Thermal Arc 201 TS User manual

Art # A-10139
50
60
Hz
32AOUTLET
STICK
TIG
230V
110V
TIG/STICK
32AOUTLET
16AOUTLET
201 TS
Operating Manual
Revision: AB Issue Date: May 20, 2011 Manual No.: 0-5149
Operating Features:
THERMAL ARC
INVERTER ARC WELDER

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to have you as
our customer and will strive to provide you with the best service and reliability
in the industry. This product is backed by our extensive warranty and world-
wide service network. To locate your nearest distributor or service agency call
[phone], 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then check for a newer version of the manual on our website or contact our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
[phone]
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
Manual 0-5149 1-1 General Information
1.01 ARC WELDING HAZARDS
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause
fatal shocks or severe burns. The electrode
and work circuit is electrically live when-
ever the output is on. The input power cir-
cuit and machine internal circuits are also
live when power is on. In semiautomatic
or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts
touching the welding wire are electrically
live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line
fuses so power cannot be turned on acciden-
tally.
5. Properly install and ground this equipment accord-
ing to its Owner’s Manual and national, state, and
local codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two welding machines at the same
time or touch other people with the holder or
electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10.Ground the workpiece to a good electrical (earth)
ground.
11.Do not touch electrode while in contact with the
work (ground) circuit.
12.Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above floor level.
15.Keep all panels and covers securely in place.
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the European Standard EN60974-1 entitled: Safety in welding and allied processes
Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment
are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE,
AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

SAFE INSTRUCTION THERMAL ARC 201 TS
General Information 1-2 Manual 0-5149
WARNING
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
Arc rays from the welding process produce
intense heat and strong ultraviolet rays
that can burn eyes and skin. Noise from
some processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted
with a proper shade of filter (see ANSI Z49.1 and
EN 60974-1 listed in Safety Standards) to protect
your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recom-
mended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
6. Never wear contact lenses while welding.
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not breath
the fumes.
2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well venti-
lated, or while wearing an air-supplied respirator.
Shielding gases used for welding can displace air
causing injury or death. Be sure the breathing air
is safe.
6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and
irritating gases.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
No.
Welding or Cutting
Operation
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
No.
Torch soldering 2 Gas metal-arc
welding (MIG)
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding
(stick) electrodes
Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in.,
4 to 6.4 mm 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14

THERMAL ARC 201 TS SAFE INSTRUCTION
Manual 0-5149 1-3 General Information
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-
supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental con-
tact of electrode or welding wire to metal
objects can cause sparks, overheating,
or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike flam-
mable material.
3. Remove all flammables within 10.7 m (35 ft) of the
welding arc. If this is not possible, tightly cover
them with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding cur-
rent from traveling long, possibly unknown paths
and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10.Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position
by chaining them to a stationary support or equip-
ment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific
application; maintain them and associated parts
in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
!
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
2. If used in a closed area, vent engine exhaust out-
side and away from any building air intakes.

SAFE INSTRUCTION THERMAL ARC 201 TS
General Information 1-4 Manual 0-5149
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
3. Allow engine to cool before fueling. If possible,
check and add fuel to cold engine before beginning
job.
4. Do not overfill tank — allow room for fuel to
expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from bat-
tery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a bat-
tery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when
working on a battery.
4. Do not use welder to charge batteries or jump
start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOL-
ANT can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely re-
moving cap.
LEAD WARNING
This product contains chemicals, includ-
ing lead, or otherwise produces chemicals
known to the State of California to cause
cancer, birth defects and other reproduc-
tive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5
et seq.)
WARNING
This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields
The following is a quotation from the General Conclu-
sions Section of the U.S. Congress, Office of Tech-