parts that are broken, missing, plainly
TIG torch and shielding gas. Advanced TIG features worn, distorted or contaminated, should be replaced
include 8 Pin Amp Plug for remote control devices, immediately. Should such repairs or replacements
down slope, 2T / 4T controls, and gas solenoid become necessary, it is recommended that such re-
operation. It also has STICK (MMA) welding mode pairs be carried out by appropriately qualified persons
which uses standard general purpose STICK (MMA) approved by Thermal Arc. Advice in this regard can
2.5mm (3/32”) electrodes for light gauge work, be obtained by contacting an Accredited Thermal Arc
generally less than 3.2mm (1/8”) thick and STICK Distributor.
(MMA) 3.2mm (1/8”) electrodes for heavier material.
This equipment or any of its parts should not be al-
tered 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.

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.
100 110VAC INPUT
90
80 TIG (GTAW)
Duty Cycle (percentage)@40°C
70
60
Safe
50
40 Operating
30 Region Stick (MMA)

20
10
0
0 20 40 60 80 100 120 140 160
Welding Current (amps)
Art # A-10141
100 230VAC INPUT
90
80
Duty Cycle (percentage)@40°C
70
60
Safe
50
40 Operating
30 Region TIG (GTAW)

20
10
0
0 20 40 60 80 100 120 140 160 180 200
Welding Current (amps)
Art # A-10142
Figure 2-1: Thermal Arc 201 TS Duty Cycle

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 Stick/TIG:
TIG: 10 - 160 Amps 10 - 200 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min. 125A @ 25%, 25.0V 200A @ 20%, 28V
(Quoted figures refer to STICK (MMA) output) 95A @ 60%, 23.8V 120A @ 60%, 24.8V
80A @ 100%, 23.2V 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 DinseTM 50
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 H230mm x W135mm x D450mm
Width x Depth) ( H 9.0” x W 5.3” x D 17.7”)
∆ The recommended time delay fuse or circuit breaker size is 32 amp for 110V and 32 amp for 230V.

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.

INSTALLATION THERMAL ARC 201 TS
SECTION 3:
INSTALLATION, OPERATION AND SETUP
H. Precautions must be taken against the power
3.01 Environment
source toppling over. The power source must
These units are designed for use in environments be located on a suitable horizontal surface in the
with increased hazard of electric shock. Examples upright position when in use.
of environments with increased hazard of electric
shock are: ! WARNING
A. In locations in which freedom of movement
Thermal Arc advises that this equipment
is restricted, so that the operator is forced
be electrically connected by a qualified
to perform the work in a cramped (kneeling,
electrician.
sitting or lying) position with physical contact
with conductive parts.
3.03 Electrical Input
B. In locations which are fully or partially limited Connections
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 WARNING
or perspiration considerable reduces the skin ELECTRIC SHOCK can kill; SIGNIFICANT
resistance of the human body and the insulation DC VOLTAGE is present after removal of
properties of accessories. input power.
Environments with increased hazard of electric shock
DO NOT TOUCH live electrical parts.
do not include places where electrically conductive
parts in the near vicinity of the operator, which can SHUT DOWN welding power source, disconnect input
cause increased hazard, have been insulated. power employing lockout/tagging procedures. Lock-
out/tagging procedures consist of padlocking line
3.02 Location disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
Be sure to locate the welder according to the following breaker or other disconnecting device.
guidelines:
• Electrical Input Requirements
A. In areas, free from moisture and dust.
Operate the welding power source from a single-phase
B. Ambient temperature between 0° C to 40° C. 50/60 Hz, AC power supply. The input voltage must
C. In areas, free from oil, steam and corrosive match one of the electrical input voltages shown on
gases. the input data label on the unit nameplate. Contact the
local electric utility for information about the type of
D. In areas, not subjected to abnormal vibration or electrical service available, how proper connections
shock. should be made, and inspection required. The line
E. In areas, not exposed to direct sunlight or rain. disconnect switch provides a safe and convenient
means to completely remove all electrical power
F. Place at a distance of 300mm or more from walls from the welding power supply whenever necessary
or similar that could restrict natural air flow for to inspect or service the unit.
cooling.
Do not connect an input (BROWN or BLUE) conductor
G. The enclosure design of this power source to the ground terminal.
meets the requirements of IP23S as outlined in
EN 60529. This provides adequate protection Do not connect the ground (GREEN or GREEN/
against solid objects (greater than 12mm), and YELLOW) conductor to an input line terminal.
direct protection from vertical drops. Under no Refer to Figure 3-1:
circumstances should the unit be operated or
connected in a micro environment that will exceed 1. Connect end of ground (GREEN or GREEN/
the stated conditions. For further information YELLOW) conductor to a suitable ground. Use
please refer to EN 60529. 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
Primary Power Cable

Art# A-10143
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

NOTE
Damage to the PCA could occur if 265 VAC or higher is applied to the Primary Power Cable.
Model Primary Supply Lead Minimum Primary Current & Duty Cycle
Size (Factory Fitted) Current Circuit Size
LIFT TIG/HF TIG STICK (MMA)
(Vin/Amps)
(GTAW)
110V/39A - 125A @ 25%
Thermal Arc 110V/30A 160A @ 30% -
H07RN-F 2.5mm²
201 TS 230V/32A - 200A @ 25%
230V/21A 200A @ 25% -
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current
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.

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.

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 Process Selection

Set Welding Current Switch to STICK.
as specified by the
Electrode Manufacturer. Set ARC Force
Negative Output Positive Output

Terminal Terminal
(Dinse™ 50) (Dinse™ 50)
200A
Art#:A-09784
Figure 3-2 Setup for STICK (MMA) Welding

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.

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
Set DOWN Slope
Electrode Manufacturer.
Secure the gas cylinder in an Positive Output

upright position by chaining it Terminal
Negative
to a stationary support to prevent (Dinse™ 50)
Output
falling or tipping.
Terminal
(Dinse™ 50)
Art # A-10100_AB
Figure 3-3: Setup for LIFT TIG / HF TIG (GTAW) Welding
LIFT TIG / HF TIG (GTAW) 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 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.
7. Connect the other end of the supplied gas hose to gauge. Check for leaks using an approved
the gas inlet fitting on the rear panel of the welder leak detector solution.
and tighten with a wrench. Caution: DO NOT over
tighten. c) If the high-pressure gauge drops and the
low-pressure gauge increases at the same
8. Open the Argon Cylinder Valve to the fully open time, there is a leak in the regulator seat.
position.
d) If the regulator requires service or repair,
9. Connect the ground (work) clamp to your work take it to a qualified repair technician.
piece.
5. Once leak testing has been performed and
10. Set the DOWN SLOPE control knob to the desire there are no leaks in the system, slowly open
weld current ramp down time. Refer to Section the cylinder valve and proceed.
4.01.
11. Set the weld current control knob to the desired ! WARNING
amperage.
If a leak has been detected anywhere in
12. The tungsten must be ground to a blunt point
the system, discontinue use and have
in order to achieve optimum welding results. It
the system repaired. DO NOT use leaking
is critical to grind the tungsten electrode in the
equipment. Do not attempt to repair a
direction the grinding wheel is turning.
leaking system while the system is under
13. Install the tungsten with approximately 1/8” to ¼” pressure.
sticking out from the gas cup, ensuring you have
correct sized collet. 3.09 When You Finish Using the
14. Tighten the back cap then open the valve on the Regulator
torch. 1. Close the cylinder valve.
15. Plug the power cable into the appropriate outlet, 2. Open the valve on the downstream equipment.
and turn the switch to the “ON” position. The This drains all pressure from the system.
power L.E.D. light should illuminate. Set the
“Process Selection Switch” to LIFT TIG and HF 3. Close the valve on the downstream
TIG equipment.
16. You are now ready to begin TIG Welding. 4. Turn the adjusting screw counterclockwise to
release the tension on the adjusting spring.
3.08 Leak Testing the System 5. Check the gauges after a few minutes for
Leak test the system before putting into operation. verification that the cylinder valve is closed
completely.
1. Be sure that there is a valve in the downstream
equipment to turn off the gas flow. 3.10 Storage of the Regulator
2. With the cylinder valve open, adjust the When the regulator is not in use and has been
regulator to deliver the maximum required removed from the cylinder, it should be stored in an
delivery pressure. area where it will be protected from dust, oil, and
3. Close the cylinder valve. grease. The inlet and outlet should be capped to
protect against internal contamination and prevent
4. Turn the adjusting screw/knob counterclockwise insects from nesting.
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 downstream equipment, hose,
hose fitting, outlet fitting or low-pressure

OPERATION THERMAL ARC 201 TS
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.
(C) Trigger Mode Selection Switch
(A) Power On Indicator (D) Process Selection Switch
(F) Arc Force/Down

Slope Control
(B) Fault Indicator
(E) Welding Current

Control STICK
TIG
32A OUTLET
32A OUTLET 110V
TIG/STICK 16A OUTLET 230V
(G) Gas Outlet (I) 8 Pin Control Socket
Negative Output Terminal Positive Output Terminal
Art # A-10146
Figure 4-1: Thermal Arc 201 TS Controls
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.
Manual 0-5149 4-1 Operation

THERMAL ARC 201 Ts OPERATION
C. TRIGGER Mode Switch (LIFT TIG Mode Only) greater penetration control to be achieved. Down Slope
operates in TIG mode only. It is used to set the time for
2T (Normal) Mode weld current to ramp down. Refer to Item C (Trigger
Press the TIG Torch Trigger Switch or Foot Control and Mode Selection Switch) for further information regard-
hold depressed to weld. Release the TIG Torch Trigger ing Downslope operation.
Switch or Foot Control to stop welding. Down Slope G. Gas Outlet
operates in LIFT TIG (GTAW) mode only. While welding
if the TIG Torch Trigger Switch is released, the weld- The Gas Outlet is a 5/8”-18 UNF female gas fitting and
ing current ramps down to zero current over a defined is utilized for the connection of a suitable TIG Torch.
period of time. The time period is determined by the H. Post Gas Flow (weld current dependant)
Down Slope Control Knob (F).
Post Gas Flow is the time Gas flows after the arc has
4T (Latch) Mode extinguished. The gas flow time is proportional to weld
This mode of welding is mainly used for long weld runs. current. This is used to cool and reduce oxidization of
The operator need only to press the TIG Torch Trigger the Tungsten Electrode. For example if the Welding Cur-
Switch to activate and then release the TIG Torch Trigger rent is set to 10 amps the Post Gas Flow time will be
Switch to continue to weld, then press the TIG Torch approximately 3 seconds. For a Welding Current set to
Trigger Switch again and release the TIG Torch Trigger 160 Amps the Post Gas Flow time will be approximately
Switch to stop welding. This eliminates the need for the 10 seconds. The Post Gas Flow time cannot be adjusted
operator to depress the TIG Torch Trigger Switch for the independently of the Welding Current.
complete length of the weld. The 4T mode incorporates I. 8 Pin Remote Socket
a current slope function which includes a fixed current
up slope of 1 second and an adjustable current down The 8 pin remote socket is used to connect the TIG
slope. Current slope operates in TIG Mode only. Up slope Torch Trigger Switch to the welding Power Source. To
is not adjustable and activates automatically in 4T mode make connections, align keyway, insert plug, and rotate
when the TIG torch trigger is depressed. To activate threaded collar fully clockwise.
the Down Slope function in 4T mode while welding,
the TIG Torch Trigger Switch must be depressed and 12345678 2 1
held while welding which will ramp the Welding Current
5 4 3
down to zero over a defined period of time. The time
period is determined by the Down Slope Control Knob 8 7 6
5k Ohms
(F). At any time while welding if the TIG Torch Trigger
Switch is depressed and released the arc will extinguish
immediately. Front View of 8 Pin Socket
D. Process Selection Switch Art # A-09815_AB
Switches between STICK (MMA), LIFT TIG (GTAW) and Plug Pin Function
HF TIG (GTAW) modes. Refer to Section 3.06 Setup 1
for STICK (MMA) Welding and 3.07 Setup for TIG / HF
2 Torch Switch Input (24V) to energize
TIG Welding.
weld current. (connect pin 2&3 to turn on
E. Welding Current Control welding current)
The welding current is increased by turning the Weld 3 Torch Switch Input (0V) to energize weld
Current Control Knob clockwise or decreased by turning current. (connect pin 2&3 to turn on
the Weld Current Control Knob counterclockwise. The welding current)
welding current should be set according to the specific 4
application. Refer to application notes in this section 5 5k ohm (maximum) connection to 5k ohm
for further information. remote control potentiometer
F. Arc Force/Down Slope Control 6 Zero ohm (minimum) connection to 5k
ohm remote control potentiometer
Arc Force is effective when in STICK (MMA) Mode only.
7 Wiper arm connection to 5k ohm remote
Arc Force control provides an adjustable amount of Arc
control potentiometer
Force (or “dig”) control. This feature can be particularly
beneficial in providing the operator the ability to com- 8
pensate for variability in joint fit-up in certain situations NOTE
with particular electrodes. In general increasing the Arc Remote Welding Current Control is not available on
Force control toward ‘10’ (maximum Arc Force) allows this model.
Operation 4-2 Manual 0-5149
J. ON/OFF Switch (located on rear panel not shown) 4.03 STICK (MMA) Electrode Polarity
This switch controls the Mains Supply Voltage to the
Stick electrodes are generally connected to the "+" Posi-
Power Source. tive Output Terminal and the work lead to the "−" Negative
Output Terminal but if in doubt consult the electrode
4.02 Welding Current Control manufacturers literature for further information.
Explanation 4.04 Effects of Stick Welding Various

32 Amp Outlet Materials
The mains power 32 Amp circuit breaker or fuse should
High Tensile and Alloy Steels
not trip at this Weld Current value when STICK welding.
The two most prominent effects of welding these steels
The environmental conditions that may cause the mains
are the formation of a hardened zone in the weld area,
power 32 Amp circuit breaker or fuse to trip are:
and, if suitable precautions are not taken, the occurrence
a) High ambient temperature in this zone of under-bead cracks. Hardened zone and
under-bead cracks in the weld area may be reduced by
b) Worn parts in circuit breaker using the correct electrodes, preheating, using higher
c) Using an extension cable current settings, using larger electrodes sizes, short
runs for larger electrode deposits or tempering in a
d) Low line mains power voltage furnace.
Output Scale for 110V Manganese Steels
The effect on manganese steel of slow cooling from
The inside number scale identifies the available high temperatures is to embrittle it. For this reason it
output weld current for STICK or LIFT TIG weld modes. is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
STICK Mode: Identifies the STICK weld point for welding to distribute the heat.
32 Amp outlet.
Cast Iron
Exceeding these points will cause nui-
sance tripping of the circuit breaker or Most types of cast iron, except white iron, are weldable.
fuse. White iron, because of its extreme brittleness, gener-
Nuisance tripping should not occur on a 16 Amp outlet. ally cracks when attempts are made to weld it. Trouble
may also be experienced when welding white-heart
Output Scale for 230V malleable, due to the porosity caused by gas held in
this type of iron.
The outside number scale identifies the available out-
put weld current for STICK or LIFT TIG/HF TIG weld Copper and Alloys
modes.
The most important factor is the high rate of heat
Nuisance tripping should not occur on a 32A 230V outlet conductivity of copper, making pre-heating of heavy
for both STICK & LIFT TIG/HF TIG Modes. sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
32 Amp Outlet Arc Welding electrodes are classified into a number of
groups depending on their applications. There are a
STICK 32A OUTLET
Output Scale for 110V great number of electrodes used for specialized indus-
TIG 32A OUTLET 110V
TIG/STICK 16A OUTLET 230V trial purposes which are not of particular interest for ev-
Output Scale for 230V eryday general work. These include some low hydrogen
Art # A-10147
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.

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

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
Welding Application Features Color Code
(Ground Finish)
DC welding of mild steel, stainless steel Excellent arc starting, long life, high
Thoriated 2% Red
and copper. current carrying capacity.
AC & DC welding of mild steel, stainless Longer life, more stable arc, easier
Ceriated 2% steel, copper, aluminium, magnesium and starting, wider current range, Grey
their alloys. narrower & more concentrated arc.
4.10 TIG Welding Parameters for Steel

DC Current
Base Metal Stainless Electrode Filler Rod Argon Gas Flow
Mild Steel
Thickness Steel Diameter Diameter Rate Joint / Type
35-45 20-30 1.0mm 1.6mm 10 CFH Butt/Corner
1.0mm
(0.040") 40-50 25-35 (0.040") (1/16" ) (5 LPM) Lap/Filler
1.2mm
(0.045") 50-60 35-50 (0.040") (1/16") (6 LPM) Lap/Filler
1.6mm
(1/16") 70-90 50-70 (1/16") (1/16") (7 LPM) Lap/Filler
80-100 65-85 1.6mm 2.4mm 15CFH Butt/Corner
3.2mm
(1/8") 90-115 90-110 (1/16") (3/32") (7 LPM) Lap/Filler
4.8mm
(3/16") 140-165 125-150 (3/32") (1/8") (10 LPM) Lap/Filler
6.4mm
(1/4") 170-200 160-180 (1/8") (5/32") (10 LPM) Lap/Filler
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.

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-07692
Figure 4-8: Vertical position, fillet weld
Art # A-07689
Art# A-07693
Figure 4-5: Horizontal position, butt weld
Figure 4-9: Overhead position, butt weld
Art # A-07690
Art # A-07694
Figure 4-6: Horizontal - Vertical (HV) position
Figure 4-10: Overhead position, fillet weld

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 Single Vee Butt Joint Not less than
70°
Joint 1.6mm (1/16” ) max
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
1.6mm (1/16”)
Not less than
Single Vee Butt Joint 45° Double Vee Butt Joint Not less than
70°
1.6mm (1/16”) max
Lap Joint 1.6mm (1/16”)
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Corner Weld Edge Joint
Plug Weld Plug Weld
Art # A-07695_AE
Figure 4-11: Typical joint designs for arc welding

4.14 Arc Welding Technique Art # A-07696
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 Figure 4-12: Striking an arc
the downhand position. Make sure that the work clamp
4.17 Arc Length
is making good electrical contact with the work, either
directly or through the work table. For light gauge ma- The securing of an arc length necessary to produce a
terial, always clamp the work lead directly to the job, neat weld soon becomes almost automatic. You will find
otherwise a poor circuit will probably result. that arc produces a crackling or spluttering noise and
the weld metal comes across in large, irregular blobs.
4.15 The Welder The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained
Place yourself in a comfortable position before begin- although if it is too short there is the danger of it being
ning to weld. Get a seat of suitable height and do as blanketed by slag and the electrode tip being solidified
much work as possible sitting down. Don’t hold your in. If this should happen, give the electrode a quick twist
body tense. A taut attitude of mind and a tensed body back over the weld to detach it. Contact or “touch-weld”
will soon make you feel tired. Relax and you will find electrodes such as E7014 electrode do not stick in this
that the job becomes much easier. You can add much way, and make welding much easier.
to your peace of mind by wearing a leather apron and
gauntlets. You won’t be worrying then about being burnt 4.18 Rate of Travel
or sparks setting alight to your clothes.
After the arc is struck, your next concern is to maintain
Place the work so that the direction of welding is across, it, and this requires moving the electrode tip towards
rather than to or from, your body. The electrode holder the molten pool at the same rate as it is melting away.
lead should be clear of any obstruction so that you At the same time, the electrode has to move along the
can move your arm freely along as the electrode burns plate to form a bead. The electrode is directed at the
down. If the lead is slung over your shoulder, it allows weld pool at about 20° from the vertical. The rate of
greater freedom of movement and takes a lot of weight travel has to be adjusted so that a well-formed bead
off your hand. Be sure the insulation on your cable and is produced.
electrode holder is not faulty, otherwise you are risking
an electric shock. If the travel is too fast, the bead will be narrow and
strung out and may even be broken up into individual
4.16 Striking the Arc globules. If the travel is too slow, the weld metal piles
up and the bead will be too large.
Practice this on a piece of scrap plate before going on
to more exacting work. You may at first experience dif-
ficulty due to the tip of the electrode “sticking” to the
work piece. This is caused by making too heavy a con-
tact 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.
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.

4.19 Making Welded Joints Heavy plate will require several runs to complete the
joint. After completing the first run, chip the slag out
Having attained some skill in the handling of an elec- and clean the weld with a wire brush. It is important
trode, you will be ready to go on to make up welded to do this to prevent slag being trapped by the second
joints. run. Subsequent runs are then deposited using either
a weave technique or single beads laid down in the
A. Butt Welds
sequence shown in Figure 4-13. The width of weave
Set up two plates with their edges parallel, as shown in should not be more than three times the core wire
Figure 4-12, allowing 1.6mm (1/16") to 2.4mm (3/32") diameter of the electrode. When the joint is completely
gap between them and tack weld at both ends. This is filled, the back is either machined, ground or gouged
to prevent contraction stresses from the cooling weld out to remove slag which may be trapped in the root,
metal pulling the plates out of alignment. Plates thicker and to prepare a suitable joint for depositing the backing
than 6.4mm (1/4") should have their mating edges bev- run. If a backing bar is used, it is not usually necessary
eled to form a 70° to 90° included angle. This allows to remove this, since it serves a similar purpose to the
full penetration of the weld metal to the root. Using a backing run in securing proper fusion at the root of
3.2mm (1/8") E7014 electrode at 120 amps, deposit a the weld.
run of weld metal on the bottom of the joint.
B. Fillet Welds
Do not weave the electrode, but maintain a steady rate of
These are welds of approximately triangular cross-sec-
travel along the joint sufficient to produce a well-formed
tion made by depositing metal in the corner of two faces
bead. At first you may notice a tendency for undercut
meeting at right angles. Refer to Figure 4-5.
to form, but keeping the arc length short, the angle of
the electrode at about 20° from vertical, and the rate of A piece of angle iron is a suitable specimen with which
travel not too fast, will help eliminate this. The electrode to begin, or two lengths of strip steel may be tacked
needs to be moved along fast enough to prevent the slag together at right angles. Using a 3.2mm (1/8") E7014
pool from getting ahead of the arc. To complete the joint electrode at 120 amps, position angle iron with one
in thin plate, turn the job over, clean the slag out of the leg horizontal and the other vertical. This is known as
back and deposit a similar weld. a horizontal-vertical (HV) fillet. Strike the arc and im-
mediately 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
Art # A-07697 with a 3.2mm (1/8") electrode, otherwise the weld metal
tends to sag towards the base, and undercut forms on
Figure 4-13: Butt weld 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

Art # A-07702
Art # A-07700
Figure 4-16: Multi-runs in HV fillet weld
C. Vertical Welds
Figure 4-18: Multi run vertical fillet weld
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, Art # A-07703
and do not attempt to weave on the first run. Figure 4-19: Examples of vertical fillet welds
When the first run has been completed de-slag
the weld deposit and begin the second run at 2. Vertical Down
the bottom. This time a slight weaving motion
is necessary to cover the first run and obtain The E7014 electrode makes welding in this
good fusion at the edges. At the completion of position particularly easy. Use a 3.2mm (1/8")
each side motion, pause for a moment to allow electrode at 120 amps. The tip of the electrode
weld metal to build up at the edges, otherwise is held in light contact with the work and the
undercut will form and too much metal will speed of downward travel is regulated so that
accumulate in the centre of the weld. Figure the tip of the electrode just keeps ahead of the
4-17 illustrates multi-run technique and Figure slag. The electrode should point upwards at an
4-18 shows the effects of pausing at the edge angle of about 45°.
of weave and of weaving too rapidly. 3. Overhead Welds
Art # A-07701
Apart from the rather awkward position neces-
sary, overhead welding is not much more dif-
ficult 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 posi-
tion 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
Figure 4-17: Single run vertical fillet weld 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.

B. Expansion and Contraction of Parent Metal in the
Art # A-07704
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 at-
tempts to expand “across the weld” or “along the weld”,
it meets considerable resistance, and to fulfill the desire
Figure 4-20: Overhead fillet weld for continued expansion, it has to deform plastically, that
is, the metal adjacent to the weld is at a high tempera-
4.20 Distortion ture and hence rather soft, and, by expanding, pushes
against the cooler, harder metal further away, and tends
Distortion in some degree is present in all forms of to bulge (or is “upset”). When the weld area begins to
welding. In many cases it is so small that it is barely cool, the “upset” metal attempts to contract as much as
perceptible, but in other cases allowance has to be made it expanded, but, because it has been “upset”, it does
before welding commences for the distortion that will not resume its former shape, and the contraction of
subsequently occur. The study of distortion is so com- the new shape exerts a strong pull on adjacent metal.
plex that only a brief outline can be attempted hear. Several things can then happen.
4.21 The Cause of Distortion The metal in the weld area is stretched (plastic defor-
mation), the job may be pulled out of shape by the
Distortion is cause by: powerful contraction stresses (distortion), or the weld
may crack, in any case, there will remain “locked-up”
A. Contraction of Weld Metal: stresses in the job. Figures 4-20 and 4- 21 illustrate
Molten steel shrinks approximately 11 per cent in vol- how distortion is created.
ume on cooling to room temperature. This means that Art # A-07705_AB Weld Upsetting
a cube of molten metal would contract approximately

Expansion with
2.2 per cent in each of its three dimensions. In a welded compression
joint, the metal becomes attached to the side of the joint Hot Hot Cool
and cannot contract freely. Therefore, cooling causes
the weld metal to flow plastically, that is, the weld itself
Figure 4-21: Parent metal expansion
has to stretch if it is to overcome the effect of shrinking
volume and still be attached to the edge of the joint. If
Weld
the restraint is very great, as, for example, in a heavy Art # A-07706_AB Permanent Upset
section of plate, the weld metal may crack. Even in Contraction

cases where the weld metal does not crack, there will with tension
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 Figure 4-22: Parent metal contraction
cause the sheet to become distorted.

4.22 Overcoming Distortion Effects Art # A-07708
There are several methods of minimizing distortion B C

Preheat Preheat
effects. Weld
A. Peening
This is done by hammering the weld while it is still hot. Dotted lines show effect if no preheat is used
The weld metal is flattened slightly and because of this Figure 4-24: Reduction of distortion by preheating
the tensile stresses are reduced a little. The effect of
peening is relatively shallow, and is not advisable on Art # A-07709
the last layer.

B. Distribution of Stresses
Distortion may be reduced by selecting a welding se-
quence 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 ef-
fective method of overcoming distortion, although an
unsuitable sequence may exaggerate it. Simultaneous
welding of both sides of a joint by two welders is often Figure 4-25: Examples of distortion
successful in eliminating 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. Art # A-07710
D. Presetting
Figure 4-26: Welding sequence
It is possible in some cases to tell from past experi-
ence 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.
Art # A-07711
E. Preheating
Figure 4-27: Step back sequence
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-07428_AB
Figure 4-28: Chain intermittent welding

Art # A-07707
Figure 4-23: Principle of presetting Art # A-07713_AB
Figure 4-29: Staggered intermittent welding

service THERMAL ARC 201 TS
SECTION 5:
SERVICE
5.01 Maintenance and Inspection To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The
The only routine maintenance required for the power unit should also be wiped clean, if necessary; with
supply is a thorough cleaning and inspection, with the solvents that are recommended for cleaning electrical
frequency depending on the usage and the operating apparatus.
environment.
CAUTION
WARNING Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
There are extremely dangerous voltages and
metal particles to interfere with sensitive
power levels present inside this product.
electrical components and cause damage
Disconnect primary power at the source
to the unit.
before opening the enclosure. Wait at least
two minutes before opening the enclosure to
allow the primary capacitors to discharge.
Maintain more often

Warning! if used under severe
Disconnect input power before maintaining. conditions
Each Use
Visual check of Visual check of torch

regulator and pressure Consumable parts
Weekly
Visually inspect
the torch body Visually inspect the
and consumables cables and leads.
Replace as needed
3 Months
Replace all Clean

broken parts 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
Art # A-10002
frequently under exceptionally
dirty conditions.
Manual 0-5149 5-1 Service

THERMAL ARC 201 Ts service
5.02 STICK (MMA) Welding Problems
Description Possible Cause Remedy
1. Gas pockets or voids in weld metal A. Electrodes are damp. A. Dry electrodes before use.
(Porosity).
B. Welding current is too high. B. Reduce welding current.
Surface impurities such as oil, C. Clean joint before welding
C.
grease, paint, etc.
2. Crack occurring in weld metal soon A. Rigidity of joint. A. Redesign to relieve weld joint of severe
after solidification commences. stresses or use crack resistance
electrodes.
B. Insufficient throat thickness. B. Travel slightly slower to allow greater
build up in throat.
C. Cooling rate is too high. C. Preheat plate and cool slowly.
3. A gap is left by failure of the weld A. Welding current is too low. A. Increase welding current
metal to fill the root of the weld.
B. Electrode too large for joint. B. Use smaller diameter electrode.
Art # A-05866_AC
C. Insufficient gap. C. Allow wider gap.
Incorrect Sequence
D. Incorrect sequence. D. Use correct build-up sequence.
Insufficient Gap
4. Portions of the weld run do not fuse A. Small electrodes used on A. Use larger electrodes and preheat
to the surface of the metal or edge heavy cold plate. the plate.
of the joint
B. Welding current is too low. B. Increase welding current
Lack of fusion caused by dirt,
electrode angle incorrect,
C. Wrong electrode angle. C. Adjust angle so the welding arc is
rate of travel too high directed more into the base metal
Art # A-05867_AC Lack of D. Travel speed of electrode is too D. Reduce travel speed of electrode
inter-run fusion
high.
Lack of side fusion, E. Clean surface before welding.
scale dirt, small electrode,
amperage too low Lack of root fusion E. Scale or dirt on joint surface.
5. Non-metallic particles are trapped A. Non-metallic particles may A. If bad undercut is present, clean slag
in the weld metal (slag inclusion). be trapped in undercut from out and cover with a run from a smaller
previous run. diameter electrode.
B. Joint preparation too restricted. B. Allow for adequate penetration and
room for cleaning out the slag.
Slag C. Irregular deposits allow slag to C. If ver y bad, chip or grind out
trapped in
undercut be trapped. irregularities.
Not cleaned,
or incorrect D. Lack of penetration with slag D. Use smaller electrode with sufficient
electrode
trapped beneath weld bead. current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E. Rust or mill scale is preventing E. Clean joint before welding.
full fusion.
Art # A-05868_AB
Slag trapped in root F. Wrong electrode for position in F. Use electrodes designed for position
which welding is done. 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.

1. Excessive bead build-up or poor Welding current is too low Increase weld current and/or
penetration or poor fusion at change joint preparation.
edges of weld.
2. Weld bead too wide and flat or Welding current is too high. Decrease welding current.
undercut at edges of weld or
excessive burn through.
3. Weld bead too small or insufficient Travel speed too fast. Reduce travel speed.
penetration or ripples in bead are
widely spaced apart.
4. Weld bead too wide or excessive Travel speed is too slow. Increase travel speed.
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 Electrode is connected to the "+" Connect the electrode to the
struck. Positive Output Terminal. "-" Negative Output Terminal.
7. Dirty weld pool. A. Electrode contaminated through A. Clean the electrode by grinding
contact with work piece or filler contaminates off.
rod material.
B. Gas contaminated with air. B. Check gas lines for cuts and loose
fitting or change gas cylinder.
8. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line
for problems
9. Arc flutters during TIG welding. Tungsten electrode is too large Select the right size electrode.
for the welding current. Refer to section Tungsten Electrode
Current Ranges.
10. W e l d i n g a r c c a n n o t b e A. Work clamp is not connected to A. Connect the work clamp to the
established. the work piece or the work/torch work piece or connect the work/
leads are not connected to the torch leads to the correct welding
correct welding terminals. terminals.
B. Torch lead is disconnected. B. Connect it to the "-" Negative
Output Terminal.
C. Gas flow incorrectly set, cylinder C. Select the right flow rate, change
empty or the torch valve is off. cylinder or turn torch valve on.
11. Electrode melts or oxidizes when A. No gas is flowing to welding A. Check the gas lines for kinks or
an arc is struck. region. breaks or cylinder contains gas.
B. Torch is clogged with dust. B. Clean torch.
C. Gas hose is cut. C. Replace gas hose.
D. Gas passage contains impurities. D. Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
E. Gas regulator turned off. E. Turn on.
F. Torch valve is turned off. F. Turn on.
G. The electrode is too small for the G. Increase electrode diameter or
welding current. reduce the welding current.
Manual 0-5149 5-3 Service

THERMAL ARC 201 Ts service
TIG Welding Problems (Continued)
12. Arc start is not smooth. A. Tungsten electrode is too A. Refer to section Tungsten Electrode
large for the welding current. Current Ranges for the correct size.
B. The wrong electrode is being B. Refer to section Tungsten Electrode
used for the welding job. Types for the correct electrode type.
C. Gas flow rate is too high. C. Select the correct flow rate for the
welding job.
D. Incorrect shield gas is being D. Use 100% argon for TIG welding.
used.
E. Poor work clamp connection E. Improve connection to work piece.
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

1. The welding arc cannot be A. The Primary supply voltage A. Switch ON the Primary
established. has not been switched ON. supply voltage.
B. The Welding Power Source B. Switch ON the Welding
switch is switched OFF. Power Source.
C. Loose connections internally. C. Have an Accredited Thermal
Arc Service Provider repair
the connection.
2. The welding arc cannot be The machines duty cycle has Wait for the Warning Indicator
established when the Warning been exceeded to extinguish before resuming
Indicator lights up continuously welding
3. Maximum output welding Defective control circuit Have an Accredited Thermal Arc
current cannot be achieved Service Provider inspect then
with nominal Mains supply repair the welder.
voltage.
4. Welding current reduces when Poor work lead connection to the Ensure that the work lead has a
welding. work piece. positive electrical connection to
the work piece.
5. Circuit breaker (or fuse) trips The circuit breaker (or fuse) is The recommended circuit
during welding. under size. 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.
6. The welding arc cannot The input current to the main Have an Accredited Thermal Arc
be established when Fault transformer has been exceeded. Service Provider inspect then
Indicator is flashing. repair the welder.
Service 5-4 Manual 0-5149

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 W4013601
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
Manual 0-5149 A-1 Appendix

THERMAL ARC 201 ts APPENDIX
APPENDIX 2: REPLACEMENT PARTS
Item
Description Part No. Reference Designator
No
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
16 W7003212
TS
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
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.
Appendix A-2 Manual 0-5149

APPENDIX THERMAL ARC 201 Ts
1
25
24
4
7
55 8 9
6
23 10
22
11
12
13
14
15
16
17
20
Art # A-10148 18
21 19
26
Manual 0-5149 A-3 Appendix

1 2 3 4 5 6
APPENDIX
Manual 0-5149
D D
J1
J24-1 FAULT INDICATOR
MB
PROCESS SELECTION
J24-2
J8-10 SWITCH
J24-3 POWER ON INDICATOR
Front Panel PCB3

J8-9
J24-4
J8-8
CONNECTOR LAYOUT DIAGRAM J24-5
J8-7
THC2 OT2 J1 J2 POWER OT1 J3 J4 OT2 J24-6
J8-6
J3-1 J24-7
J8-5 TRIGGER MODE
J3-2 SOU/HF/QF J5 J24-8
J8-4 SELECTION SWITCH WELD CURRENT
THC1
J24-9 CONTROL
J4-1 J8-3
J24-10
J4-2 J8-2
GUN JC
OT1 J6 J8-1 J25-1 110VAC --4.5VDC
WA MB WV DOWN SLOPE/
J9 J8 J7 J25-2 230VAC --0.05VDC
ARC FORCE CONTROL
J-MB
J26-1
J26-3
J26-2
J26-4
3 2 1
APPENDIX 3: 201 TS SYSTEM SCHEMATIC
Over Current Signal

NO
IGBT Driver B
IGBT Driver A
IGBT Driver A
IGBT Driver B
WA R-G
Control PCB2 GND J9-1
J29-8
J9-2 Remote PCB4 J29-7
+15V
Current Feedback
GND
SOU/HF/QF J29-6 8 6
POWER GUN -15V J9-3
J29-5 5 3
+15V J9-4
J5-1
J5-2
J5-3
J5-4
J2-1
J5-5
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J2-2
J2-3
J6-1
J6-2
WV TIG Torch J29-4
J-RC 2 1
J7-1
J7-2
J7-3
Switch Signal J29-3
GUN1 J29-2
J27-3
J27-1
J27-2
J27-4
J28-1
J28-3
J29-1
GAS
FAN
SOLENOID
C C
ACOUT ACOUT DC - DC +
J12-1
J12-2
J12-3
J12-4
J13-1
J13-2
J13-3
J13-4
J13-5
J10-1
J10-2
J10-3
J10-4
J10-5
J10-6
J10-7
J11-1
J11-2
J11-3
J18-1
J18-2
J16-1
J17-1
J17-3
J16-2
J17-2
60W4Ω RX24
J22-1
FJ/QF DY1 IN DY2 SWOUT JC SWIN
+24V
+24V
GND
GND
+24V
-24V
GND
+24V
+24V
J22-2
YELLOW
BLACK
WHITE
RED
RED
GRAY
CONNECTOR LAYOUT DIAGRAM WVOUT
OC1 J23 J10 IN J11 FJ/QF J12 J13 DY1 J14 JC3 J19-1
DY2 OC2 J19-2
J20 JC2 J15
A-4
RX24 J22 J19-3
JC
J16
J30
J21 JC1 HFOUT
INPUT 230VAC/110VAC BLACK RED
WVOUT
50/60Hz SWIN
J17
J19
SWOUT
J18
+
D
Current Sensor
POS
B G B
D
PFC CIRCUIT
D S
G
G
SHEETMETAL COVER
-
S
NEG
S
HFOUT
110VAC --155VDC Main Power PCB1
230VAC --325VDC J30-1
J30-2
+15V
GND
Over Current Signal Over Current Signal
J30-3
JC1 JC3 JC2 OC1 OC2 J30-4
THERMAL ARC 201 ts
J14-1
J14-2
J14-3
J21-1
J21-2
J20-1
J20-3
J23-1
J15-2
J20-2
J20-4
J20-5
J20-6
J23-2
J15-1
RED
WHITE
Art # A-10149_AB
J1,J10 J29 J20 J5,J13
1 7 1 8 1 6 1 5
A A
J9,J12,J26,J27 J2,J11,J14,J17,J28 J3,J4,J23,J15,J16,J21,J25 J6, ,J22,J18 J7,J19 J30
J8,J24
1 4 1 2 3 1 2
1 2 1 2 1 2
1 5
10 6
Appendix
PCB MOUNTED HARNESS CONNECTORS PIN OUT
VIEWED FROM COMPONENT SIDE OF BOARD
1 2 3 4 5 6
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
Thermal 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 modified 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 speciﬁcations 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 Ridge Road, Suite 300 • St. Louis, Missouri 63017 U.S.A.
THE AMERICAS EUROPE ASIA/PACIFIC

Denton, TX USA Miami, FL USA Chorley, United Kingdom Cikarang, Indonesia Melbourne, Australia Shanghai, China
U.S. Customer Care Sales Office, Latin America Customer Care Customer Care Australia Customer Care Sales Office
Ph: 1-800-426-1888 (tollfree) Ph: 1-954-727-8371 Ph: +44 1257-261755 Ph: 6221-8990-6095 Ph: 1300-654-674 (tollfree) Ph: +86 21-64072626
Fax: 1-800-535-0557 (tollfree) Fax: 1-954-727-8376 Fax: +44 1257-224800 Fax: 6221-8990-6096 Ph: 61-3-9474-7400 Fax: +86 21-64483032
International Customer Care Fax: 61-3-9474-7391
Ph: 1-940-381-1212 Oakville, Ontario, Canada Milan, Italy Rawang, Malaysia International Singapore
Fax: 1-940-483-8178 Canada Customer Care Customer Care Customer Care Ph: 61-3-9474-7508 Sales Office
Ph: 1-905-827-4515 Ph: +39 0236546801 Ph: +603 6092-2988 Fax: 61-3-9474-7488 Ph: +65 6832-8066
Fax: 1-800-588-1714 (tollfree) Fax: +39 0236546840 Fax: +603 6092-1085 Fax: +65 6763-5812
Form No. 0-5149 (11-April-2011) © 2011 Thermadyne Industries, Inc. www.thermadyne.com Printed in China

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201 TS

STICK 32A OUTLET

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-leading,

Above all, we are committed to develop technologically advanced products to

Operating Manual Number 0-5149 for:

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the

Publication Date: April 20, 2011

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________

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

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

LIMITED WARRANTY & WARRANTY SCHEDULE

Electrode Size Filter Electrode Size Filter

General Information 1-2 Manual 0-5149

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

Manual 0-5149 1-3 General Information

Engine fuel is highly flammable.

1.02 Principal Safety Standards

Manual 0-5149 1-5 General Information

General Information 1-6 Manual 0-5149

Manual 0-5149 2-1 Introduction

On Single Phase Wire Feed Function

Wire Feed Towards

Increase/Decrease Remote Purging Of Gas

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time

Gas Metal Arc

Gas Tungsten Arc 2 Step Trigger

Negative Constant Current 4 Step Trigger

Direct Current (DC) High Temperature t Burnback Time

Protective Earth Disturbance In

Line Arc Force IPM Inches Per Minute

Line Connection Touch Start (GTAW) MPM Meters Per Minute

Auxiliary Power Variable Inductance

115V 15A Receptacle Rating-

Introduction 2-2 Manual 0-5149

Manual 0-5149 2-3 Introduction

100 110VAC INPUT

30 Region Stick (MMA)

100 230VAC INPUT

30 Region TIG (GTAW)

Figure 2-1: Thermal Arc 201 TS Duty Cycle

Introduction 2-4 Manual 0-5149

Manual 0-5149 2-5 Introduction

Introduction 2-6 Manual 0-5149

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

Welding Power Supply

Primary Power Cable

Figure 3-1 Electrical Input Connections

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

3.04 Electromagnetic Compatibility

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

3.05 Setup for Welding

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

3.06 STICK (MMA) Setup