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Art # A-10139

50

60

Hz

32A OUTLET

STICK

TIG

230V

110V

TIG/STICK

32A OUTLET

16A OUTLET

201 TS

Operating Manual

Revision:

AB

Issue Date: May

20, 2011

Manual No.:

0-5149

Operating Features:

THERMAL ARC

invERTER ARC wELdER

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Summary of Contents for 201 TS

Page 1: ...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 wel...

Page 2: ...ize 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 ab...

Page 3: ...n 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 th...

Page 4: ...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 Envir...

Page 5: ...1 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...

Page 6: ...1003803 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 Th...

Page 7: ...rkpiece 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 co...

Page 8: ...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 Shie...

Page 9: ...ot 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 grindi...

Page 10: ...RY 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 cable...

Page 11: ...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 O...

Page 12: ...8 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 wi...

Page 13: ...ly and would look something like this 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the...

Page 14: ...ase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connectio...

Page 15: ...information contained herein when installed operated maintained and repaired in accordance with the instructions pro vided This equipment must be checked periodically Defective equipment including we...

Page 16: ...s 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 th...

Page 17: ...10 min Quoted figures refer to STICK MMA output 125A 25 25 0V 95A 60 23 8V 80A 100 23 2V 200A 20 28V 120A 60 24 8V 100A 100 24 0V Rated Input Current A 39A 32A for STICK MMA Welding Io 125A 25 0V Io 2...

Page 18: ...s 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 foll...

Page 19: ...ELLOW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 3 01 Environment These units are designed for use in environments with increased hazard o...

Page 20: ...ION 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 brea...

Page 21: ...ete 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 sa...

Page 22: ...ered 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 oper...

Page 23: ...er 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 200A Set Welding Current a...

Page 24: ...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 sw...

Page 25: ...serted 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...

Page 26: ...4 Turntheadjustingscrew knobcounterclockwise 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...

Page 27: ...formation 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 th...

Page 28: ...ing current should be set according to the specific application Refer to application notes in this section for further information F Arc Force Down Slope Control Arc Force is effective when in STICK M...

Page 29: ...arious Materials High Tensile and Alloy Steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area and if suitable precautions are not taken th...

Page 30: ...m 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 Idea...

Page 31: ...nt Electrode Diameter Filler Rod Diameter Argon Gas Flow Rate Joint Type Mild Steel Stainless Steel 1 0mm 0 040 35 45 20 30 1 0mm 0 040 1 6mm 1 16 10 CFH 5 LPM Butt Corner 40 50 25 35 Lap Filler 1 2mm...

Page 32: ...etween these Some of the common types of welds are shown in Figures 4 3 through 4 10 Art A 07691 Figure 4 7 Vertical position butt weld Art A 07692 Art A 07693 Art A 07694 Figure 4 8 Vertical position...

Page 33: ...es 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 Gap varies from 1 6mm 1 16 to 4 8mm 3...

Page 34: ...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 ti...

Page 35: ...revent slag being trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 13 The width of weave should n...

Page 36: ...07702 Figure 4 18 Multi run vertical fillet weld Art A 07703 Figure 4 19 Examples of vertical fillet welds 2 Vertical Down The E7014 electrode makes welding in this position particularly easy Use a 3...

Page 37: ...ot Hot Weld Upsetting Expansion with compression Cool Figure 4 21 Parent metal expansion Art A 07706_AB Weld Permanent Upset Contraction with tension Figure 4 22 Parent metal contraction Art A 07704 F...

Page 38: ...Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experi ence or to find by trial and error or less frequently to calcul...

Page 39: ...y with solvents that are recommended for cleaning electrical apparatus CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere wi...

Page 40: ...Use larger electrodes and preheat the plate B Increase welding current C Adjust angle so the welding arc is directed more into the base metal D Reduce travel speed of electrode E Clean surface before...

Page 41: ...grinding contaminates off 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 flutte...

Page 42: ...The Primary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF C Loose connections internally A Switch ON the Primary supply voltage B Switch ON the Welding Powe...

Page 43: ...lider 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 Aut...

Page 44: ...9 16 Connector Gas Outlet 161 STL 201 TS W7003212 17 Output Terminal 50mm dinse W7003020 18 Socket 8 Pin cable 161 STL 201 TS W7003220 19 Gas Solenoid W7003033 20 Current Sensor 161 201TS W7003076 Cur...

Page 45: ...APPENDIX THERMAL ARC 201 Ts Manual 0 5149 A 3 Appendix 2 5 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 Art A 10148 26 5 1...

Page 46: ...J11 1 J11 2 J11 3 4 1 J 3 1 J 2 1 J 0 1 J 3 2 J J15 J16 J17 J18 J19 J20 J21 CONNECTOR LAYOUT DIAGRAM J22 GAS SOLENOID J2 3 J2 2 J2 1 J13 1 J13 2 J13 3 J13 4 J13 5 J6 2 J6 1 J9 1 J9 2 J9 3 J9 4 J8 4 J8...

Page 47: ...ior written consent obtained from Thermadyne service department UK Equipment that has been used beyond the speci cations established in the operating manual Installation not in accordance with the ins...

Page 48: ...o Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39...

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