Thermal Arc 161 STL 201 TS Operating Manual_(0

161 STL
THERMAL ARC
®
201 ts Inverter Arc Welder
Art # 09783_AB
Operating Manual
Revision: AG
Issue Date: Dec. 03, 2012
Operating Features:
Manual No.: 0-5147
50Hz
60
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 worldwide service network. To locate your nearest distributor or service agency call
1-800-462-2782, 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received, then check for a newer version of the manual on our website or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.
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The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for Victor
Technologies International, Inc. We manufacture and supply to major welding
industry sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
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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 judgment, the
Manufacturer assumes no liability for its use.
Operating Manual Number 0-5147 for:
Thermal Arc 161 STL Power Source Arc Welder
Thermal Arc 161 STL System with Stick/TIG Kit & Case Thermal Arc 201 TS Power Source Arc Welder
Thermal Arc 201 TS System with Stick/TIG Kit & Case Part No. W1003700
Part No. W1003701
Part No. W1003800
Part No. W1003801
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road, Suite 300St
Louis, Mo 63017
USA
www.thermalarc.com
Copyright © 2010, 2011, 2012 by
Victor Technologies International, 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: October 7, 2010
Revision AG Date: December 03, 2012
Record the following information for Warranty purposes:
Where Purchased:
_____________________________________
Purchase Date:
_____________________________________
Equipment Serial #:
_____________________________________
i
TABLE OF CONTENTS
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS................................................ 1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
1.09
Arc Welding Hazards........................................................................................ 1-1
General Safety Information for Victor CS Regulator........................................... 1-4
Principal Safety Standards............................................................................... 1-5
Symbol Chart................................................................................................... 1-6
Precautions De Securite En Soudage A L’arc................................................... 1-7
Dangers relatifs au soudage à l’arc.................................................................. 1-7
Informations Générales de Sécurité............................................................... 1-10
Principales Normes De Securite.................................................................... 1-12
Graphique de Symbole................................................................................... 1-13
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
2.04Description...................................................................................................... 2-1
2.05
Transportation Methods................................................................................... 2-1
2.06
Duty Cycle........................................................................................................ 2-2
2.07
Specifications -161 STL................................................................................... 2-3
2.08
Specifications - 201 TS.................................................................................... 2-4
SECTION 3: INSTALLATION................................................................................ 3-1
3.01Environment.................................................................................................... 3-1
3.02Location........................................................................................................... 3-1
3.03
Electrical Input Connections............................................................................ 3-1
3.04
Electromagnetic Compatibility......................................................................... 3-4
3.05
Setup for Welding............................................................................................ 3-5
3.06
STICK (SMAW) Setup...................................................................................... 3-6
3.07
LIFT TIG (GTAW) Setup................................................................................... 3-7
3.08
HF TIG (GTAW) Setup (201 TS Only)............................................................... 3-9
3.09
Victor Regulator............................................................................................. 3-10
3.10
Leak Testing the System................................................................................ 3-12
3.11
When You Finish Using the Regulator............................................................ 3-13
3.12
Storage of the Regulator................................................................................ 3-13
TABLE OF CONTENTS
SECTION 4: OPERATION.................................................................................... 4-1
4.01
Front Panel...................................................................................................... 4-1
4.02
Welding Current Control Explanation............................................................... 4-4
4.03
STICK (SMAW) Electrode Polarity................................................................... 4-5
4.04
Effects of Stick Welding Various Materials....................................................... 4-5
4.05
GTAW Electrode Polarity.................................................................................. 4-6
4.06
Guide for Selecting Filler Wire......................................................................... 4-6
4.07
Tungsten Electrode Current Ranges................................................................. 4-6
4.08
Shielding Gas Selection................................................................................... 4-6
4.09
Tungsten Electrode Types................................................................................ 4-7
4.10
TIG Welding Parameters for Steel.................................................................... 4-7
4.11
Arc Welding Practice........................................................................................ 4-7
4.12
Welding Position.............................................................................................. 4-8
4.13
Joint Preparations............................................................................................ 4-9
4.14
Arc Welding Technique.................................................................................. 4-10
4.15
The Welder..................................................................................................... 4-10
4.16
Striking the Arc.............................................................................................. 4-10
4.17
Arc Length..................................................................................................... 4-10
4.18
Rate of Travel................................................................................................. 4-11
4.19
Making Welded Joints.................................................................................... 4-11
4.20Distortion....................................................................................................... 4-13
4.21
The Cause of Distortion................................................................................. 4-13
4.22
Overcoming Distortion Effects....................................................................... 4-14
SECTION 5: SERVICE....................................................................................... 5-1
5.01
5.02
5.03
5.04
Maintenance and Inspection............................................................................ 5-1
STICK (SMAW) Welding Problems ................................................................. 5-2
TIG Welding Problems .................................................................................... 5-3
Power Source Problems ................................................................................. 5-4
APPENDIX 1: OPTIONS AND ACCESSORIES............................................................. A-1
APPENDIX 2: REPLACEMENT PARTS-161 STL.......................................................... A-2
APPENDIX 3: REPLACEMENT PARTS-201 TS ........................................................... A-4
APPENDIX 4: SYSTEM SCHEMATIC - 161 STL .......................................................... A-6
APPENDIX 5: SYSTEM SCHEMATIC -201 TS ............................................................ A-7
LIMITED WARRANTY
WARRANTY SCHEDULE
Thermal Arc 161 STL Stick/TIG System
Part Number W1003701
•
Thermal Arc 161 STL power supply in toolbox
•
17 TIG torch, 12.5ft (3.8m) with Integrated Controls & accessory kit
•
Tweco electrode holder, 13ft (4m) lead
•
Tweco ground (work) clamp, 10ft (3.1m) lead
•
4 GP 1/8" (3.2mm) dia stick electrodes
•
230V to 115V adapter
•
Victor Cutskill 2G Gas Regulator
• Thermal Arc 161 STL gas hose assembly, 13ft (4m)
•
Quick set-up DVD
•
Operating manual
Art # A-09782_AB
Thermal Arc 201 TS Stick System
Part Number W1003801
•
Thermal Arc 201 TS power supply in toolbox
•
26 TIG torch, 12.5ft (3.8m) with Integrated Controls & accessory kit
•
Tweco WeldSkill 200Amp electrode holder, 13ft (4m) lead
•
Tweco WeldSkill 200Amp ground (work) clamp, 10ft (3.1m) lead
•
4 GP 1/8" (3.2mm) dia stick electrodes
•
230V to 115V adapter
•
Victor Cutskill 2G Gas Regulator •
Thermal Arc 201 TS gas hose assembly, 13ft (4m)
•
Quick set-up DVD
•
Operating manual
Art # A-10096
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
SECTION 1:
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 American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. 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
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power
circuit and machine internal circuits are also live when
power is on. In semi-automatic 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.
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.
WARNING
1. Do not touch live electrical parts.
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.
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
accidentally.
5. Properly install and ground this equipment according 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.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
Manual 0-5147
1-1
Safety Instructions
THERMAL ARC 161 STL, 201 ts
SAFETY INSTRUCTIONS
WARNING
WARNING
WELDING can cause fire or explosion.
FUMES AND GASES can be hazardous to your health.
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
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
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 breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. If ventilation is poor, use an approved air-supplied respirator.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
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.
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.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
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.
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Filter
Shade
No.
Welding or Cutting
Operation
Torch soldering
2
Gas metal-arc
welding (MIG)
Torch brazing
3 or 4
Non-ferrous base metal
All
11
Non-ferrous base metal
All
12
Welding or Cutting
Operation
Electrode Size
Metal Thickness
or Welding Current
Oxygen Cutting
Electrode Size
Filter
Metal Thickness Shade
or Welding Current No.
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
Carbon arc welding
All
12
Gas welding
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
Safety Instructions
1-2
Manual 0-5147
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
WARNING
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
ENGINE FUEL can cause fire or explosion.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
2. Wear proper body protection to protect skin.
3. Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to
treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
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.
3. Keep cylinders away from any welding or other electrical
circuits.
2. Stop engine before installing or connecting unit.
4. Never allow a welding electrode to touch any cylinder.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
6. Turn face away from valve outlet when opening cylinder valve.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
!
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
WARNING
Engines can be dangerous.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
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.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
Manual 0-5147
1-3
Safety Instructions
THERMAL ARC 161 STL, 201 ts
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1.02 General Safety Information for Victor
CS Regulator
A Fire Prevention
Welding and cutting operations use fire or combustion as a basic
tool. The process is very useful when properly controlled. ­However,
it can be extremely destructive if not performed cor­rectly in the proper
environment.
1. The work area must have a fireproof floor.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Work benches or tables used during welding or cutting
operations must have fireproof tops.
2. Wear gloves and put a rag over cap area when removing cap.
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring from sparks and hot
metal.
3. Allow pressure to escape before completely removing cap.
SAFETY INSTRUCTIONS
4. Keep an approved fire extinguisher of the proper size and
type in the work area. Inspect it regularly to ensure that it
is in proper working order. Know how to use the fire extin­
guisher.
LEAD WARNING
This product contains chemicals, including lead, or
otherwise produces chemicals known to the State of
California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)
5. Move combustible materials away from the work site. If you
­can not move them, protect them with fireproof covers. ­
!
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology 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
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.
WARNING
NEVER perform welding, heating, or cutting operations
on a container that has held toxic, combustible or
flammable liq­uids, or vapors. NEVER perform welding,
heating, or cutting operations in an area containing combustible vapors, flam­mable liquids, or explosive dust.
BHousekeeping
!
WARNING
NEVER allow oxygen to contact grease, oil, or other
flam­mable substances. Although oxygen by itself will not
burn, these substances become highly explosive. They
can ignite and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and other flammable
substances.
CVentilation
!
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
WARNING
Ade­quately ventilate welding, heating, and cutting work
areas to prevent accumulation of explosive or toxic
concen­trations of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When
welding/brazing, read and understand the Material Safety
Data Sheet for the welding/brazing alloy.
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.
Safety Instructions
1-4
Manual 0-5147
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
D Personal Protection
3. Store empty cylinders away from full cylinders. Mark them
“EMPTY” and close the cylinder valve.
Gas flames produce infrared radiation which may have a harm­ful effect
on the skin and especially on the eyes. Select goggles or a mask with
tempered lenses, shaded 4 or darker, to protect your eyes from injury
and provide good visibility of the work.
4. NEVER use compressed gas cylinders without a pressure
reducing regulator attached to the cylinder valve. ­
5. Inspect the cylinder valve for oil, grease, and damaged
parts.
Always wear protective gloves and flame-resistant clothing to protect skin
and clothing from sparks and slag. Keep collars, sleeves, and pockets
buttoned. DO NOT roll up sleeves or cuff pants.
!
When working in a non-welding or cutting environment, always wear
suitable eye protection or face shield.
!
WARNING
DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition
immediately.
WARNING
6. Momentarily open and close (called “cracking”) the cylinder
valve to dislodge any dust or dirt that may be present in the
valve.
Practice the following safety and operation precautions
EVERY TIME you use pressure regulation equipment.
Deviation from the following safety and operation
instructions can result in fire, explosion, damage to
equipment, or injury to the operator.
CAUTION
E Compressed Gas Cylinders
Open the cylinder valve slightly. If you open the valve
too much, the cylinder could tip over. When cracking
the cylinder valve, DO NOT stand directly in front of
the cylinder valve. Always perform cracking in a well
ventilated area. If an acetylene cylinder sprays a mist
when cracked, let it stand for 15 minutes. Then, try to
crack the cylinder valve again. If this problem persists,
contact your gas supplier.
The Department of Transportation (DOT) approves the design and
manufacture of cylinders that contain gases used for welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will use it. Keep
the cylinder in a vertical position. Secure it to a cart, wall, work
bench, post, etc.
1.03 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.
Figure 1-1: Gas Cylinders
!
WARNING
Cylinders are highly pressurized. Handle with care.
Serious accidents can result from improper handling
or mis­use of compressed gas cylinders DO NOT drop
the cylinder, knock it over, or expose it to excessive
heat, flames or sparks. DO NOT strike it against other
cylinders. Contact your gas supplier or refer to CGA P-1
“Safe Handling of Compressed Gases in Containers”
publication.
NOTE
CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly,VA 20151-2923
2. Place the valve protection cap on the cylinder whenever
mov­ing it, placing it in storage, or not using it. Never drag or
roll cylinders in any way. Use a suitable hand truck to move
cylin­ders.
Manual 0-5147
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5
Safety Instructions
THERMAL ARC 161 STL, 201 ts
SAFETY INSTRUCTIONS
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
S
See Note
See Note
Voltage Input
Art # A-04130_AB
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
Safety Instructions
1-6
Manual 0-5147
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
1.05 Precautions De Securite En Soudage A L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions
de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.06 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès
la mise en circuit. Le circuit d’alimentation et les circuits
internes de l’équipement sont aussi sous tension dès
la mise en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage sont
sous tension. Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation
afin d’éviter une mise en marche accidentelle.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux
et la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
Manual 0-5147
1-7
Safety Instructions
THERMAL ARC 161 STL, 201 ts
SAFETY INSTRUCTIONS
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives
aux métaux, aux produits consummables, aux revêtements et aux
produits nettoyants.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs
de soudage peuvent déplacer l’oxygène de l’air et ainsi causer
des malaises ou la mort. Assurez-vous que l’air est propre à la
respiration.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent
réagir avec des vapeurs et former des gaz hautement toxiques et
irritants.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé; si nécessaire portez un respirateur à
adduction d’air. Car ces revêtements et tout métal qui contient
ces éléments peuvent dégager des fumées toxiques au moment
du soudage.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Nuance de
filtre
oculaire
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Oxycoupage
mince
moins de 1 po. (25 mm)
2 ou 3
Soudage á l'arc sous gaz avec
électrode de tungstène
(GTAW)
toutes conditions
12
moyen
de 1 á 6 po. (25 á 150 mm)
4 ou 5
Soudage á l'hydrogène
atomique (AHW)
toutes conditions
12
plus de 6 po. (150 mm)
5 ou 6
Soudage á l'arc avec
électrode de carbone (CAW)
toutes conditions
12
Soudage á l'arc Plasma (PAW)
toutes dimensions
12
épais
Soudage aux gaz
Gougeage Air-Arc avec
électrode de carbone
mince
moins de 1/8 po. (3 mm)
4 ou 5
moyen
de 1/8 á 1/2 po. (3 á 12 mm)
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
épais
plus de 400 amperès
14
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
Safety Instructions
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Opération de coupage
ou soudage
Coupage á l'arc Plasma (PAC)
1-8
Manual 0-5147
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
AVERTISSEMENT
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure
et l’équipement surchauffé peuvent causer un incendie
et des brûlures. Le contact accidentel de l’électrode ou
du fil-électrode avec un objet métallique peut provoquer
des étincelles, un échauffement ou un incendie.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et
d’incendie.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
9. Ne dégelez pas les tuyaux avec un source de courant.
AVERTISSEMENT
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact
lorsqu’inutilisé après le soudage.
LES MOTEURS PEUVENT ETRE DANGEREUX
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
AVERTISSEMENT
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
2. Portez des vêtements appropriés pour protéger la peau.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.
Manual 0-5147
1-9
Safety Instructions
THERMAL ARC 161 STL, 201 ts
SAFETY INSTRUCTIONS
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme
le plomb, ou engendre des produits chimiques,
reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations
fœtales ou d’autres problèmes de reproduction.
Il faut se laver les mains après toute manipulation.
(Code de Californie de la sécurité et santé, paragraphe
25249.5 et suivants)
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des
outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
1.07 Informations Générales de Sécurité
A
Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion comme outil
de base. Ce processus est très utile quand il est cor­rectement contrôlé.
1. La zone doit comporter un sol ignifugé.
AVERTISSEMENT
2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement ignifuge.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR
PEUT BRULER LA PEAU ET LES YEUX.
3. Utilisez des écrans résistants à la chaleur ou en matériau
approuvé pour protéger les cloisons proches ou le sol vul­
nérable des étincelles et du métal chaud.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
4. Gardez un extincteur approuvé du bon type et de la bonne taille
dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
5. Enlevez tous les matériaux combustibles de la zone de travail.
Si vous ne pouvez pas les enlever, protégez-les avec une cou­vre
ignifuge.
3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
Safety Instructions
1-10
Manual 0-5147
SAFETY INSTRUCTIONS
!
THERMAL ARC 161 STL, 201 ts
!
AVERTISSEMENT
N’effectuez JAMAIS d’opérations de soudage sur un
récipient qui a contenu des liquides ou vapeurs toxiques,
combustibles ou inflammables. N’effectuez JAMAIS
d’opérations de soudage dans une zone contenant des
vapeurs combustibles, des liquides inflammables ou des
poussières explosives.
B
Entretien des Locaux
!
AVERTISSEMENT
AVERTISSEMENT
Mettez en pratique les procédures de sécurité et de
mode opératoire suivantes à chaque fois que vous
utilisez cet appareil de régulation de pression. Si vous
déviez de ces procédures, cela peut entraîner incendie,
explosion, dégâts matériels et/ou blessures corporelles
pour l’opérateur.
E
Bouteilles de Gaz Comprimé
Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour
les opérations de soudage ou de découpage.
1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la
en position verticale. Fixez-la sur un chariot une cloison, un établi,
etc.
Ne laissez jamais l’oxygène en contact avec la graisse,
l’huile ou d’autres substances inflammables. Bien
que l’oxygène elle­même ne brûle pas, ces substances
peuvent devenir extrême­ment explosives. Elles peuvent
prendre feu et brûler violem­ment en présence d’oxygène.
Gardez TOUS les appareils propres et exempts de graisse, huile ou
autres substances inflammables.
CAération
!
AVERTISSEMENT
Le schéma 1-1: Cylindres de gaz
Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de
gaz explosifs ou toxiques. Certaines combinaisons de
métaux, revêtements et gaz génèrent des fumées toxiques: Utilisez un équipement de protection respiratoire
dans ces circonstances. Si vous soudez ou brasez, lisez
et assimilez la fiche technique de sécurité de matériau
relative à l’alliage de soudage/brasage.
D
!
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulez-les avec
précautions. Des accidents sérieux peuvent résulter d’une
mauvaise manutention ou d’un mauvais emploi des bouteilles
de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez
pas, ne l’exposez pas à une chaleur excessive, aux flammes ou
étincelles. NE la cognez PAS contre d’autres bouteilles. Contactez
votre fournisseur de gaz ou reportez­vous à la publication CGA
P-1 “Manipulation sécurisée des gaz comprimés en conteneur”
pour plus d’informations sur l’utilisation et la manutention des
bouteilles.
Protection Personnelle
Les flammes de gaz produisent une radiation infrarouge qui peut avoir
un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris
au niveau 4 ou plus sombre, pour protéger vos yeux des dommages
et garder une bonne visibilité sur le travail.
AVIS
Portez en permanence des gants de protection et des vête­ments
ignifuges pour la protection de la peau et des vêtements contre les
étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne
faut pas remonter vos manches ou les pantalons à revers.
Ce document CGA p. t peut être obtenu en écrivant à
“Compressed Gas Association”, 4221 Walney Roed,
5th Floor. Chantilly, VA 20151.2923, USA.
Quand vous travaillez dans un environnement non dédié au soudage
ou découpage, portez toujours une protection des yeux appropriées
ou un masque facial.
2. Placez le bouchon de protection de vanne sur la bouteille
à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne
faites jamais glisser ou rouler d’aucune manière les bouteilles.
Utilisez un diable approprié pour les déplacer.
3. Entreposez les bouteilles vides à l’écart des bouteilles pleines.
Marquez-les “VIDE” et refermez leur vanne.
4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un
régulateur de pression en série sur la vanne de bouteille.
5. Inspectez la vanne de bouteille pour y détecter de l’huile ou
de la graisse, ou dès pièces endommagées.
Manual 0-5147
1-11
Safety Instructions
THERMAL ARC 161 STL, 201 ts
!
SAFETY INSTRUCTIONS
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez de l’huile,
de la graisse ou des pièces endommagées. Informez
immédiate­ment votre fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de la bouteille,
délogeant ainsi d’éventu lIes poussières ou saletés. qui pour­
raient être présentes dans la vanne.
Mise en Garde
Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez
trop en grand, la bouteille pourrait se renverser. Quand
vous ouvrez/fermez rapidement la vanne de bouteille, ne
vous tenez pas directement devant. Opérez toujours cette
opération dans une zone bien ventilée. Si une bouteille
d’acétylène crache un brouillard, laissez reposer pendant
15 minutes. Essayez de nouveau la vanne. Si le problème
persiste, con­tactez votre fournisseur de gaz.
1.08 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, 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, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association
canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safety Instructions
1-12
Manual 0-5147
SAFETY INSTRUCTIONS
THERMAL ARC 161 STL, 201 ts
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Mono Phasé
Déroulement du Fil
Hors Tension
Trois Phasé
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Tri-Phase Statique
Torch de Soudage
Tension dangereuse
Fréquence Convertisseur
Transformateur-Redresseur
Augmentez/Diminuer
Distant
Purge Du Gaz
Facteur de Marche
Mode Continu de
Soudure
Pourcentage
Soudure Par Point
Disjoncteur
Source AC Auxiliaire
X
%
Fusible
Panneau/Local
Intensité de Courant
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Tension
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Hertz (cycles/sec)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Fréquence
Decoupe Arc Carbone
(CAC-A)
t
Duréc du Pulse
Durée de Pré-Dèbit
t1
t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Détente à 4-Temps
Négatif
Courant Constant
Positif
Tension Constante
Ou Potentiel Constant
Courant Continue (DC)
Haute Température
Terre de Protection
Force d'Arc
Ligne
Amorçage de L’arc au
Contact (GTAW)
Connexion de la Ligne
Inductance Variable
Source Auxiliaire
115V 15A
V
Tension
Classement de PriseSource Auxiliaire
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
t
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
S
Voir Note
Voir Note
Art # A-07639_AB
Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque S conforme
à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à
l'hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Manual 0-5147
1-13
Safety Instructions
THERMAL ARC 161 STL, 201 ts
SAFETY INSTRUCTIONS
This page left blank intentionally.
Safety Instructions
1-14
Manual 0-5147
INTRODUCTIONtHERMAL ARC 161 STL, 201 ts
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual
2.03 Receipt of Equipment
This Manual usually applies to the part numbers listed on
page i. To ensure safe operation, read the entire manual,
including the chapter on safety instructions and warnings.
Throughout this manual, the word WARNING, CAUTION
and NOTE may appear. Pay particular attention to the information provided under these headings. These special
annotations are easily recognized as follows:
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in the
inside back cover of this manual. Include all equipment
identification numbers as described above along with a
full description of the parts in error.
!
WARNING
Gives information regarding possible personal
injury. Warnings will be enclosed in a box
such as this.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics
You will also notice icons from the safety section appearing throughout the manual. These are to advise you of
specific types of hazards or cautions related to the portion
of information that follows. Some may have multiple
hazards that apply and would look something like this:
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the machine. Equipment which
does not have a nameplate attached to the machine is
identified only by the specification or part number printed
on the shipping container. Record these numbers for
future reference.
2.04Description
The Thermal Arc 161STL is compact inverter welding
machine has infinitely adjustable welding current from 10
to 160 amps. It has a LIFT TIG (GTAW) welding mode that
offers stable TIG welding characteristics with an optimized
Lift Start TIG sequence to initiate the welding arc when
used with a suitable TIG torch and shielding gas.
The Thermal Arc 201TS is compact inverter welding
machine has infinitely adjustable welding current from
10 to 200 amps. It has a LIFT TIG (GTAW) and HF TIG
(GTAW) welding modes that offers stable TIG welding
characteristics with an optimized start TIG sequence to
initiate the welding arc when used with a suitable TIG
torch and shielding gas.
Both models have advanced TIG features including 8 Pin
Amp Plug for remote control devices, down slope, 2T /
4T controls, and gas solenoid operation. They also have
STICK (SMAW) welding mode which uses standard general purpose STICK (SMAW) 3/32” (2.5mm) electrodes
for light gauge work, generally less than 1/8” (3.2mm)
thick and STICK (SMAW) 1/8” (3.2mm) electrodes for
heavier material.
2.05 Transportation Methods
!
Disconnect input power
conductors from de-energized supply line before moving
the welding power source.
Lift unit with handle on top of case. Use handcart or similar
device of adequate capacity. If using a fork lift vehicle,
secure the unit on a proper skid before transporting.
Manual 0-5147
2-1Introduction
THERMAL ARC 161 STL, 201 ts
INTRODUCTION
2.06 Duty Cycle
The rated duty cycle of a Welding Power Source, is the percentage of a ten minute time period that it may be operated
at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain
the 10 minute duty cycle period, suppose a Welding Power Source is designed to operate with a 30% duty cycle at
160 amperes and 26.4 volts. This means that it has been designed and built to provide the rated amperage (160A) for
3 minutes, i.e. arc welding time, out of every 10 minute period (30% of 10 minutes is 3 minutes). During the other 7
minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.
Introduction 2-2
Manual 0-5147
INTRODUCTIONtHERMAL ARC 161 STL, 201 ts
2.07 Specifications -161 STL
Power Source Part Number
Mains Power
Nominal Supply Voltage
Number of Phases
Input Voltage Range
Nominal Supply Frequency
Effective Input Current (l1eff)
Maximum Input Current (l1 max)
Single Phase Generator Requirements [Continuous rating at
nominal supply voltage with maximum output for STICK (SMAW)
welding]
Welding Output
Welding Current Range
W1003700
AC 115V
Single Phase
AC 104- 127V
50/60 Hz
20 Amps
∆ 28.6 Amps
5 KVA
AC 208/230V
Single Phase
AC 187- 253V
50/60 Hz
16 Amps
∆ 25 Amps
6 KVA
Stick: 10 - 125 Amps
Stick/TIG:
TIG: 10 - 160 Amps
10 - 160 Amps
71V
71V
100A @ 45%, 24.0V
160A @ 30%, 26.4V
95A @ 60%, 23.8V
120A @ 60%, 24.8V
80A @ 100%, 23.2V
100A @ 100%, 24.0V
28.6A
25A
Io = 100A @ 24.0V
Io = 160A @ 26.4V
28.6A
15.5A
Io = 150A @ 16.0V
Io = 160A @ 16.4V
24.0V, 100A @ 45%
26.4V, 160A @ 30%
16.0V, 150A @ 35%
16.4V, 160A @ 30%
45% @ 100A
30% @ 160A
Inverter Power Source
Heavy Duty DinseTM 50
Nominal DC Open Circuit Voltage (OCV)
Welding Output, 104º F (40º C), 10 min.
(Quoted figures refer to STICK (SMAW) output)
Rated Input Current (A)
for STICK (SMAW) Welding
Rated Input Current (A)
for LIFT TIG (GTAW) Welding
Rated Output for STICK (SMAW) Welding
Rated Output for LIFT TIG (GTAW) Welding
Duty Cycle (%)
Welder Type
Output Terminal Type
Classification
Protection Class
Standards
Cooling Method
Dimensions and Weight
Welding Power Source Mass
Welding Power Source Dimensions (Height x Width x Depth)
IP23S
EN 60974-1
EN50199
Fan Cooled
21.6 lb. (9.8 kg)
H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆ The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes and protected
by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent of the rated input amperage
of the welding power source (Based on Article 630, National Electrical Code)
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.
Manual 0-5147
2-3Introduction
THERMAL ARC 161 STL, 201 ts
2.08 Specifications - 201 TS2.08
INTRODUCTION
Specifications -201 TS
Power Source Part Number
Mains Power
Nominal Supply Voltage
Number of Phases
Input Voltage Range
Nominal Supply Frequency
Effective Input Current (l1eff)
Maximum Input Current (l1 max)
Single Phase Generator Requirements [Continuous rating at
nominal supply voltage with maximum output for STICK (SMAW)
welding]
Welding Output
Welding Current Range
Nominal DC Open Circuit Voltage (OCV)
Welding Output, 104º F (40º C), 10 min.
(Quoted figures refer to STICK (SMAW) output)
Rated Input Current (A)
for STICK (SMAW) Welding
Rated Input Current (A)
for LIFT TIG/HF TIG (GTAW) Welding
Rated Output for STICK (SMAW) Welding
Rated Output for LIFT TIG/HF TIG (GTAW) Welding
Duty Cycle (%)
Welder Type
Output Terminal Type
Classification
Protection Class
Standards
Cooling Method
Dimensions and Weight
Welding Power Source Mass
Welding Power Source Dimensions (Height x Width x Depth)
W1003800
AC 115V
Single Phase
AC 104- 127V
50/60 Hz
20 Amps
∆ 28.6 Amps
5 KVA
AC 208/230V
Single Phase
AC 187- 253V
50/60 Hz
16 Amps
∆ 32 Amps
6 KVA
Stick: 10 - 125 Amps
Stick/TIG:
TIG: 10 - 160 Amps
10 - 200 Amps
71V
71V
100A @ 45%, 24.0V
200A @ 20%, 28V
95A @ 60%, 23.8V
120A @ 60%, 24.8V
80A @ 100%, 23.2V
100A @ 100%, 24.0V
28.6A
32A
Io = 100A @ 24.0V
Io = 200A @ 28V
28.6A
20.6A
Io = 150A @ 16.0V
Io = 200A @ 18V
24.0V, 100A @ 45%
28V, 200A @ 20%
16.0V, 150A @ 35%
18V, 200A @ 25%
45% @ 100A
20% @ 200A
Inverter Power Source
Heavy Duty DinseTM 50
IP23S
EN 60974-1
EN50199
Fan Cooled
22 lb. (10 kg)
H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆ The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes
and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent
of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code)
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.
Introduction 2-4
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
SECTION 3:
INSTALLATION
3.01Environment
These units are designed for use in environments with increased hazard of electric shock. Examples of environments
with increased hazard of electric shock are:
A. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
B. In locations which are fully or partially limited 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 or perspiration considerably reduces the skin resistance of the human
body and the insulation properties of accessories.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased hazard, have been insulated.
3.02Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between 14°F (-10°C) to 104° F (40° C).
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air flow for
cooling
!
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.03 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging
procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other disconnecting device.
Manual 0-5147
3-1Installation
THERMAL ARC 161 STL, 201 TS
INSTALLATION
• Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one
of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility
for information about the type of electrical service available, how proper connections should be made, and inspection
required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power
from the welding power supply whenever necessary to inspect or service the unit.
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3-1:
1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that
complies with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.
3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.
Input Voltage
Circuit Breaker or Fuse Size
115V
30A
208-230V
50A
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.
Installation3-2
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
208-230V, 50A, 1Ø
Welding Power Supply
120 V, 20A, 1Ø
The Adapters enable
connection to all these
power outlets
120 V, 15A, 1Ø
Art# A-09789
Primary Power Cable
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)
NOTE
Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.
Model
Thermal Arc
161 STL
Thermal Arc
201 TS
Primary Supply Lead Minimum Primary
Current & Duty Cycle
Size (Factory Fitted) Current Circuit Size LIFT TIG/ HF TIG STICK (SMAW)
(Vin/Amps)
(GTAW)
115V/30A
100A @ 45%
115V/30A
150A @ 35%
12 AWG (3.3mm²)
208-230V/25A
160A @ 30%
208-230V/15A
160A @ 30%
115V/30A
100A @ 45%
115V/30A
150A @ 35%
12 AWG (3.3mm²)
208-230V/25A
200A @ 20%
208-230V/25A
200A @ 25%
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current
Manual 0-5147
3-3Installation
THERMAL ARC 161 STL, 201 TS
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.
INSTALLATION
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 its 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
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.
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 stabilizing devices should be adjusted
and maintained according to the manufacturer’s
recommendation
1. Other supply cables, control cables, signaling and
telephone cables; above, below and adjacent to the
welding equipment.
3. Welding Cables
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 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.
Installation3-4
Manual 0-5147
INSTALLATION
5. Earthing of the Work Piece
Where the work piece is not bonded to earth for
electrical safety, nor connected to earth because of its
size and position, e.g. ship’s hull or building steelwork,
a connection bonding the work piece to earth may
reduce emissions in some, but not all instances. Care
should be taken to prevent the earthing of the work
piece increasing the risk of injury to users, or damage
to other electrical equipment. Where necessary, the
connection of the work piece to earth should be made
by direct connection to the work piece, 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.
THERMAL ARC 161 sTL, 201 TS
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.
Manual 0-5147
3-5Installation
THERMAL ARC 161 STL, 201 TS
INSTALLATION
3.06 STICK (SMAW) Setup
Set Process Selection
Switch to STICK.
Set Welding Current
as specified by the
Electrode Manufacturer.
Set ARC Force
Negative Output
Terminal
(Dinse™ 50)
Positive Output
Terminal
(Dinse™ 50)
200A
Art#:A-09784
Figure 3-2: Setup for STICK (SMAW) Welding
STICK (SMAW) Mode Sequence of Operation
NOTE
This set up is known as DC Electrode Positive
or reverse polarity. Please consult with the
stick electrode manufacturer for specific
polarity recommendations.
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.
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.
Installation3-6
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
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 (GTAW) Setup
Set Process Selection
Switch to LIFT TIG.
Switch to 2T/4T
Set Welding Current
as specified by the
Electrode Manufacturer.
Secure the gas cylinder in an
upright position by chaining it
Negative
to a stationary support to prevent
Output
falling or tipping.
Terminal
(Dinse™ 50)
Set DOWN Slope
Positive Output
Terminal
(Dinse™ 50)
Art # A-09785_AB
Figure 3-3: Setup for LIFT TIG (GTAW) Welding
Manual 0-5147
3-7Installation
THERMAL ARC 161 STL, 201 TS
LIFT 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.
INSTALLATION
12.The tungsten must be ground to a blunt point in order
to achieve optimum welding results. It is critical to
grind the tungsten electrode in the direction the
grinding wheel is turning.
13.Install the tungsten with approximately 1/8” to ¼”
sticking out from the gas cup, ensuring you have
correct sized collet.
14.Tighten the back cap then open the valve on the torch.
15.Plug the power cable into the appropriate outlet, and
turn the switch to the “ON” position. The power L.E.D.
light should illuminate. Set the “Process Selection
Switch” to LIFT TIG
16.You are now ready to begin TIG Welding.
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 the
gas inlet fitting on the rear panel of the welder and
tighten with a wrench. Caution: DO NOT over tighten.
8. Open the Argon Cylinder Valve to the fully open
position.
9. Connect the ground (work) clamp to your work piece.
10.Set the DOWN SLOPE control knob to the desire weld
current ramp down time. Refer to Section 4.01.
11.Set the weld current control knob to the desired
amperage.
Installation3-8
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
3.08 HF TIG (GTAW) Setup (201 TS Only)
Set Process Selection
Switch to LIFT TIG or HF TIG.
Switch to 2T/4T
Set Welding Current
as specified by the
Electrode Manufacturer.
Set DOWN Slope
Secure the gas cylinder in an
upright position by chaining it
Negative
to a stationary support to prevent
Output
falling or tipping.
Terminal
(Dinse™ 50)
Positive Output
Terminal
(Dinse™ 50)
Art # A-10100_AB
Figure 3-4: Setup for HF TIG (GTAW) Welding of 201 TS
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;
Manual 0-5147
3-9Installation
THERMAL ARC 161 STL, 201 TS
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.
3.09 Victor Regulator
Pressure regulator (Figure 3-5) attached to the cylinder
valve reduce high cylinder pressures to suitable low
working pressures for welding, cutting, and other
applications.
INLET
CONNECTION
5. Install the regulator (for details of VICTOR regulator,
please refer to 3.09 ) and tighten with a wrench.
OUTLET
CONNECTION
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.
Figure 3-5: Victor CS Regulator
!
14.Tighten the back cap then open the valve on the torch.
15.Plug the power cable into the appropriate outlet, and
turn the switch to the “ON” position. The power L.E.D.
light should illuminate. Set the “Process Selection
Switch” to HF TIG
16.You are now ready to begin HF TIG Welding.
WARNING
Use the regulator for the gas and pressure for
which it is designed. NEVER alter a regulator
for use with any other gas.
8. Open the Argon Cylinder Valve to the fully open
position.
9. Connect the ground (work) clamp to your work
piece.
13.Install the tungsten with approximately 1/8” to ¼”
sticking out from the gas cup, ensuring you have
correct sized collet.
PRESSURE
ADJUSTING
SCREW
A-09414_AB
7. Connect the other end of the supplied gas hose to the
gas inlet fitting on the rear panel of the welder and
tighten with a wrench. Caution: DO NOT over tighten.
12.The tungsten must be ground to a blunt point in order
to achieve optimum welding results. It is critical to
grind the tungsten electrode in the direction the
grinding wheel is turning.
HIGH PRESSURE
GAUGE (SUPPLY)
FLOW GAUGE
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.
10.Set the DOWN SLOPE control knob to the desire weld
current ramp down time. Refer to Section 4.01.
11.Set the weld current control knob to the desired
amperage.
INSTALLATION
NOTE
Regulators purchased with open 1/8”, 1/4”,
3/8”, or 1/2” NPT ports must be assembled
to their intended system.
1. Note the maximum inlet pressure stamped on the
regulator. DO NOT attach the regulator to a system
that has a higher pressure than the maximum rated
pressure stamped on the regulator.
2. The regulator body will be stamped “IN” or “HP” at the
inlet port. Attach the inlet port to the system supply
pressure connection.
3. Wrap pipe threads with Teflon tape 1 1/2 to 2 turns
to effect a seal. If other sealants are used, they must
be compatible with the gas that will be used in the
system.
4. If gauges are to be attached to the regulator and the
regu­lator is stamped and listed by a third party (i.e.
“UL” or “ETL”). The following requirements must be
met:
Installation3-10
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
a) Inlet gauges over 1000 PSIG (6.87 mPa) shall
conform with the requirements of UL 404,
“Indicating Pressure Gauges for Compressed Gas
Service.”
b) Low pressure gauges must be UL recognized
for the class of regulator they are being used on
according to UL252A.
!
WARNING
Do not use a regulator that delivers
pressure exceeding the pressure rating of the
downstream equipment unless pro­visions
are made to prevent over-pressurization (i.e.
system relief valve). Make sure the pressure
rating of the down­s tream equipment is
compatible with the maximum delivery
pressure of the regulator.
5. Be sure that the regulator has the correct pressure
rating and gas service for the cylinder used.
6. Carefully inspect the regulator for damaged threads,
dirt, dust, grease, oil, or other flammable substances.
Remove dust and dirt with a clean cloth. Be sure the
inlet swivel filter is clean and in place. Attach the
regulator (Figure 3-6) to the cylinder valve. Tighten
securely with a wrench.
!
WARNING
DO NOT attach or use the regulator if oil,
grease, flamma­ble substances or damage is
present! Have a qualified repair technician
clean the regulator or repair any damage.
Manual 0-5147
Art # A-09845
Figure 3-6: Regulator to Cylinder Valve
7. Before opening the cylinder valve, turn the regulator
adjusting screw counterclockwise until there is no
pressure on the adjusting spring and the screw turns
freely.
8. Relief Valve (where provided): The relief valve is
designed to protect the low pressure side of the
regulator from high pres­sures. Relief valves are not
intended to protect down­stream equipment from high
pressures.
!
WARNING
DO NOT tamper with the relief valve or remove
it from the regulator.
!
WARNING
Stand to the side of the cylinder opposite the
regulator when opening the cylinder valve.
Keep the cylinder valve between you and the
regulator. For your safety, NEVER STAND IN
FRONT OF OR BEHIND A REGULATOR WHEN
OPENING THE CYLINDER VALVE!
3-11Installation
THERMAL ARC 161 STL, 201 TS
9. Slowly and carefully open the cylinder valve (Figure
3-7) until the maximum pressure shows on the high
pressure gauge.
INSTALLATION
3.10 Leak Testing the System
Leak test the system before putting into operation.
1. Be sure that there is a valve in the downstream
equipment to turn off the gas flow.
2. With the cylinder valve open, adjust the regulator
to deliver the maximum required delivery
pressure.
3. Close the cylinder valve.
4. Turn the adjusting screw/knob counterclockwise
one turn.
a) If the high-pressure gauge reading drops,
there is a leak in the cylinder valve, inlet fitting,
or high-pressure gauge.
Art # A-09828
Figure 3-7: Open Cylinder Valve
10.On all cylinders, except acetylene, open the valve
completely to seal the valve packing. On gaugeless
regulators, the indicator will register the cylinder
contents open.
11.On acetylene cylinders, open the valve 3/4 of a turn
and no more than 1-1/2.
!
WARNING
Acetylene delivery pressure must not exceed
15 PSIG (103 kPa) or 30 PSIG (207 kPa).
Acetylene can dissociate (decompose with
explosive violence) above these pressure
limits.
CAUTION
Keep the cylinder valve wrench, if one is
required, on the cylinder valve to turn off the
cylinder quickly, if necessary.
b) If the low-pressure gauge drops, there is a
leak in the down­stream equipment, hose, hose
fitting, outlet fitting or low-pressure gauge.
Check for leaks using an approved leak detector solution.
c) If the high-pressure gauge drops and the lowpressure gauge increases at the same time,
there is a leak in the regulator seat.
d) If the regulator requires service or repair, take
it to a qualified repair technician.
5. Once leak testing has been performed and there
are no leaks in the system, slowly open the
cylinder valve and proceed.
!
WARNING
If a leak has been detected anywhere in the
system, dis­continue use and have the system
repaired. DO NOT use leaking equipment. Do
not attempt to repair a leaking system while
the system is under pressure.
12.Attach the desired downstream equipment.
Installation3-12
Manual 0-5147
INSTALLATION
THERMAL ARC 161 sTL, 201 TS
3.11 When You Finish Using the
Regulator
1. Close the cylinder valve.
2. Open the valve on the downstream equipment.
This drains all pressure from the system.
3. Close the valve on the downstream equipment.
4. Turn the adjusting screw counterclockwise to
release the ten­sion on the adjusting spring.
5. Check the gauges after a few minutes for
verification that the cylinder valve is closed
completely.
3.12 Storage of the Regulator
When the regulator is not in use and has been removed
from the cylinder, it should be stored in an area where
it will be pro­tected from dust, oil, and grease. The inlet
and outlet should be capped to protect against internal
contamination and prevent insects from nesting.
Manual 0-5147
3-13Installation
THERMAL ARC 161 STL, 201 TS
INSTALLATION
This page left blank intentionally.
Installation3-14
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 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
(G) Gas Outlet
(I) 8 Pin Control Socket
Negative Output Terminal
Positive Output Terminal
Art # A-09786_AC
Figure 4-1: Thermal Arc 161 STL Controls
Manual 0-5147
4-1
Operation
THERMAL ARC 161 STL, 201 TS
OPERATION
(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
(G) Gas Outlet
(I) 8 Pin Control Socket
Negative Output Terminal
Positive Output Terminal
Art # A-10097
Figure 4-2: 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.
C. TRIGGER Mode Switch (LIFT TIG Mode Only)
2T (Normal) Mode
Press the TIG Torch Trigger Switch or Foot Control and hold depressed to weld. Release the TIG Torch Trigger Switch
or Foot Control to stop welding. Down Slope operates in LIFT TIG/HF TIG (GTAW) mode only. While welding if the
TIG Torch Trigger Switch is released, the welding current ramps down to zero current over a defined period of time.
The time period is determined by the Down Slope Control Knob (F).
4T (Latch) Mode
This mode of welding is mainly used for long weld runs. The operator need only to press the TIG Torch Trigger Switch
to activate and then release the TIG Torch Trigger Switch to continue to weld, then press the TIG Torch Trigger Switch
again and release the TIG Torch Trigger Switch to stop welding. This eliminates the need for the operator to depress the
TIG Torch Trigger Switch for the complete length of the weld. The 4T mode incorporates a current slope function which
includes a fixed current up slope of 1 second and an adjustable current down slope. Current slope operates in TIG Mode
Operation
4-2
Manual 0-5147
OPERATION
only. Up Slope is not adjustable and activates automatically
in 4T mode when the TIG torch trigger is depressed. To
activate the Down Slope function in 4T mode while welding,
the TIG Torch Trigger Switch must be depressed and held
while welding which will ramp the Welding Current down
to zero over a defined period of time. The time period is
determined by the Down Slope Control Knob (F). At any time
while welding if the TIG Torch Trigger Switch is depressed
and released the arc will extinguish immediately.
THERMAL ARC 161 sTL, 201 TS
H. Post Gas Flow (weld current dependant)
D. Process Selection Switch-
Post Gas Flow is the time Gas flows after the arc has
extinguished. The gas flow time is proportional to weld
current. This is used to cool and reduce oxidization of the
Tungsten Electrode. For example if the Welding Current
is set to 10 amps the Post Gas Flow time will be approximately 3 seconds. For a Welding Current set to 160 Amps
the Post Gas Flow time will be approximately 10 seconds.
The Post Gas Flow time cannot be adjusted independently
of the Welding Current.
161 STL
I. 8 Pin Remote Socket
Switches between STICK (SMAW) and LIFT TIG (GTAW)
modes. Refer to Section 3.06 Setup for STICK (SMAW)
Welding and 3.07 Setup for TIG Welding.
The 8 pin remote socket is used to connect the TIG Torch
Trigger Switch to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded
collar fully clockwise.
201 TS
Switches between STICK (SMAW), LIFT TIG (GTAW) and HF
TIG (GTAW) modes. Refer to Section 3.06 Setup for STICK
(SMAW) Welding, 3.07 Setup for LIFT TIG (GTAW)Welding
and 3.08 Setup for HF TIG (GTAW)Welding.
12345678
2
5k Ohms
E. Welding Current Control
The welding current is increased by turning the Weld Current
Control Knob clockwise or decreased by turning the Weld
Current Control Knob counterclockwise. The welding current
should be set according to the specific application. Refer
to application notes in this section for further information.
1
5
4
3
8
7
6
Front View of 8 Pin Socket
Art # A-09815_AB
Plug Pin
1
2
F. Arc Force/Down Slope Control
Arc Force is effective when in STICK (SMAW) Mode only. Arc
Force control provides an adjustable amount of Arc Force
(or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for
variability in joint fit-up in certain situations with particular
electrodes. In general increasing the Arc Force control toward ‘10’ (maximum Arc Force) allows greater penetration
control to be achieved. Down Slope operates in TIG mode
only. It is used to set the time for weld current to ramp down.
Refer to Item C (Trigger Mode Selection Switch) for further
information regarding Downslope operation.
3
4
5
6
G. Gas Outlet
7
The Gas Outlet is a 5/8”-18 UNF female gas fitting and is
utilized for the connection of a suitable TIG Torch.
Function
Torch Switch Input (24V) to energize weld
current. (connect pin 2&3 to turn on welding current)
Torch Switch Input (0V) to energize weld
current. (connect pin 2&3 to turn on welding current)
5k ohm (maximum) connection to 5k ohm
remote control potentiometer
Zero ohm (minimum) connection to 5k ohm
remote control potentiometer
Wiper arm connection to 5k ohm remote
control potentiometer
8
NOTE
Remote Welding Current Control is available through the
front panel of this unit. The remote will only go to the
maximum value that is set at the panel. If the panel is
set to 100 amps, the remote can't go above 100 amps
when fully adjusted.
Manual 0-5147
4-3
Operation
THERMAL ARC 161 STL, 201 TS
OPERATION
J. ON/OFF Switch (located on rear panel not shown)
This switch controls the Mains Supply Voltage to the Power Source.
4.02 Welding Current Control Explanation
15 Amp Outlet
The mains power 15 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding.
The environmental conditions that may cause the mains power 15 Amp circuit breaker or fuse to trip are:
a) High ambient temperature
b) Worn parts in circuit breaker
c) Using an extension cable
d) Low line mains power voltage
20 Amp Outlet
The mains power 20 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding.
The environmental conditions that may cause the mains power 20 Amp circuit breaker or fuse to trip are:
a) High ambient temperature
b) Worn parts in circuit breaker
c) Using an extension cable
d) Low line mains power voltage
Output Scale for 115V
The inside number scale identifies the available output weld current for STICK or LIFT TIG weld modes.
STICK Mode:
Identifies the STICK weld point for 15 Amp outlet.
Identifies the STICK weld point for 20 Amp outlet.
Exceeding these points will cause nuisance tripping of the circuit breaker or fuse.
LIFT TIG Mode/HF Mode: A 15 Amp outlet is capable of supplying enough input power for all TIG (GTAW) output
weld current values.
Nuisance tripping should not occur on a 15 Amp outlet.
Output Scale for 208/230V
The outside number scale identifies the available output weld current for STICK or LIFT TIG/HF TIG weld modes.
Nuisance tripping should not occur on a 50A 208/230V outlet for both STICK & LIFT TIG/HF TIG Modes.
Operation
4-4
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 201 TS
15 Amp Outlet
15 Amp Outlet
20 Amp Outlet
20 Amp Outlet
Output Scale for 115V
Output Scale for 115V
Output Scale for 230V
Output Scale for 230V
Art# A-09787
Art # A-10098
Figur4-3: Current Control for 161 STL
Figur4-4: Current Control for 201 TS
4.03 STICK (SMAW) Electrode Polarity
Stick electrodes are generally connected to the "+" Positive Output Terminal and the work lead to the "−" Negative Output
Terminal but if in doubt consult the electrode manufacturers literature for further information.
4.04 Effects of Stick Welding Various 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, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead
cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely
essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the
heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks
when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the
porosity caused by gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great
number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter
pipes, etc The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be
encountered; are all easy to use.
Manual 0-5147
4-5
Operation
THERMAL ARC 161 STL, 201 TS
Metal Being Joined
Mild Steel
Electrode
E6011
Mild Steel
E6013
Mild Steel
E7014
Mild Steel
E7018
Cast Iron
Stainless Steel
Eni-Cl
E318L-16
OPERATION
Comments
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.
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.
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.
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.
Suitable for joining all cast irons except white cast iron.
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)
1/16" (1.6mm)
20 - 90
3/32" (2.4mm)
65 - 115
1/8" (3.2mm)
100 - 165
4.07 Tungsten Electrode Current Ranges
Electrode Diameter
.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
DC Current
25 - 85
50 - 160
135 - 235
4.08 Shielding Gas Selection
Alloy
Carbon Steel
Stainless Steel
Nickel Alloy
Copper
Titanium
Operation
Shielding Gas
Welding Argon
Welding Argon
Welding Argon
Welding Argon
Welding Argon
4-6
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 201 TS
4.09 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Welding Application
Features
Color Code
Thoriated 2%
DC welding of mild steel, stainless steel Excellent arc starting, long life, high
and copper.
current carrying capacity.
Red
Ceriated 2%
AC & DC welding of mild steel, stainless Longer life, more stable arc, easier
steel, copper, aluminum, magnesium and starting, wider current range,
their alloys.
narrower & more concentrated arc.
Grey
4.10 TIG Welding Parameters for Steel
DC Current
Base Metal
Mild Steel
Thickness
0.040"
(1.0mm)
0.045"
(1.22mm)
1/16"
(1.6mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/4"
(6.4mm)
Stainless
Steel
35-45
20-30
40-50
25-35
45-55
30-45
50-60
35-50
60-70
40-60
70-90
50-70
80-100
65-85
90-115
90-110
115-135
100-125
140-165
125-150
160-175
135-160
170-200
160-180
Electrode
Diameter
Filler Rod
Diameter
Argon Gas Flow
Rate
0.040" (1.0mm)
1/16" (1.6mm)
10 CFH
(5 LPM)
Butt/Corner
0.040" (1.0mm)
1/16" (1.6mm)
13 CFH
(6 LPM)
Butt/Corner
1/16" (1.6mm)
1/16" (1.6mm)
15 CFH
(7 LPM)
Butt/Corner
1/16" (1.16mm) 3/32" (2.4mm)
15CFH
(7 LPM)
Butt/Corner
3/32" (2.4mm)
1/8" (3.2mm)
21CFH
(10 LPM)
Butt/Corner
1/8" (3.2mm)
5/32" (4.0mm)
21CFH
(10 LPM)
Butt/Corner
Joint / Type
Lap/Filler
Lap/Filler
Lap/Filler
Lap/Filler
Lap/Filler
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.
Manual 0-5147
4-7
Operation
THERMAL ARC 161 STL, 201 TS
OPERATION
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 4-5 through 4-12.
Art # A-07687
Figure 4-5: Flat position, down hand butt weld
Art A-07691
Figure 4-9: Vertical position, butt weld
Art # A-07688
Figure 4-6: Flat position, gravity fillet weld
Art # A-07692
Figure 4-10: Vertical position, fillet weld
Art # A-07689
Art# A-07693
Figure 4-7: Horizontal position, butt weld
Figure 4-11: Overhead position, butt weld
Art # A-07690
Art # A-07694
Figure 4-8: Horizontal - Vertical (HV) position
Figure 4-12: Overhead position, fillet weld
Operation
4-8
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 201 TS
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 4-13.
Single Vee Butt Joint
Open Square Butt
Joint
Not less than
70°
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”)
Single Vee Butt Joint
Not less than
45°
Double Vee Butt Joint
Lap Joint
Fillet Joint
Not less than
70°
1.6mm (1/16”) max
1.6mm (1/16”)
Tee Joints
(Fillet both sides of the
joint)
Corner Weld
Edge Joint
Plug Weld
Plug Weld
Art # A-07695_AE
Figure 4-13: Typical joint designs for arc welding
Manual 0-5147
4-9
Operation
THERMAL ARC 161 STL, 201 TS
OPERATION
4.14 Arc Welding Technique
4.16 Striking the Arc
A Word to Beginners
Practice this on a piece of scrap plate before going on to
more exacting work. You may at first experience difficulty
due to the tip of the electrode “sticking” to the work piece.
This is caused by making too heavy a contact 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 1/16" (1.6mm)
to 1/8" (3.2mm) gap between the burning electrode end
and the parent metal. Draw the electrode slowly along as
it melts down.
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 1/4" (6.4mm) thick and
a 1/8" (3.2mm) 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 the downhand position.
Make sure that the work clamp is making good electrical contact with the work, either directly or through the
work table. For light gauge material, always clamp the
work lead directly to the job, otherwise a poor circuit will
probably result.
4.15 The Welder
Place yourself in a comfortable position before beginning
to weld. Get a seat of suitable height and do as much work
as possible sitting down. Don’t hold your body tense. A
taut attitude of mind and a tensed body will soon make
you feel tired. Relax and you will find that the job becomes
much easier. You can add much to your peace of mind
by wearing a leather apron and gauntlets. You won’t be
worrying then about being burnt or sparks setting alight
to your clothes.
Place the work so that the direction of welding is across,
rather than to or from, your body. The electrode holder
lead should be clear of any obstruction so that you can
move your arm freely along as the electrode burns down.
If the lead is slung over your shoulder, it allows greater
freedom of movement and takes a lot of weight off your
hand. Be sure the insulation on your cable and electrode
holder is not faulty, otherwise you are risking an electric
shock.
Operation
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.
20°
Art # A-07696_AB
1.6 mm (1/16”)
Figure 4-14: Striking an arc
4.17 Arc Length
The securing of an arc length necessary to produce a
neat weld soon becomes almost automatic. You will find
that arc produces a crackling or spluttering noise and
the weld metal comes across in large, irregular blobs.
The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained
although if it is too short there is the danger of it being
blanketed by slag and the electrode tip being solidified
in. If this should happen, give the electrode a quick twist
back over the weld to detach it. Contact or “touch-weld”
electrodes such as E7014 electrode do not stick in this
way, and make welding much easier.
4-10
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 201 TS
4.18 Rate of Travel
After the arc is struck, your next concern is to maintain
it, and this requires moving the electrode tip towards the
molten pool at the same rate as it is melting away. At the
same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at
about 20° from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and strung
out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the
bead will be too large.
4.19 Making Welded Joints
Having attained some skill in the handling of an electrode,
you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in
Figure 4-15, allowing 1/16" (1.6mm) to 3/32" (2.4mm)
gap between them and tack weld at both ends. This is to
prevent contraction stresses from the cooling weld metal
pulling the plates out of alignment. Plates thicker than 1/4"
(6.4mm) should have their mating edges beveled to form
a 70° to 90° included angle. This allows full penetration of
the weld metal to the root. Using a 1/8" (3.2mm) E7014 electrode at 120 amps, deposit a run of weld metal on the
bottom of the joint.
Do not weave the electrode, but maintain a steady rate of
travel along the joint sufficient to produce a well-formed
bead. At first you may notice a tendency for undercut to
form, but keeping the arc length short, the angle of the
electrode at about 20° from vertical, and the rate of travel
not too fast, will help eliminate this. The electrode needs
to be moved along fast enough to prevent the slag pool
from getting ahead of the arc. To complete the joint in thin
plate, turn the job over, clean the slag out of the back and
deposit a similar weld.
20°-30°
Electrode
Tack Weld
Art # A-07698
Figure 4-16: Weld build up sequence
Heavy plate will require several runs to complete the joint.
After completing the first run, chip the slag out and clean
the weld with a wire brush. It is important to do this to
prevent 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
4-16. The width of weave should not be more than three
times the core wire diameter of the electrode. When the
joint is completely filled, the back is either machined,
ground or gouged out to remove slag which may be
trapped in the root, and to prepare a suitable joint for
depositing the backing run. If a backing bar is used, it
is not usually necessary to remove this, since it serves
a similar purpose to the backing run in securing proper
fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces
meeting at right angles. Refer to Figure 4-8.
A piece of angle iron is a suitable specimen with which to
begin, or two lengths of strip steel may be tacked together
at right angles. Using a 1/8" (3.2mm) E7014 electrode at
120 amps, position angle iron with one leg horizontal and
the other vertical. This is known as a horizontal-vertical
(HV) fillet. Strike the arc and immediately 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 4-17. Do not attempt to build up much larger
than 1/4" (6.4mm) width with a 1/8" (3.2mm) electrode,
otherwise the weld metal tends to sag towards the base,
and undercut forms on the vertical leg. Multi-runs can be
made as shown in Figure 4-18. Weaving in HV fillet welds
is undesirable.
Tack Weld
Art # A-07697_AB
Figure 4-15: Butt weld
Manual 0-5147
4-11
Operation
THERMAL ARC 161 STL, 201 TS
45° from
vertical
OPERATION
Art # A-07701
60° - 70° from line
of weld
Art # A-07699_AB
Figure 4-17: Electrode position for HV fillet weld
Art # A-07700_AB
Figure 4-19: Single run vertical fillet weld
6
Art # A-07702
3
5
1
2
4
Figure 4-18: Multi-runs in HV fillet weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your
work bench in an upright position. Use a 1/8"
(3.2mm) 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 4-19. Use a short arc, and
do not attempt to weave on the first run. When
the first run has been completed de-slag the weld
deposit and begin the second run at the bottom.
This time a slight weaving motion is necessary
to cover the first run and obtain good fusion at
the edges. At the completion of each side motion,
pause for a moment to allow weld metal to build
up at the edges, otherwise undercut will form and
too much metal will accumulate in the centre of the
weld. Figure 4-20 illustrates multi-run technique
and Figure 4-21 shows the effects of pausing at
the edge of weave and of weaving too rapidly.
Operation
Figure 4-20: Multi run vertical fillet weld
Art # A-07703
Figure 4-21: Examples of vertical fillet welds
2. Vertical Down
The E7014 electrode makes welding in this
position particularly easy. Use a 1/8" (3.2mm)
electrode at 120 amps. The tip of the electrode is
held in light contact with the work and the speed
of downward travel is regulated so that the tip of
the electrode just keeps ahead of the slag. The
electrode should point upwards at an angle of
about 45°.
4-12
Manual 0-5147
OPERATION
THERMAL ARC 161 sTL, 201 TS
3. Overhead Welds
4.21 The Cause of Distortion
Distortion is cause by:
Apart from the rather awkward position necessary,
overhead welding is not much more difficult 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 position as shown
in the sketch. The electrode is held at 45° to
the horizontal and tilted 10° in the line of travel
(Figure 4-22). The tip of the electrode 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 1/8" (3.2mm) 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.
Art # A-07704
Figure 4-22: Overhead fillet weld
4.20Distortion
Distortion in some degree is present in all forms of
welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be made
before welding commences for the distortion that will
subsequently occur. The study of distortion is so complex
that only a brief outline can be attempted hear.
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume
on cooling to room temperature. This means that a cube
of molten metal would contract approximately 2.2 per
cent in each of its three dimensions. In a welded joint, the
metal becomes attached to the side of the joint and cannot
contract freely. Therefore, cooling causes the weld metal
to flow plastically, that is, the weld itself has to stretch if
it is to overcome the effect of shrinking volume and still
be attached to the edge of the joint. If the restraint is very
great, as, for example, in a heavy section of plate, the weld
metal may crack. Even in cases where the weld metal does
not crack, there will still remain stresses “locked-up” in
the structure. If the joint material is relatively weak, for example, a butt joint in 5/64" (2.0mm) sheet, the contracting
weld metal may cause the sheet to become distorted.
B. Expansion and Contraction of Parent Metal in the
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 attempts
to expand “across the weld” or “along the weld”, it meets
considerable resistance, and to fulfill the desire for continued expansion, it has to deform plastically, that is, the
metal adjacent to the weld is at a high temperature and
hence rather soft, and, by expanding, pushes against the
cooler, harder metal further away, and tends to bulge (or
is “upset”). When the weld area begins to cool, the “upset” metal attempts to contract as much as it expanded,
but, because it has been “upset”, it does not resume its
former shape, and the contraction of the new shape exerts
a strong pull on adjacent metal. Several things can then
happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful
contraction stresses (distortion), or the weld may crack,
in any case, there will remain “locked-up” stresses in the
job. Figures 4-23 and 4- 24 illustrate how distortion is
created.
Manual 0-5147
4-13
Operation
THERMAL ARC 161 STL, 201 TS
Upsetting
Weld
Art # A-07705_AB
Expansion with
compression
Hot
Hot
Cool
Figure 4-23: Parent metal expansion
Art # A-07706_AB
Weld
OPERATION
E.Preheating
Suitable preheating of parts of the structure other than
the area to be welded can be sometimes used to reduce
distortion. Figure 4-26 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.
Permanent Upset
Contraction
with tension
Art # A-07707
Figure 4-24: Parent metal contraction
Figure 4-25: Principle of presetting
4.22 Overcoming Distortion Effects
Art # A-07708
B
There are several methods of minimizing distortion effects.
C
Preheat
Preheat
Weld
A.Peening
This is done by hammering the weld while it is still hot.
The weld metal is flattened slightly and because of this
the tensile stresses are reduced a little. The effect of
peening is relatively shallow, and is not advisable on the
last layer.
Dotted lines show effect if no preheat is used
Figure 4-26: Reduction of distortion by preheating
B. Distribution of Stresses
Art # A-07709
Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so
that they tend to cancel each other out. See Figures 4-28
through 4-31 for various weld sequences. Choice of a
suitable weld sequence is probably the most effective
method of overcoming distortion, although an unsuitable
sequence may exaggerate it. Simultaneous welding of
both sides of a joint by two welders is often successful
in eliminating distortion.
C. Restraint of Parts
Figure 4-27: Examples of distortion
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.
1
2
3
D.Presetting
It is possible in some cases to tell from past experience 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 4-25.
Operation
Art # A-07710_AB
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-28: Welding sequence
4-14
Manual 0-5147
OPERATION
4
THERMAL ARC 161 sTL, 201 TS
3
2
1
Art # A-07711_AB
Figure 4-29: Step back sequence
Art # A-07428_AB
Figure 4-30: Chain intermittent welding
Art # A-07713_AB
Figure 4-31: Staggered intermittent welding
Manual 0-5147
4-15
Operation
THERMAL ARC 161 STL, 201 TS
OPERATION
This page left blank intentionally.
Operation
4-16
Manual 0-5147
SERVICE
THERMAL ARC 161 sTL, 201 TS
SECTION 5:
SERVICE
5.01 Maintenance and Inspection
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating
environment.
To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The unit
should also be wiped clean, if necessary; 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 with sensitive
electrical components and cause damage to
the unit.
WARNING
There are extremely dangerous voltages and
power levels present inside this product.
Disconnect primary power at the source before opening the enclosure. Wait at least two
minutes before opening the enclosure to allow
the primary capacitors to discharge.
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect
the torch body
and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Art # A-10002
Manual 0-5147
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
frequently under exceptionally
dirty conditions.
5-1Service
THERMAL ARC 161 STL, 201 TS
SERVICE
5.02 STICK (SMAW) Welding Problems
Description
Possible Cause
1. Gas pockets or voids in weld metal A. Electrodes are damp.
(Porosity).
B. Welding current is too high.
Remedy
A. Dry electrodes before use.
B. Reduce welding current.
Surface impurities such as oil, C. Clean joint before welding
grease, paint, etc.
A. Redesign to relieve weld joint of severe
2. Crack occurring in weld metal soon A. Rigidity of joint.
stresses or use crack resistance
after solidification commences.
electrodes.
C.
B. Insufficient throat thickness. B. Travel slightly slower to allow greater
build up in throat.
C. Cooling rate is too high.
3. A gap is left by failure of the weld A. Welding current is too low.
metal to fill the root of the weld.
B. Electrode too large for joint.
Art # A-05866_AC
Incorrect Sequence
C. Preheat plate and cool slowly.
A. Increase welding current
B. Use smaller diameter electrode.
C. Insufficient gap.
C. Allow wider gap.
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
to the surface of the metal or edge
heavy cold plate.
of the joint
B. Welding current is too low.
C. Wrong electrode angle.
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Lack of
inter-run fusion
Art # A-05867_AC
Lack of side fusion,
scale dirt, small electrode,
amperage too low
Lack of root fusion
B. Increase welding current
C. Adjust angle so the welding arc is
directed more into the base metal
D. Travel speed of electrode is too D. Reduce travel speed of electrode
high.
E. Clean surface before welding.
E. Scale or dirt on joint surface.
5. Non-metallic particles are trapped A. Non-metallic particles may
in the weld metal (slag inclusion).
be trapped in undercut from
previous run.
Not cleaned,
or incorrect
electrode
A. Use larger electrodes and preheat
the plate.
A. If bad undercut is present, clean slag
out and cover with a run from a smaller
diameter electrode.
B. Joint preparation too restricted. B. Allow for adequate penetration and
room for cleaning out the slag.
Slag
trapped in
undercut
Slag trapped in root
Art # A-05868_AC
C. Irregular deposits allow slag to C. If ver y bad, chip or grind out
irregularities.
be trapped.
D. Lack of penetration with slag D. Use smaller electrode with sufficient
current to give adequate penetration.
trapped beneath weld bead.
Use suitable tools to remove all slag
from corners.
E. Rust or mill scale is preventing E. Clean joint before welding.
full fusion.
F. Wrong electrode for position in F. Use electrodes designed for position
in which welding is done, otherwise
which welding is done.
proper control of slag is difficult.
Service
5-2
Manual 0-5147
SERVICE
THERMAL ARC 161 sTL, 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.
2.
3.
4.
5.
6.
7.
Description
Excessive bead build-up or poor
penetration or poor fusion at
edges of weld.
Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.
Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart.
Weld bead too wide or excessive
bead build up or excessive
penetration in butt joint.
Uneven leg length in fillet joint.
Electrode melts when arc is
struck.
Dirty weld pool.
Possible Cause
Welding current is too low
Remedy
Increase weld current and/or
change joint preparation.
Welding current is too high.
Decrease welding current.
Travel speed too fast.
Reduce travel speed.
Travel speed is too slow.
Increase travel speed.
Wrong placement of filler rod.
Electrode is connected to the "+"
Positive Output Terminal.
A. Electrode contaminated through
contact with work piece or filler
rod material.
B. Gas contaminated with air.
8. Poor weld finish.
9. Arc flutters during TIG welding.
Tungsten electrode is too large
for the welding current.
10.W e l d i n g a r c c a n n o t b e
established.
A. Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the
correct welding terminals.
B. Torch lead is disconnected.
11. Electrode melts or oxidizes when
an arc is struck.
Inadequate shielding gas.
C. Gas flow incorrectly set, cylinder
empty or the torch valve is off.
A. No gas is flowing to welding
region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impurities.
E. Gas regulator turned off.
F. Torch valve is turned off.
G. The electrode is too small for the
welding current.
Manual 0-5147
Re-position filler rod.
Connect the electrode to the
"-" Negative Output Terminal.
A. Clean the electrode by grinding
contaminates off.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
Increase gas flow or check gas line
for problems
Select the right size electrode.
Refer to section Tungsten Electrode
Current Ranges.
A. Connect the work clamp to the
work piece or connect the work/
torch leads to the correct welding
terminals.
B. Connect it to the "-" Negative
Output Terminal.
C. Select the right flow rate, change
cylinder or turn torch valve on.
A. Check the gas lines for kinks or
breaks or cylinder contains gas.
B. Clean torch.
C. Replace gas hose.
D.Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
E. Turn on.
F. Turn on.
G.Increase electrode diameter or
reduce the welding current.
5-3Service
THERMAL ARC 161 STL, 201 TS
SERVICE
TIG Welding Problems (Continued)
Description
12. Arc start is not smooth.
Possible Cause
Remedy
A. Tungsten electrode is too large
for the welding current.
B. The wrong electrode is being
used for the welding job.
C. Gas flow rate is too high.
A. Refer to section Tungsten Electrode
Current Ranges for the correct size.
B. Refer to section Tungsten Electrode
Types for the correct electrode type.
C. Select the correct flow rate for the
welding job.
D. Use 100% argon for TIG welding.
D. Incorrect shield gas is being
used.
E. Poor work clamp connection
to work piece.
E. Improve connection 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
Description
1. The welding arc cannot be
established.
Possible Cause
A. The Primary supply voltage
has not been switched ON.
B. The Welding Power Source
switch is switched OFF.
C. Loose connections internally.
2. The welding arc cannot
be established when the
Warning Indicator lights up
continuously
3. Maximum output welding
current cannot be achieved with
nominal Mains supply voltage.
4. Welding current reduces when
welding.
The machines duty cycle has been
exceeded
5. Circuit breaker (or fuse) trips
during welding.
The circuit breaker (or fuse) is
under size.
6. The welding arc cannot be
established when Fault Indicator
is flashing.
The input current to the main
transformer has been exceeded.
Service
Defective control circuit
Poor work lead connection to the
work piece.
5-4
Remedy
A. Switch ON the Primary supply
voltage.
B. Switch ON the Welding Power
Source.
C. Have an Accredited Thermal
Arc Service Provider repair the
connection.
Wait for the Warning Indicator
to extinguish before resuming
welding
Have an Accredited Thermal Arc
Service Provider inspect then
repair the welder.
Ensure that the work lead has a
positive electrical connection to
the work piece.
The recommended circuit breaker
(or fuse) size is 30 amp. An
individual branch circuit capable
of carrying 30 amperes and
protected by fuses or circuit
breaker is recommended for this
application.
Have an Accredited Thermal Arc
Service Provider inspect then
repair the welder.
Manual 0-5147
APPENDIX
THERMAL ARC 161 sTL, 201 TS
APPENDIX 1: OPTIONS AND ACCESSORIES
Description
17 style TIG Torch with 12.5ft lead, finger remote control, 50mm dinse connection and
accessory kit
26 style TIG Torch with 12.5ft lead, finger remote control, 50mm dinse connection and
accessory kit
Foot Control, 8 pin amphenol, 15ft
Slider Current Control with Torch Switch, 15ft, suits 7/8” to 1-1/8” dia. 17 TIG Torch Handle
Slider Current Control with Torch Switch, 15ft, suits 1-1/8” to 1-3/8" dia. 26 TIG Torch Handle
VICTOR AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection
Power Adapter-230V,50A Socket (Nema 6-50R) to 115V, 15A Plug (Nema 5-15P)
USA Graphics Auto-Darkening welding helmet, spare cover lens and operating manual
Canadian Graphics Auto-Darkening welding helmet, spare cover lens and operating manual
Claret Color Auto-Darkening welding helmet, spare cover lens and operating manual
Black Graphics Auto-Darkening welding helmet, spare cover lens and operating manual
Manual 0-5147
Part Number
W4012701
W4013600
600285
10-4009
10-4010
0781-4169
W4014000
W4011700
W4011800
W4011900
W4012000
A-1Appendix
THERMAL ARC 161 STL, 201 TS
APPENDIX
APPENDIX 2: REPLACEMENT PARTS-161 STL
Item No
Description
Part No.
Reference Designator
1
Handle
W7003040
2
Panel, Cover
W7003200
3
Rectifier 1000V,50A
W7003010
4
PCB,Control,161STL
W7003202
PCB2
5
Thermostat
W7003016
THC1, THC2
6
Resistor,4 ohm,60W
W7003055
R1
7
PCB,Power,161STL
W7003203
PCB1
8
Insulation Sheet
W7003214
9
PCB,Front Control,161STL
W7003204
10
Front Panel
W7003205
11
Front Panel Label
W7003206
12
Rubber Boot
W7003064
13
Knob, control, Red, 21 ODx6 ID
W7003079
14
Output Terminal, 50mm dinse
W7003020
15
Socket,8 Pin,w/cable,161STL-201TS
W7003220
16
Connector,Gas Outlet,161STL-201TS
W7003212
17
Output Inductor Magnetic Core
W7003210
18
Gas Solenoid
W7003033
19
Base Panel
W7003209
20
Fan,24V DC
W7003090
21
Rear Panel
W7003201
22
Connector,Gas Inlet,161STL-201TS
W7003215
23
ON/OFF Switch
W7003053
SW1
24
Current Sensor, 161-201TS
W7003076
Current Sensor
25
Cable Cord,12AWG,10ft,6-50P
W7003052
26
PCB,Remote,161STL-201TS
W7003221
PCB3
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.
AppendixA-2
Manual 0-5147
APPENDIX
THERMAL ARC 161 sTL, 201 TS
1
2
23
22
25
3
21
4
7
5
20
8
6
9
10
11
12
13
19
Art # A-10022_AB
18
17
16
15
14
26
Manual 0-5147
A-3Appendix
THERMAL ARC 161 STL, 201 TS
APPENDIX
APPENDIX 3: REPLACEMENT PARTS-201 ts
Item No
Description
Part No.
Reference Designator
1
Handle
W7003040
2
Panel, Cover
W7003200
3
Rectifier 1000V,50A
W7003010
4
PCB,Control,201TS
W7003222
PCB2
5
Thermostat
W7003016
THC1, THC2
6
Resistor,4 ohm,60W
W7003055
R1
7
PCB,Power,201TS
W7003216
PCB1
8
Insulation Sheet
W7003214
9
Points,HF Starter,201TS
W7003034
10
Output Inductor Magnetic Core
W7003210
11
Front Control PCB3
W7003218
12
Front Panel
W7003205
13
Front Panel Label
W7003219
14
Rubber Boot
W7003064
15
Knob, control, Red, 21 ODx6 ID
W7003079
16
Connector,Gas Outlet,161STL-201TS
W7003212
17
Output Terminal, 50mm dinse
W7003020
18
Socket,8 Pin,cable,161STL-201TS
W7003220
19
Gas Solenoid
W7003033
20
Current Sensor, 161-201TS
W7003076
21
Base Panel
W7003209
22
Fan,24V DC
W7003090
23
Rear Panel
W7003201
24
Cable Cord,12AWG,10ft,6-50P
W7003052
25
Connector,Gas Inlet,161STL-201TS
W7003215
26
ON/OFF Switch
W7003053
SW1
27
PCB,Remote,161STL-201TS
W7003221
PCB4
PCB3
Current Sensor
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.
AppendixA-4
Manual 0-5147
APPENDIX
THERMAL ARC 161 sTL, 201 TS
1
2
26
25
3
4
24
7
55
8
6
23
9
10
22
11
12
13
14
15
16
17
20
18
Art # A-10104_AB
21
19
27
Manual 0-5147
A-5Appendix
THERMAL ARC 161 STL, 201 TS
APPENDIX
INPUT 230VAC/115VAC
50/60Hz
Art # A-10280
APPENDIX 4: SYSTEM SCHEMATIC - 161 STL
AppendixA-6
Manual 0-5147
THERMAL ARC 161 sTL, 201 TS
APPENDIX 5: SYSTEM SCHEMATIC -201 ts
INPUT 230VAC/115VAC
50/60Hz
Art # A-11277
APPENDIX
Manual 0-5147
A-7Appendix
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
January 2009
LIMITED WARRANTY: Thermal Arc®, Inc., A Victor Technologies Company (“Thermal Arc”),
warrants to customers of authorized distributors (“Purchaser”) that its products will be free of
defects in workmanship or material. Should any failure to conform to this warranty appear within
the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation
that the product has been stored, installed, operated, and maintained in accordance with
Thermal Arc’s specifications, instructions, recommendations and recognized standard industry
practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects
by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of
the product determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of merchantability,
fitness for any particular purpose, or other warranty of quality, whether
express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,
incidental, or consequential damages, including but not limited to lost profits and business
interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of
Thermal Arc with respect to any contract, or anything done in connection therewith such as the
performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by Thermal Arc, whether arising out of contract, tort, including
negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the
goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this warranty in
any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.
Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment
of thermal’s obligations to purchaser with respect to the product.
This warranty is void, and seller bears no liability hereunder, if purchaser used replacement
parts or accessories which, in Thermal Arc’s sole judgment, impaired the safety or performance
of any Thermal Arc product. Purchaser’s rights under this warranty are void if the product is sold
to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the authorized
distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal
Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal
Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s discovery
of any defect. Thermal Arc shall pay no transportation costs of any kind under this warranty.
Transportation charges to send products to an authorized warranty repair facility shall be the
responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense.
This warranty dated January 1st 2009 supersedes all previous Thermal Arc warranties. Thermal
Arc® is a Registered Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
January 2009
SAFETY EQUIPMENT
Auto-Darkening Welding Helmet (Electronic Lens)
Harness Assembly
ENGINE DRIVEN WELDERS
Scout, Raider, Explorer
Original Main Power Stators and Inductors
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, power switch semi-conductors
Engines and associated components are NOT warranted by Thermal Arc, although most are
warranted by the engine manufacturer
BY THE ENGINE MANUFACTURER, SEE THE ENGINE MANUFACTURES WARRANTY FOR
DETAILS.
GMAW/FCAW (MIG) WELDING EQUIPMENT
Warranty Period
Labor
2 year
1 Month
Warranty Period
2 year
1 Month
Labor
3 years
3 years
3 years
3 years
1 year
1 year
See the Engine Manufactures’ Warranty for Details
Warranty Period
Labor
5 years
3 years
3 years
3 years
1 year
Warranty Period
1 year
Labor
5 years
3 years
3 years
3 years
1 year
Warranty Period
1 year
Labor
5 years
3 years
3 years
3 years
3 years
3 years
1 year
Warranty Period
1 year
Labor
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans,
161S, 161STL, 201TS
1 year
1 year
1 year
1 year
1 year
1 year
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans
160S, 300S, 400S
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, power switch semi-conductors
GENERAL ARC EQUIPMENT
3 years
3 years
3 years
3 years
1 year
Fabricator 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, electric motors.
TIG (GTAW) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400MST, 300MST, 400MSTP
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, electric motors.
PLASMA WELDING EQUIPMENT
Ultima 150
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors
Welding Console, Weld Controller, Weld Timer
All other original circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, electric motors, Coolant Recirculator.
STICK (SMAW) WELDING EQUIPMENT
Thermal Arc 95S
Water Recirculators
Plasma Welding Torches
Gas Regulators (Supplied with power sources)
MIG and TIG Torches (Supplied with power sources)
Replacement repair parts
MIG, TIG and Plasma welding torch consumable items
1 year
5 years
3 years
3 years
3 years
1 year
1 year
Labor
Warranty Period
1 year
80 days
180 days
90 days
90 days
Nil
1 year
180 days
Nil
Nil
Nil
Nil
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph:1-940-381-1212
Fax:1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph:1-954-727-8371
Fax:1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph:1-905-827-4515
Fax:1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax:+44 1257-224800
Milan, Italy
Customer Care
Ph: +39 0236546801
Fax:+39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph:6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph: +603 6092-2988
Fax:+603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph:61-3-9474-7400
Fax:61-3-9474-7391
International
Ph:61-3-9474-7508
Fax:61-3-9474-7488
Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax:+65 6763-5812
TECHNOLOGIES
™
I n n o v atio n to S hape the W orld ™
U.S. Customer Care: 800-426-1888 / fax 800-535-0557 • Canada Customer Care: 905-827-4515 /
International Customer Care: 940-381-1212 / fax 940-483-8178
© 2012 Victor Technologies International, Inc.
victortechnologies.com
fax
800-588-1714
.

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