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201 TS Operating Manual THERMAL ARC

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1. ot un beu Oe Pv US e Vol 2 3 2 07 X User Responsibility essseeem nnne 2 3 208 Pec 2 4 2 09 2 5 SECTION 3 INSTALLATION OPERATION AND 5 3 1 3 01 3 1 3 02 DI ME EE 3 1 3 03 Electrical Input Connections ucdssanidetesosetanesudatutua satueE 3 1 3 04 Electromagnetic tct secet vacet ceno ace mci 3 3 3 05 ute 3 4 3 06 STICK MMA 3 5 3 07 TIG HF TIG GTAW 3 7 3 08 4 Leak Testing the System 3 0 3 09 When You Finish Using the Regulator 3 0 3 10 of the 3 0 TABLE OF CONTENTS SECTION 4 Das Tp E 4 1 4 01 1 4 1 4 00 Welding Current Control 4 3 403 STICK MMA Electrode Polarity eee 4 3 4 04 Effects of Stick Welding Various 4 3 405 GTAW Electrode Polarity eene 4 4 4 06 X Guide for Selecting Filler 4 4 4 07 4 Tungsten Electrode Current Ranges 4 4 4 08 Gas Selection us sic 4 4 409 Tungsten Electrode Types 4 5 4 10 Welding Parameters for Steel 4 5 4 1
2. 4 06 Guide for Selecting Filler Wire 4 07 Tungsten Electrode Current Ranges Electrode Diameter 1 0mm 040 29 85 1 6mm 1 16 50 160 2 4mm 3 32 135 235 4 08 Shielding Gas Selection Alloy shielding Gas Carbon Steel Welding Argon Stainless Steel Welding Argon Nickel Alloy Welding Argon Welding Argon Welding Argon Operation 4 4 Manual 0 5149 OPERATION THERMAL ARC 201 TS 4 08 Shielding Gas Selection Alloy shielding Gas Carbon Steel Welding Argon Stainless Steel Welding Argon Nickel Alloy Welding Argon Copper Welding Argon Titanium Welding Argon 4 09 Tungsten Electrode Types Electrode Type Thoriated 2 DC welding of mild steel stainless steel Excellent arc starting long life high and copper current carrying capacity AC amp DC welding of mild steel stainless Longer life more stable arc easier 290 steel copper aluminium magnesium andjstarting wider current range Grey narrower amp more concentrated arc 4 10 TIG Welding Parameters for Steel Base Metal Stainless Electrode Filler Rod Argon Gas Flow Thickness Steel Diameter Diameter Rate Joint Type 1 0mm 20 30 1 0mm 1 6mm 10 CFH 0 040 40 50 25 35 0 040 116 5 LPM Lap Filler 12mm LU 1 0mm 1 6mm 13 CFH 0 045 50 60 35 50 0 0407 1 16 6 LPM Lap Filler 1 6mm 80 70 40 60 1 6mm 1 6mm 15 CFH 1 16 70 90 50 70 1 167 1 16 7 Lap Filler 3 2mm 80 100 65 8
3. 4 21 The Cause of Distortion Distortion is cause by A Contraction of Weld Metal Molten steel shrinks approximately 11 per cent in vol ume 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 2 0mm 5 64 sheet the contracting weld metal may cause the sheet to become distorted Manual 0 5149 THERMAL ARC 201 TS 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 at tempts to expand across the weld or along the weld it meets considerable resistance and to fulfil
4. 4 GP 3 2mm 1 8 dia stick electrodes Thermal Arc 201 TS Gas Hose lead 4m 131 Operating manual Art A 10140 THERMAL ARC 201 TS SAFE INSTRUCTION SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS A 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 oafe 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 oafe practices are outlined in the European Standard EN60974 1 entitled Safety in welding and allied processes Part 2 Electrical This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOP
5. v Visual check of regulator and pressure Visual check of torch Weekly Visually inspect the torch body and consumables A Visually inspect the cables and leads Replace as needed 3 Months y eae Replace all Clean exterior broken parts Consumable parts of power supply 6 Months Art A 10002 Manual 0 5149 Bring the unit to an authorized Thermal Arc Service Centre to remove any accumulated dirt TT t and dust from the interior amp 6 This may need to be done more frequently under exceptionally dirty conditions Service THERMAL ARC 201 TS 5 02 STICK Welding Problems Possible Cause 2 Gas pockets or voids in weld metal A Porosity B C Crack occurring in weld metal soon A after solidification commences Electrodes are damp Welding current is too high ourface impurities such as oil grease paint etc Rigidity of joint Insufficient throat thickness Cooling rate is too high Welding current is too low Electrode too large for joint Insufficient gap Incorrect sequence Portions of the weld run do not fuse A to the surface of the metal or edge of the joint Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack of inter run fusion Art 05867 Lack of side fusion scale dirt small electrode amperage too low 9 Lack of root fusion Non metallic p
6. IHERMAL 201 THERMAL ARC INVERTER ARC WELDER IHERMAL TRIGGER P 2T Art A 10139 Revision AB Issue Date May 20 2011 Manual No 0 5149 Operating Features Ec ec Incl l8 IHERMAL WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network locate your nearest distributor or service agency call 44 0 1257 261 755 or visit us on the web at www Thermalarc com RC 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 w
7. 60 80 100 120 140 160 180 200 Welding Current amps Art A 10142 Figure 2 1 Thermal Arc 201 TS Duty Cycle Introduction 2 4 Manual 0 5149 INTRODUCTION THERMAL ARC 201 TS 2 09 Specifications single Phase Generator Requirements 5 8 Continuous rating at nominal supply voltage with maximum output for STICK MMA welding Welding Output TO Welding Current Range Stick 10 125 Amps otick TlG TIG 10 160 Amps 10 200 Amps Nominal DC Open Circuit Voltage OCV Welding Output 104 F 40 C 10 min 125A 25 25 0V 200A 20 28V Quoted figures refer to STICK MMA output 95A 60 23 8V 120A 60 24 8V 80A Q 100 23 2V 100A Q 100 24 0V Rated Input Current A 39A 32A Rated Input Current A 30A 20 6A for LIFT TIG HF TIG GTAW Welding Rated Output for STICK MMA Welding 29 0V 125A 25 28V 200A 20 Rated Output for LIFT TIG HF TIG GTAW 16 4V 160A 30 18V 200A 2590 Welding NUT az Gm Welding Power Source Dimensions Height x Width x Depth H90 x W 5 3 17 7 A The recommended time delay fuse or circuit breaker size is 32 amp for 110V and 32 amp for 230V Manual 0 5149 2 5 Introduction THERMAL ARC 201 TS INTRODUCTION Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specification
8. National legislation for the enforcement of this Directive serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60974 1 EN50192 EN50078 applicable to welding equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides e Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications WARNING This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system it is the responsibility of the installer or user of the equipment to ensure by consultation With the distributi
9. TIG GTAW SETUP V 1 7 E Set Process Selection Switch to LIFT TIG or HF TIG Switch to 2T 4T IC 34 Set Welding Current as specified by the Electrode Manufacturer NY NY Set DOWN Slope lt S N A Secure the gas cylinder in an 77 Positive Output upright position by chaining it 0 Terminal to a stationary support to prevent Negative Sy Dinse 50 falling or tipping Output Terminal Dinse 50 Art 10100 Figure 3 3 Setup for LIFT TIG HF TIG GTAW Welding LIFT GTAW Sequence of Operation A CAUTION Before any welding is to begin be sure to wear all appropriate and recommended safety equipment 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the ground work clamp cable to positive output terminal It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection 3 Connect the TIG torch as follows a Place the power cable into the negative output terminal It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection b Place the 8 pin plug into the 8 pin socket To make connections align keyway insert plug and rotate threaded collar fully clockwise c Place the TIG torch gas
10. 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 8 Manual 0 5149 OPERATION 4 19 Making Welded Joints Having attained some skill in the handling of an elec trode you will be ready to go on to make up welded joints Butt Welds oet up two plates with their edges parallel as shown in Figure 4 12 allowing 1 6mm 1 16 to 2 4mm 3 32 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 6 4mm 1 4 should have their mating edges bev eled to form 70 to 90 included angle This allows full penetration of the weld metal to the root Using a 3 2mm 1 8 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 rat
11. be located on a suitable horizontal surface in the upright position when in use WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician 3 03 ELECTRICAL INPUT CONNECTIONS A 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 e 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 BROWN or BLUE conductor to the ground terminal Do not connect the ground GREEN or GREEN YELLOW conductor to an input line terminal Refer to Figure 3 1 1 Connect end of gro
12. 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 amp 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 Manual 0 5149 3 7 Installation Operation And Setup THERMAL ARC 201 TS 7 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 Open the Argon Cylinder Valve to the fully open position 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 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 4 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 th
13. or welding current reduce the welding current Manual 0 5149 5 3 Service THERMAL ARC 201 TS TIG Welding Problems Continued Tungsten electrode is too large for the welding current The wrong electrode is being used for the welding job 12 Arc start is not smooth Gas flow rate is too high Incorrect shield gas is being used Poor work clamp connection to work piece A WARNING SERVICE Refer to section Tungsten Electrode Current Ranges for the correct size Refer to section Tungsten Electrode Types for the correct electrode type Select the correct flow rate for the welding job Use 100 argon for TIG welding Improve connection to work piece 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 Possible Cause A The Primary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF Description 1 he welding arc cannot be established C Loose connections internally C The machines duty cycle has been exceeded 2 he welding arc cannot be established when the Warning Indicator ligh
14. 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 110V inside number scale identifies the available output weld current for STICK or LIFT weld modes STICK Mode Identifies the STICK weld point for 32 Amp outlet Exceeding these points will cause nui sance tripping of the circuit breaker or fuse Nuisance tripping should not occur on a 16 Amp outlet Output Scale for 230V The outside number scale identifies the available out put weld current for STICK or LIFT TIG HF TIG weld modes Nuisance tripping should not occur on a 32A 230V outlet for both STICK amp LIFT TIG HF Modes 32 Amp Outlet 10220 Output Scale for 110V A HANN 230V Output Scale for 230V Art A 10147 Figure 4 2 Current Control Manual 0 5149 THERMAL ARC 201 TS 4 03 STICK MMA Electrode Polarity Stick electrodes are generally connected to the Posi tive 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
15. slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Manual 0 5149 SERVICE THERMAL ARC 201 TS 5 03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique Possible Cause 1 Excessive bead build up or poor Welding current is too low Increase weld current and or penetration or poor fusion at change joint preparation edges of weld Weld bead too wide and flat or Welding current is too high Decrease welding current undercut at edges of weld or excessive burn through Weld bead too small or insufficient Travel speed too fast Reduce travel speed penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or excessive Travel speed is too slow Increase travel speed bead build up or excessive penetration in butt joint 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts when arc is Electrode is connected to the Connect the electrode to the struck Positive Output Terminal Negative Output Terminal 7 Dirty weld pool A Electrode contaminated through A Clean the electrode by grin
16. suits 1 1 8 dia 26 TIG Torch Handle 10 4010 Manual 0 5149 1 Appendix THERMAL ARC 201 TS APPENDIX APPENDIX 2 REPLACEMENT PARTS 1 7003200 3 i 10 Output Inductor Ferrite Core Front Control PCB3 W7003218 N Front Panel Label 4 Rubber Boot W7003064 1 ES 2 3 6 8 EE 10 12 M 17 20 24 25 Knob control Red 21 ODx6 ID Connector Gas Outlet 161 STL 201 m TS 1 20 9 Gas Solenoid W7003033 20 Current Sensor 161 201TS W7003076 20 7003205 3 w7003209 3 Fan 24V DC W7003090 8 Socket 8 Pin cable 161 STL 201 TS W7003220 3 Connector Gas Inlet 161 STL 201 TS W7003215 25 ON OFF Switch W7003053 6 PCB Remote 161 STL 201 TS W7003221 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 Output Terminal 50mm dinse W7003020 Appendix A 2 Manual 0 5149 APPENDIX THERMAL ARC 201 TS gi wi al 4 Art 10148 26 Manual 0 5149 A 3 Appendix APPENDIX 201 TS SYSTEM SCHEMATIC APPENDIX 3 THERMAL ARC 20
17. will cover the vast majority of applications likely to be encountered are all easy to use 4 3 Operation THERMAL ARC 201 TS OPERATION Comments Mild Steel E6011 This electrode is used for all position welding or for welding on rusty dirty less than new metal It has a deep penetrating arc and is often the first choice for repair or maintenance work Mild Steel E6013 This all position electrode is used for welding clean new sheet metal Its soft arc has minimal spatter moderate penetration and an easy to clean slag Mild Steel E7014 positional ease to use electrode for use on thicker steel than E6013 Especially suitable sheet metal lap joints and fillet welds general purpose plate welding Mild Steel E 018 A low hydrogen all position electrode used when quality is an issue or for hard to weld metals It hasthe capability of producing more uniform weld metal which has better impact properties at low temperatures ouitable for joining all cast irons except white cast iron otainless Steel E318L 16 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
18. 1 Arc Welding 4 5 4 12 Welding esusu ounces 4 6 413 ag S nn 4 7 4 14 Arc Welding rn MEOS roS 4 0 415 The 4 8 4 16 Striking the 4 8 4 17 Aro Length 4 8 418 Re 4 8 419 Making Welded Joints eee mne 4 9 4 11 4 21 The Cause of Distortion 4 11 4 02 Overcoming Distortion 4 12 SECTION 5 A m 5 1 5 01 Maintenance and 5 1 9 02 STICK MMA Welding Problems 5 2 503 TIG Welding Problems seeenmm nnne 5 3 5 04 Power Source Problems seen 5 4 APPENDIX 1 OPTIONS AND ACCESSORIES eere HH mmm A 1 APPENDIX 2 REPLACEMENT A 2 APPENDIX 3 201 TS SYSTEM SCHEMATIC eee Hmmm A 4 LIMITED WARRANTY amp WARRANTY SCHEDULE TABLE OF CONTENTS Thermal Arc 201 TS Stick TIG System Part Number W1003803 Thermal Arc 201 TS power supply in toolbox 26 TIG torch 3 8m 12 5ft with Integrated Controls amp accessory Kit Electrode holder 5m 16 48 Work lead 5m 16 4ft
19. 1 TS TRIGGER MODE 2 J 5 SELECTION SWITCH WELD CURRENT THC1 C CONTROL ESI 110 4 5VDC 230VAC 0 05VDC DOWNISEOPEI ARC FORCE CONTROL INDICATOR LO PROCESS SELECTION SWITCH OWER ON INDICATOR CONNECTOR LAYOUT DIAGRAM 2 THC2 ES Front Panel PCB3 GND gt J9 1 Current Feedback gt J9 2 Y 15V 99 3 Switch Signal J1 4 IGBT Driver B J1 5 IGBT Driver B 412 Over Current Signal J1 3 IGBT Driver A es ACOUT CS AI E SADA A 60W4O0 cere o d monu Is SS TT 5355335 5555555 So UE SE rao RAN n PARADAS I aS AS gt 292 gt 844 6 963 5 8 4 cd g CONNECTOR LAYOUT DIAGRAM 2 lt p lt 1 1 INPUT 230VAC 10VAc BLACK RED 50 60Hz C Q T POS A PFC CIRCUIT Is SHEETMETAL COVER HFOUT Main Power PCB1 804 o 30 2 Over Current Signal Over Current Signal VW aci N NN NV sic2 VY oct 304 mm 3 5 2 1 si 4 3 3 me 2 AU 5 gt 5 gt SOS SS 55 N J1 J10 J20 J5 J13 J9 J12 J26 J27 J2 J11 J14 J17 J28 J3 J4 J23 J15 J16 J21 J25 J6 22 18 J7 J19 Art A 10149 AB J8 J24 see feb pep beg ee PCB
20. 5 1 6mm 2 4mm 15CFH 1 8 90 115 90 110 116 3 32 7 Lap Filler 48mm 117195 190129 2 4mm 3 2mm 21CFH 3 16 140 165 125 150 3 32 1 8 10 LPM Lap Filler Bam 3 2mm 4 0mm 21 1 4 170 200 160 180 1 8 5 32 10 LPM Lap Filler 4 11 Arc Welding Practice The techniques used for arc welding are almost identical regardless of what types of metals are being joined Naturally enough different types of electrodes would be used for different metals as described in the preceding section Manual 0 5149 4 5 Operation THERMAL ARC 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 3 through 4 10 TIRES Art A 07691 Figure 4 7 Vertical position butt weld Art A 07692 Figure 4 8 Vertical position fillet weld Art A 07693 Figure 4 9 Overhead position butt weld Art A 07690 Figure 4 6 Horizontal Vertical HV position Art A 07694 Figure 4 10 Overhead position fillet weld Operation 4 6 Manual 0 5149 OPERATION THERMAL ARC 201 TS 4 13 Joint Preparations In many cases it will be possible to weld steel sections without any special prep
21. LE 1 01 ARC WELDING HAZARDS Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service 9 7 7 Use fully insulated electrode holders Never dip EARNING holder in water to cool it or lay it down on the ELECTRIC SHOCK can kill ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live when ever the output is on The input power cir 8 Do not use worn damaged undersized or poorly cuit and machine internal circuits are also spliced cables live when power 15 on In semiautomatic 9 Do not wrap cables around your body or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power
22. MOUNTED HARNESS CONNECTORS PIN OUT VIEWED FROM COMPONENT SIDE OF BOARD Appendix LIMITED WARRANTY amp WARRANTY SCHEDULE In accordance with the warranty periods stated below Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment Thermadyne will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the warranty period The warranty period begins on the date of sale to the end user Welding Equipment Limited Warranty Period Product Period Thermal Arc 20115 torch electrode holder and work lead 30 Days If warranty is being sought Thermadyne must be notified in writing within 30 days of the failure and at such time we will make arrangements to fulfil the warranty claim Please contact your Thermadyne product supplier for the warranty repair procedure Thermadyne warranty will not apply to e Equipment that has been modified by any other party other than Thermadyne s own service personnel with prior written consent obtained from Thermadyne service department UK Equipment that has been used beyond the specif
23. Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermadyne com Copyright 2011 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date April 20 2011 Revision AB date May 20 2011 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Arc Welding 5 1 1 1 02 Principal Safety 5 1 5 1 03 Declaration Of Conformity Set sube tu estu sd Eie prd a 1 6 SECTION 2 INTRODUCTION 2 1 2 01 TAS IV eG waco ene 2 1 2 02 2 1 2 03 Receipt e ER NN RT 2 1 2 04 Transportation 2 1 209 YMO NI 2 2 1 6 2
24. able specimen with which to begin or two lengths of strip steel may be tacked together at right angles Using a 3 2mm 1 8 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 im mediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the vertical 50 electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 4 14 Do not attempt build up much larger than 6 4mm 1 4 width with a 3 2mm 1 8 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 15 Weaving in HV fillet welds is undesirable 45 from vertical ay 60 70 from line of weld Art A 07699 Figure 4 15 Electrode position for HV fillet weld 4 9 Operation THERMAL ARC 201 TS Art 07700 Figure 4 16 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 3 2mm 1 8 E7014 electrode and set the current at 120 amps Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead
25. aration For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 11 Open Square Butt Single Vee Butt Joint Not pa than Joint OO N C O gt 1 6mm 1 16 max Gap varies from 1 6mm 1 16 to 4 8mm 3 16 EN E depending on plate thickness 1 6mm 1 16 E Single Vee Butt Joint 6 Double Vee Butt Joint Not less than 0 1 6mm 1 16 max Lap Joint 1 6mm 116 ba Tee Joints Fillet Joint Fillet both sides of the joint Corner Weld Edge Joint Plug Weld Plug Weld Art 07695 AE Figure 4 11 Typical joint designs for arc welding Manual 0 5149 4 Operation THERMAL ARC 201 TS 4 14 Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence is to run beads on a piece of scrap plate Use mild steel plate about 6 4mm 1 4 thick and a 3 2mm 1 8 electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position Make sure that the work clamp is making good electrical contact with the work either directly or throug
26. articles are trapped A in the weld metal slag inclusion Slag trapped in undercut Not cleaned or incorrect electrode Service IN SS 5 Slag trapped in root Small electrodes used heavy cold plate Welding current is too low Wrong electrode angle Travel speed of electrode is too high or dirt on joint surface Non metallic particles may be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is preventing full fusion Wrong electrode for position in which welding is done 92 SERVICE Dry electrodes before use Reduce welding current C Clean joint before welding Redesign to relieve weld joint of severe stresses or use crack resistance electrodes Travel slightly slower to allow greater build up in throat Preheat plate and cool slowly Increase welding current Use smaller diameter electrode Allow wider gap Use correct build up sequence Use larger electrodes and preheat the plate Increase welding current Adjust angle so the welding arc is directed more into the base metal Reduce travel speed of electrode Clean surface before welding If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the
27. c 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 D Process Selection Switch 7 Arc Force Down slope Control A Power On Indicator B Fault Indicator E Welding Current Control mm Fe G Gas Outlet 8 Pin Control Socket Negative Output Terminal Positive Output Terminal Art A 10146 Figure 4 1 Thermal Arc 201 TS Controls A POWER Indicator The POWER Indicator illuminates when the ON OFF switch is in the ON position and the correct mains voltage is present B FAULT Indicator If Fault indicator lights up continuously then that is an Overcurrent Condition and needs to be serviced by an Authorized Thermalarc Technician Manual 0 5149 4 1 Operation THERMAL ARC 201 TS C TRIGGER Mode Switch LIFT TIG Mode Only 21 Normal Mode Press the TIG Torch Trigger Switch or Foot Control and hold depressed to weld Release the TIG Torch Trigger owitch or Foot Control to stop welding Down Slope operates in LIFT TlG GTAW mode only While welding if the Torch Trigger Sw
28. 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 considerable 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 02 LOCATION Be sure to locate the welder according to the following guidelines A B C In areas free from moisture and dust Ambient temperature between 0 C to 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 Placeata distance of 300mm or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to EN 60529 Manual 0 5149 3 1 Precautions must be taken against the power source toppling over The power source must
29. ding contact with work piece or filler contaminates off rod material B Gas contaminated with air B Check gas lines for cuts and loose fitting or change gas cylinder 0 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for problems 9 Arc flutters during TIG welding Tungsten electrode is too large select the right size electrode for the welding current Refer to section Tungsten Electrode Current Ranges 10 Welding arc cannot be A Workclamp is not connected to A Connect the work clamp to the established the work piece or the work torch work piece or connect the work leads are not connected to the torch leads to the correct welding correct welding terminals terminals Torch lead is disconnected B Connect it to the Negative Output Terminal Gasflow incorrectly set cylinder C Select the right flow rate change empty or the torch valve is off cylinder or turn torch valve on 11 Electrode melts or oxidizes when A No gas is flowing to welding Check the gas lines for kinks or an arc is struck region breaks or cylinder contains gas Torch is clogged with dust Clean torch Gas hose is cut Replace gas hose Gas passage contains impurities Disconnect gas hose from torch then raise gas pressure and blow out impurities Gas regulator turned off Turn on Torch valve is turned off Turn on The electrode is too small for the Increase electrode diameter
30. ding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout it s length The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level 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 p
31. disconnect switch open or remove line fuses so power cannot be turned on acciden tally 9 Properly install and ground this equipment accord ing to its Owner s Manual and national state and local codes Manual 0 5149 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations 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 General Information SAFE INSTRUCTION EJ ilr WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing Usea Welding Helmet or Welding Faceshield fitted with a proper shade of filter see ANSI 249 1 and EN 60974 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recom mended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Never wear contact lenses whi
32. e Factory Fitted Current Circuit Size LIFT TIG HF TI TICK Vin Amps G Li 110V 39A 125A Q 25 110V 30A 160A 30 Thermal Arc HO7RN F 2 5mm 110V 30A 201 TS 230V 32A 200A 259 230V 21A 200A Q 25 Table 3 2 Primary Circuit Sizes to Achieve Maximum Current 3 04 ELECTROMAGNETIC COMPATIBILITY e Sd WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation A Installation and Use Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome NOTE The welding circuit may or may nor be earthed for safety reasons Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes Will increase the risk of injury e g by allowing parallel weld
33. e 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 209 20 Electrode Tack weld Tack weld Art A 07697 Art A 07698 Figure 4 14 Weld build up sequence Manual 0 5149 THERMAL ARC 201 TS 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 13 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 sec tion made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 4 5 piece of angle iron is a suit
34. e 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 and TIG 16 You are now ready to begin TIG Welding 3 08 LEAK TESTING THE SYSTEM Leak test the system before putting into operation 1 Besurethatthere is a valve in the downstream equipment to turn off the gas flow With the cylinder valve open adjust the regulator to deliver the maximum required delivery pressure 3 4 Turnthe adjusting screw knob counterclockwise one turn Close the cylinder valve a Ifthe high pressure gauge reading drops there is a leak in the cylinder valve inlet fitting or high pressure gauge b Ifthe low pressure gauge drops there is a leak in the downstream equipment hose hose fitting outlet fitting or low pressure Installation Operation And Setup 3 8 INSTALLATION gauge Check for leaks using an approved leak detector solution c If the high pressure gauge drops and the low pressure gauge increases at the same time there is a leak in the regulator seat d Ifthe regulator requires service or repair take it to a qualified repair technician Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed A WARNING If a leak has been detected anywhere in the system discontinue use and have the system repaired DO NOT use leaking e
35. et 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 8 Pin Remote Socket 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 1213415161718 Ji D ms Front View of 8 Pin Socket Art A 09815_AB EO Torch Switch Input 24V to energize weld current connect pin 2 amp 3 to turn on welding current 3 Torch Switch Input OV to energize weld current connect pin 2 amp 3 to turn on welding current __4 o ok ohm maximum connection to ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer NOTE Remote Welding Current Control is not available on this model 4 2 Manual 0 5149 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 32 Amp Outlet The mains power 32 Amp circuit breaker or fuse should nottrip at this Weld Current value when STICK welding The environmental conditions that may cause the mains power 32 Amp circuit breaker
36. g cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Electrode Size Metal Thickness or Welding Current Welding or Cutting Operation Plasma arc cutting Over 400 Amp Manual 0 5149 f 9 THERMAL ARC 201 TS 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 AR N W WELDING can cause fire or explosion WARNING Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workplece and hot equipment can cause fires and burns Accidental con tact of electrode or welding wire to metal objects can cause sparks overheating fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flam mable material Remove all flammables within 10 7 m 35 ft of the welding arc If this is not possible tightly cover them with approved covers Bealertthat welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Beaware that weldin
37. g on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding cur rent from traveling long possibly unknown paths and causing electric shock and fire hazards 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 4h gt a WARNING FLYING SPARKS AND HOT METAL can cause Injury Chipping and grinding cause flying metal As welds cool they can throw off slag Manual 0 5149 SAFE INSTRUCTION 1 Wear approved face shield or safety goggles Side Shields recommended 2 Wear proper body protection to protect skin Sj 2 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 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equip ment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Useonly correct shield
38. h the work table For light gauge ma terial 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 begin ning 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 4 16 Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work You may at first experience dif ficulty due to the tip of the electrode sticking to the work piece This is caused by making too heavy a con tact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezi
39. hat apply and would look something like this Manual 0 5149 2 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 03 Receipt of Equipment 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 concern ing 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 2 04 Transportation Methods 7 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 Introduction INTRODUCTION THERMAL ARC 201 TS 2 05 Symbol Chart Note that only some of these symbols will appear Ue jin A Increase Decrease Circuit B
40. hat you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sec tors worldwide including Manufacturing Construction Mining Automotive Aerospace Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry A WARNINGS ES a Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Operating Manual Number 0 5149 for Thermal Arc 201 TS Power Source Arc Welder Part Number W1003802 Thermal Arc 201 TS System with Stick TIG Kit amp Case Part Number W1003803
41. ications established in the operating manual e nstallation not in accordance with the installation operating manual Any product that has been subjected to abuse misuse negligence accident improper care and or main tenance including lack of lubrication maintenance and protection will be refused warranty e Failure to clean and maintain the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation This manual also offers basic troubleshooting operational and technical details including application usage Using this manual correctly will ensure the quickest time possible for resolving any technical questions application issues or defects with your Thermadyne product You may also wish to visit our web site www thermadyne com select your product class and then select literature Here you will find documentation including e Operator manuals Service manuals Product guides Alternatively please contact your Thermadyne distributor and speak with a technical representative Warranty repairs must be performed by either a Thermadyne Service Centre a Thermadyne distributor or an Authorised Service Agent approved by the Company Customer Care UK 44 0 1257 261 755 Fax 44 0 1257 224 800 Customer Care Italy 39 02 36546801 Fax 39 02 36546480 www thermadyne com THERMADYNE A Globa
42. iece 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 Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of it s size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations screening and Shielding selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications 3 05 SETUP FOR WELDING NOTE Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins provided by the design ensure that the Welding Power Source will withstand short term ove
43. ing current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 60974 13 Arc Welding Equipment Installation and use under preparation B Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signalling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control equipment Safety critical equipment e g guarding of industrial equipment The health of people around e g the use of pacemakers and hearing aids Equipment used for calibration and measurement The time of day that welding or other activities are to be carried out C A W N 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 Manual 0 5149 3 3 Installation Operation And Setup THERMAL ARC 201 TS 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 Wel
44. ing gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards A WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust out side and away from any building air intakes General Information SAFE INSTRUCTION WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine f WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keepall doors panels covers and guards closed and secure
45. itch is released the weld ing 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 owitch to activate and then release the TIG Torch Trigger owitch to continue to weld then press the Torch Trigger Switch again and release the TIG Torch Trigger owitch 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 only Up slope is not adjustable and activates automatically in 41 mode when the 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 owitch is depressed and released the arc will extinguish immediately D Process Selection Switch Switches between STICK LIFT TIG GTAW and HF GTAW modes Refer to Section 3 06 Setup for STICK Welding and 3 07 Setup fo
46. l Cutting amp Welding Market Leader WORLD HEADQUARTERS 16052 Swingley Ridge Road Suite 300 e St Louis Missouri 63017 U S A THE AMERICAS EUROPE ASIA PACIFIC Denton TX USA Miami FL USA Chorley United Kingdom Cikarang Indonesia Melbourne Australia Shanghai China U S Customer Care Sales Office Latin America Customer Care Customer Care Australia Customer Care Sales Office Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Form No 0 5149 11 April 201 1 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 Ph 44 1257 261 755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 2011 Thermadyne Industries Inc Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 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 www thermadyne com Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 Printed in China
47. l the desire for continued expansion it has to deform plastically that is the metal adjacent to the weld is at a high tempera ture and hence rather soft and by expanding pushes against the cooler harder metal further away and tends 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 defor mation 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 20 and 4 21 illustrate how distortion is created Weld Upsetting Art 07705_ Expansion with d x compression Hot Cool Figure 4 22 Parent metal contraction 4 11 Operation THERMAL ARC 201 TS 4 22 Overcoming Distortion Effects There are several methods of minimizing distortion effects 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 B Distribution of Stresses Distortion may be reduced by selecti
48. le welding Electrode Size Metal Thickness or Welding Current Welding or Cutting Operation No Torch soldering 2 Torch brazing Oxygen Cutting Light Under 1 in 25 mm Gas welding 5 32 to 1 4 in 4 to 6 4 mm General Information Filter Shade welding MIG Worteroustase meat Medium w o um 8mm 4o Pasmaarcvetdng omn ermm M Way Um J _ Shielded metal arc welding Under 5 32 in 4 mm 10 Heavy 14 stick electrodes j ownam M 5 1 2 THERMAL ARC 201 TS P 2 WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is well venti lated or while wearing an air supplied respirator shielding gases used for welding can displace air causing injury or death Be sure the breathing air Is safe Donot weld in locations near degreasin
49. lines show effect if no preheat is used Figure 4 24 Reduction of distortion by preheating Art A 07709 dJ Ses Figure 4 25 Examples of distortion Art 07710 Block Sequence The spaces between the welds are filled in when the welds are cool Figure 4 26 Welding sequence Figure 4 29 Staggered intermittent welding 4 12 Manual 0 5149 SERVICE THERMAL ARC 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 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 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 Maintain more often if used under severe conditions Each Use
50. ly in place 2 otop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 o prevent accidental starting during servicing disconnect negative battery cable from bat tery 9 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine uw WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a bat tery 2 Stop engine before disconnecting or connecting battery cables 3 Do not allow tools to cause sparks when working on a battery General Information THERMAL ARC 201 TS 4 Do not use welder to charge batteries or jump Start vehicles 9 Observe correct polarity and on batteries Pe WARNING STEAM AND PRESSURIZED HOT COOL ANT can burn face eyes and skin The coolant in the radiator can be very hot under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely re moving cap LEAD WARNING This product contains chemicals includ ing lead or otherwise produces chemicals known
51. ng a welding se quence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 4 25 through 4 28 for various weld sequences Choice of a suitable weld sequence is probably the most ef fective method of overcoming distortion although an unsuitable sequence may exaggerate it Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experi ence or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 22 E Preheating ouitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 4 23 shows a simple application By removing the heating source from b and c as soon as welding is completed the sections b and c will contract at a similar rate thus reducing distortion Art A 07707 Figure 4 23 Principle of presetting Operation OPERATION 07708 Preheat Preheat Dotted
52. ng on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 6mm 1 16 to 3 2mm 1 8 gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults Operation OPERATION Art 07696 ro p Y 1 55 2 1 6mm 1 16 Figure 4 12 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 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
53. o initiate the welding arc when used with a suitable TIG torch and shielding gas Advanced TIG features include 8 Pin Amp Plug for remote control devices down slope 2T 4T controls and gas solenoid operation It also has STICK MMA welding mode which uses standard general purpose STICK MMA 2 0mm 3 32 electrodes for light gauge work generally less than 3 2mm 1 8 thick and STICK MMA 3 2mm 1 8 electrodes for heavier material Manual 0 5149 2 3 THERMAL ARC 201 TS 2 07 User Responsibility This equipment will perform as per the information contained herein when installed operated maintained and repaired in accordance with the instructions pro vided This equipment must be checked periodically Defective equipment including welding leads should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced immediately Should such repairs or replacements become necessary it is recommended that such re pairs be carried out by appropriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or any of its parts should not be al tered from standard specification without prior written approval of Thermal Arc The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification fault
54. on network operator if necessary that the equipment may be connected Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative oteve Ward Operations Director Thermadyne Europe Europa Building N Industrial Park Chorley Lancashire England PR6 7BX General Information 1 6 Manual 0 5149 INTRODUCTION THERMAL ARC 201 TS SECTION 2 INTRODUCTION 2 01 How to Use This Manual 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 A WARNING Gives information regarding possible per sonal injury Warnings will be enclosed in box such as this A 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 ap pearing 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 t
55. quipment Do not attempt to repair a leaking system while the system is under pressure 3 09 WHEN YOU FINISH USING THE REGULATOR 1 Close the cylinder valve Open the valve on the downstream equipment This drains all pressure from the system Close the valve on the downstream equipment Turn the adjusting screw counterclockwise to release the tension on the adjusting spring Check the gauges after a few minutes for verification that the cylinder valve is closed completely 3 10 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 he inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting Manual 0 5149 OPERATION THERMAL ARC 201 TS SECTION 4 OPERATION Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold the electrode The welding current range values should be used as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrode welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then fine tune the welding current to suit the specifi
56. r HF TIG Welding 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 F Arc Force Down Slope Control Arc Force is effective when in STICK MMA 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 com pensate 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 Operation OPERATION 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 regard ing Downslope operation G Gas Outlet The Gas Outlet is a 5 8 18 UNF female gas fitting and is utilized for the connection of a suitable TIG Torch H Post Gas Flow weld current dependant 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 Cur rent is s
57. rds Association Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 oafe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 safety in welding and allied processes Part 1 Fire Precautions EN 60974 1 from SAI Global Limited www saiglobal com safety in welding and allied processes Part 2 Electrical EN 60974 1 from SAI Global Limited www saiglobal com Filters for eye protectors Filters for protection against radiation generated in welding and allied operations AS NZS 1338 1 1992 from SAI Global Limited www saiglobal com Manual 0 5149 1 5 General Information SAFE INSTRUCTION THERMAL ARC 201 TS 1 08 DECLARATION OF CONFORMITY Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC and to the
58. reaker n ___ vpe Frequency j Direct Current DC Ground D poje _ AC Auxiliary Power Hertz cycles sec Auxiliary Power Receptacle Rating Auxiliary Power Introduction Fault Indication Touch Start on your model Single Phase Wire Feed Function Three Phase Three Phase Static Frequency Converter Transformer Rectifier Shielded Metal Arc Welding SMAW Wire Feed Towards Workpiece With Output Voltage Off Welding Gun Purging Of Gas Continuous Weld Mode Spot Weld Mode Spot Time Preflow Time We Press to initiate wirefeed and welding release to stop Press and hold for preflow release to start arc Press to stop arc and hold for preflow A Disturbance In Ground System Inches Per Minute Lg Meters Per Minute Gas Metal Arc Welding GMAW Postflow Time Gas Tungsten Arc Welding GTAW 2 Step Trigger Operation Air Carbon Arc Cutting CAC A 4 Step Trigger Constant Current Operation onstant Voltage C Or Constant Potential High Temperature Burnback Time Variable Inductance Manual 0 5149 INTRODUCTION 2 06 Description This compact inverter welding machine has infinitely adjustable welding current from 10 to 200 amps The 20175 has a LIFT GTAW and HF TIG GTAW welding mode that offers stable welding characteristics with an optimized start TIG sequence t
59. recommended safety equipment 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the ground work clamp cable to the negative output terminal and the electrode holder cable to the positive output terminal It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection NOTE This set up is known as DC Electrode Positive or reverse polarity Please consult with the stick electrode manufacturer for specific polarity recommendations 3 Connect the ground work clamp to your workpiece 4 Plug the power cable into the appropriate outlet and turn the switch to the ON position The power L E D light should illuminate 5 the Process Selection Switch to STICK 6 Set the weld current control knob to the desired amperage 7 Set the ARC FORCE control knob to 2 Minimum 0 provides a soft arc low spatter amp low penetration Medium 2 provides a normal arc improved fusion amp normal penetration Maximum 10 provides a hard arc amp deep penetration 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 Installation Operation And Setup 3 6 Manual 0 5149 INSTALLATION THERMAL ARC 201 TS 3 07 LIFT TIG HF
60. rload 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 Installation Operation And Setup 3 4 Manual 0 5149 INSTALLATION THERMAL ARC 201 TS A WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source 3 06 STICK MMA SETUP j Switch to STICK 6 oet Process Selection Set Welding Curent 26 amp as specified by the h Electrode Manufacturer rr Set ARC Force Hy rj Negative Output Positive Output Terminal L P Dinse 50 7 5 Dinse 50 Art A 09784 Figure 3 2 Setup for STICK MMA Welding Manual 0 5149 3 5 Installation Operation And Setup THERMAL ARC 201 TS INSTALLATION STICK MMA Mode Sequence of Operation A CAUTION Before any welding is to begin be sure to wear all appropriate and
61. s or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items The values specified in the table above are optimal values your values may differ Individual equipment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation location and conditions and local power grid supply conditions NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service Introduction 2 6 Manual 0 5149 INSTALLATION THERMAL ARC 201 TS SECTION 3 INSTALLATION OPERATION AND SETUP 3 01 ENVIRONMENT 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
62. to be deposited Refer Figure 4 16 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 5 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 17 illustrates multi run technique and Figure 4 18 shows the effects of pausing at the edge of weave and of weaving too rapidly Art A 07701 4 o gt Figure 4 17 Single run vertical fillet weld Operation 4 10 CORRECT OPERATION Weaving motion forsecond and subsequent runs Pause at edge of weave Figure 4 18 Multi run vertical fillet weld INCORRECT D EN Pause at edge of weave allows weld metal to build up and eliminates undercut Note weld contour when insufficient pause at edge of weave Art A 07703 Figure 4 19 Examples of vertical fillet welds 2 Vertical Down The E7014 electrode makes welding in this position particularly easy Use a 3 2mm 1 8 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
63. to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 PRINCIPAL SAFETY STANDARDS safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 oafe 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 Standa
64. to the State of California to cause cancer birth defects and other tive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq Uh e o WARNING This product when used for welding or cutting produces fumes or gases Which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclu sions Section of the U S Congress Office of Tech 1 4 Manual 0 5149 THERMAL ARC 201 TS SAFE INSTRUCTION nology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or
65. ts up continuously 3 Maximum output welding Defective control circuit current cannot be achieved with nominal Mains supply voltage 4 Welding current reduces when Poor work lead connection to the welding Work piece 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 Service 5 4 A Switch ON the Primary supply voltage B Switch ON the Welding Power Source 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 32 amp An individual branch circuit capable of carrying 32 amperes and protected by fuses or circuit breaker is recommended for this application The input current to the main Have an Accredited Thermal Arc transformer has been exceeded Service Provider inspect then repair the welder Manual 0 5149 APPENDIX THERMAL ARC 201 TS APPENDIX 1 OPTIONS AND ACCESSORIES Part Number 26 TIG Torch with 12 5ft lead finger remote control 50mm dinse connection and W4013601 accessory kit Foot Control 8 pin amphenol 15ft 600285 Slider Current Control with Torch Switch 15ft
66. und GREEN or GREEN YELLOW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes Installation Operation And Setup THERMAL ARC 201 TS INSTALLATION 2 Connect ends of line Active BROWN and Neutral BLUE input conductors to a suitable power suply system that complies with all applicable local electrical codes 3 Use Table 3 1 as a guide to select line fuses for the disconnect switch Input Voltage Circuit Breaker or Fuse Size Table 3 1 Fuse Guide CAUTION The time delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this product due to the amperage rating of the time delay fuses or circuit breaker Welding Power Supply EM _ E eO Figure 3 1 Electrical Input Connections Primary Power Cable Art A 10143 Input Power Each unit incorporates an INRUSH circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides pre charging for the input capacitors A relay in the Power Control Assembly PCA will turn on after the input capacitors have charged to operating voltage after approximately 5 seconds Installation Operation And Setup 3 2 Manual 0 5149 INSTALLATION THERMAL ARC 201 TS NOTE Damage to the PCA could occur if 265 VAC or higher is applied to the Primary Power Cable Primary Supply Lead Minimum Primary Current amp Duty Cycle Siz
67. upwards at an angle of about 45 Overhead Welds Apart from the rather awkward position neces sary overhead welding is not much more dif ficult that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead posi tion as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 4 19 The tip of the electrode may be touched lightly on the metal which helps to give a steady run A weave technique is not advisable for overhead fillet welds Use a 3 2mm 1 8 E6012 electrode at 120 amps and deposit the first run by simply drawing the electrode along at a steady rate You will notice that the weld deposit is rather convex due to the effect of gravity before the metal freezes Manual 0 5149 OPERATION Tilted 40 in line of travel Pd 45 to plate Angle tacked to pipe Figure 4 20 Overhead fillet weld 4 20 Distortion 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 com plex that only a brief outline can be attempted hear
68. y maintenance damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc Introduction THERMAL ARC 201 TS INTRODUCTION 2 08 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts To explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 2090 duty cycle 200 amperes at 18 volts This means that it has been designed and built to provide the rated amperage 200A for 2 minutes i e arc welding time out of every 10 minute period 209 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power oource must idle and be allowed to cool 100 110VAC INPUT 90 TIG GTAW 80 70 60 Safe 50 Duty Cycle percentage amp 40 C 40 _ Operating 30 Region Stick 20 0 0 20 40 60 80 100 120 140 160 Welding Current amps Art A 10141 100 230VAC INPUT 90 80 70 60 Safe e er a 59 50 10 Operating 0 Region TIG GTAW 20 10 0 jm 0 20 40
69. 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 Most types of cast iron except white iron are weldable White iron because of its extreme brittleness gener ally 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 indus trial purposes which are not of particular interest for ev eryday 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

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