Thermal Arc 201 TS Service Manual
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Thermal Arc 201 TS Service Manual

Inverter arc welde
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See also: Operating Manual
161 STL
201 TS
Service Manual
THERMAL ARC
InvERTER ARC WELdER
Revision: AC
Operating Features:
Issue Date: Dec. 03, 2012
®
Art # A-10144
Manual No.: 0-5148
50
Hz
60
50
Hz
60

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Summary of Contents for Thermal Arc 201 TS

  • Page 1 161 STL THERMAL ARC ® 201 TS InvERTER ARC WELdER Service Manual Art # A-10144 Revision: AC Issue Date: Dec. 03, 2012 Manual No.: 0-5148 Operating Features:...
  • Page 2 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.
  • Page 3 Thermal Arc 161 STL System with Stick/TIG Kit & Case Part No. W1003701 Thermal Arc 201 TS Power Source Arc Welder Part No. W1003800 Thermal Arc 201 TS System with Stick/TIG Kit & Case Part No. W1003801 Published by: Victor Technologies International, Inc.

  • Page 4: Table Of Contents

    Welding Current Control Explanation ............4-10 4.07 Victor Regulator .................... 4-11 4.08 Leak Testing the System ................4-12 4.09 Lift Start TIG with the Thermal Arc 161STL ..........4-12 SECTION 5: THEORY OF OPERATION ................5-1 5.01 Inverter Design ....................5-1...
  • Page 5 TABLE OF CONTENTS SECTION 6: TROUBLESHOOTING ................6-1 6.01 Basic Troubleshooting ..................6-1 6.02 Checking Unit Before Applying Power ............6-2 6.03 Tools Needed for Troubleshooting and Servicing ..........6-2 6.04 Case Removal ....................6-3 6.05 Clear Cover Sheet Removal ................6-4 6.06 Pre-Power Check ....................

  • Page 7: Safety Instructions And Warnings

    SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS WARNING WARNING WELDING can cause fire or explosion. FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these Sparks and spatter fly off from the welding arc. The flying fumes and gases can be hazardous to your health.
  • Page 9 SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS WARNING WARNING ENGINE FUEL can cause fire or explosion. FLYING SPARKS AND HOT METAL can cause injury. Engine fuel is highly flammable. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: General Safety Information For Victor Cs Regulator

    THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS 1.02 General Safety Information for Victor CS Regulator WARNING Fire Prevention STEAM AND PRESSURIZED HOT COOLANT can burn Welding and cutting operations use fire or combustion as a basic face, eyes, and skin.

  • Page 11: Principal Safety Standards

    SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS D Personal Protection 3. Store empty cylinders away from full cylinders. Mark them “EMPTY” and close the cylinder valve. Gas flames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes. Select goggles or a mask with 4.

  • Page 12: Symbol Chart

    THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static...

  • Page 13: Servicing Hazards

    SAFETY INSTRUCTIONS AND WARNINGS THERMAL ARC 161STL, 201TS 1.05 Servicing Hazards WARNING FLYING METAL or DIRT can injure eyes. WARNING • Wear safety glasses with side shields or face shield during The symbols shown below are used throughout this servicing.

  • Page 14: Emf Information

    THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS • Have only qualified persons remove doors, panels, covers, or 1.06 EMF Information guards for maintenance as necessary. • Keep hands, hair, loose clothing, and tools away from moving Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields parts. • Reinstall doors, panels, covers, or guards when maintenance Welding current, as it flows through welding cables, will cause elec- is finished and before reconnecting input power.

  • Page 15: Introduction

    2.04 Description Gives information regarding possible personal injury. Warnings will be enclosed in a box The Thermal Arc 161STL is compact inverter welding such as this. machine has infinitely adjustable welding current from 10 to 160 amps. It has a LIFT TIG (GTAW) welding mode that...
  • Page 16 THERMAL ARC 161STL, 201TS INTRODUCTION Notes Introduction Manual 0-5148...

  • Page 17: Safety And Installation

    SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS SECTION 3: SAFETY AND INSTALLATION 3.01 Duty Cycle The rated duty cycle of a Welding Power Source, is the percentage of a ten minute time period that it may be operated at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period, suppose a Welding Power Source is designed to operate with a 30% duty cycle at 160 amperes and 26.4 volts.
  • Page 18 THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION 230VAC Input Lift TIG/HF TIG Stick AMPS Art # A-10145 115VAC Input Lift TIG/HF TIG Stick AMPS Art # A-10157 Figure 3-2: 201TS Duty Cycle Safety and Installation Manual 0-5148...

  • Page 19: Specifications - 161Stl

    (Based on Article 630, National Electrical Code) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 20: Specifications -201Ts

    (Based on Article 630, National Electrical Code) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 21: Environment

    • In areas, not subjected to abnormal vibration or shock. • In areas, not exposed to direct sunlight or rain. • Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air flow for cooling WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician. 3.06 Electrical Input Connections WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.
  • Page 22 THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION Do not connect the ground (GREEN) conductor to an input line terminal. Refer to Figure 3-3: 1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.
  • Page 23 SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS 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...

  • Page 24: Electromagnetic Compatibility

    THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION 3.07 Electromagnetic Compatibility 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.
  • Page 25 SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS 5. Earthing of the Work Piece Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances.

  • Page 26: Volt-Ampere Curves

    THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION 3.08 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 230VAC Input Lift TIG Max Stick Max A-09949 AMPS...
  • Page 27 SAFETY AND INSTALLATION THERMAL ARC 161STL, 201TS 230VAC Input Stick Max Lift TIG Max AMPS Art # A-10158 115VAC Input Lift Tig Max Stick Max AMPS Art # A-10159 Figure 3-4: 201TS Volt-Ampere Curves Manual 0-5148 3-11 Safety and Installation...
  • Page 28 THERMAL ARC 161STL, 201TS SAFETY AND INSTALLATION Notes Safety and Installation 3-12 Manual 0-5148...

  • Page 29: Operation

    (D) Process Selection Switch (F) Arc Force/Down Slope Control (B) Fault Indicator (E) Welding Current Control (I) 8 Pin Control Socket (G) Gas Outlet Positive Output Terminal Negative Output Terminal Art # A-09786_AC Figure 4-1: Thermal Arc 161STL Controls Manual 0-5148 Operation...
  • Page 30 Fault Indicator to extinguish before resuming welding. Over Primary Current Protection If the Fault Indicator flashes on and off then the primary current into the main transformer has been exceeded. Have an Accredited Thermal Arc Service Provider inspect then repair the welder. Operation Manual 0-5148...
  • Page 31 OPERATION THERMAL ARC 161STL, 201TS F. Arc Force/Down Slope Control C. TRIGGER Mode Switch (LIFT TIG Mode Only) Arc Force is effective when in STICK (SMAW) Mode only. 2T (Normal) Mode Arc Force control provides an adjustable amount of Arc Press the TIG Torch Trigger Switch or Foot Control and Force (or “dig”) control.
  • Page 32 THERMAL ARC 161STL, 201TS OPERATION I. 8 Pin Control Socket The 8 pin Torch Trigger 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.

  • Page 33: Setup For Welding

    OPERATION THERMAL ARC 161STL, 201TS 4.02 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 holder and lead is connected to the electrode. Wide safety margins provided by the design ensure that the Welding Power Source will withstand short-term overload without adverse effects.

  • Page 34: Stick (Smaw) Setup

    THERMAL ARC 161STL, 201TS OPERATION 4.03 Stick (SMAW) Setup Set Process Selection Set Welding Current Switch to STICK. as specified by the Electrode Manufacturer. Set ARC Force Negative Output Positive Output Terminal Terminal (Dinse™ 50) (Dinse™ 50) Art#: A-09784 Figure 4-3: Setup for STICK (SMAW) Welding...

  • Page 35: Lift Tig (Gtaw) Setup

    OPERATION THERMAL ARC 161STL, 201TS 3. Connect the work clamp to your workpiece. 4. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D light should illuminate. 5. Set the “Process Selection Switch” to STICK.
  • Page 36 THERMAL ARC 161STL, 201TS OPERATION LIFT TIG (GTAW) Sequence of Operation 12. The tungsten must be ground to a blunt point in or- der to achieve optimum welding results. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning.

  • Page 37: Hf Tig (Gtaw) Setup (201Ts Only)

    OPERATION THERMAL ARC 161STL, 201TS 4.05 HF TIG (GTAW) Setup (201TS only) Set Process Selection Switch to LIFT TIG or HF TIG. Switch to 2T/4T Set Welding Current as specified by the Set DOWN Slope Electrode Manufacturer. Secure the gas cylinder in an...

  • Page 38: Welding Current Control Explanation

    THERMAL ARC 161STL, 201TS OPERATION 4.06 Welding Current Control 3. Connect the TIG torch as follows: Explanation a) Place the power cable into the negative output ter- minal. It is essential that the male plug is inserted 15 Amp Outlet and turned fully clockwise until connector locks in place to achieve reliable electrical connection;...

  • Page 39: Victor Regulator

    OPERATION THERMAL ARC 161STL, 201TS Nuisance tripping should not occur on a 50A 208/230V outlet for both STICK & LIFT TIG/HF TIG Modes. WARNING 15 Amp Outlet Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator 20 Amp Outlet for use with any other gas.

  • Page 40: Leak Testing The System

    4. Attach the desired downstream equipment. stabilize the arc. To TIG weld with the Thermal Arc 161STL you will need to: 4.08 Leak Testing the System 1. Open the torch valve and adjust the argon flow Leak test the system before putting into operation.

  • Page 41: Theory Of Operation

    THEORY OF OPERATION THERMAL ARC 161STL, 201TS SECTION 5: THEORY OF OPERATION 5.01 Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC.
  • Page 42 THERMAL ARC 161STL, 201TS THEORY OF OPERATION Notes Theory of Operation Manual 0-5148...

  • Page 43: Troubleshooting

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS SECTION 6: TROUBLESHOOTING 6.01 Basic Troubleshooting Symptom Inspection Methods ON/OFF Switch “ON” Check power supply input Power Indicator OFF Check ON/OFF switch continuity (See 6.06.7) Check Inrush Resistor (see 6.06.6)） Check control PCB2 J8 connector and front panel PCB3 J24 connector to make sure they are properly inserted.

  • Page 44: Checking Unit Before Applying Power

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 6.02 Checking Unit Before Applying Power Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit. Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing case.

  • Page 45: Case Removal

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6.04 Case Removal Read and follow safety information in Section 6.02 before proceeding. 1. Cover 2. Screws - Remove the 4 screws, 2 on each side of the unit. - Remove 2 screws from both the Front and Rear Panels.

  • Page 46: Clear Cover Sheet Removal

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 3. Ground screw - Carefully lift the case to access and remove the screw which connects the ground wire to the cover. Art # A-09851_AB 6.05 Clear Cover Sheet Removal Read and follow safety information in Section 6.02 before proceeding.

  • Page 47: Pre-Power Check

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6.06 Pre-Power Check Measure Points for following tests Manual 0-5148 Troubleshooting...

  • Page 48: Measurement

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING Read and follow safety information in Section 6.02 before proceeding. Measure point 1 to 18. 1. Measurement of Input Rectifier Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200 V - 0.700 V.
  • Page 49 TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6. Measurement of In Rush Resistor R1. Set multimeter to Ohm mode. Ohm reading should be 4Ω±5%. Positive Probe Negative Probe Measure Point 17 Measure Point 18 If reading is not 4ohms within ±5%, replace Resistor R1.

  • Page 50: Dc Bus Voltage Check

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 6.07 DC Bus Voltage Check Warning: Measure DC voltage reading with multimeter before inspection. Set multimeter to DC voltage mode. Read and follow safety information in Section 6.02 before proceeding. 1. DC Positive 2. DC Negative Check and make sure input capacitors are discharged and voltage is near 0 VDC.

  • Page 51: Installing Clear Cover Sheet

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6.08 Installing Clear Cover Sheet Read and follow safety information in Section 6.02 before proceeding. 1. Replace the clear protective sheet. Art # A-10160 Manual 0-5148 Troubleshooting...

  • Page 52: Waveforms For Section 6-10

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 6.09 Waveforms for Section 6-10 A. OCV Waveform of Transformer primary Art # A-09858 Troubleshooting 6-10 Manual 0-5148...
  • Page 53 TROUBLESHOOTING THERMAL ARC 161STL, 201TS B.Output 160A/26.4V transformer primary waveform under input 230VAC Art # A-09859 C. Output 160A/26.4 V output voltage waveform under input 230VAC Art # A-09860 Manual 0-5148 6-11 Troubleshooting...
  • Page 54 THERMAL ARC 161STL, 201TS TROUBLESHOOTING D. Output 125A/25V transformer primary waveform under input 115VAC Art # A-09894 E. Output 125A/25V output voltage waveform under input 115VAC Art # A-09895 Troubleshooting 6-12 Manual 0-5148...

  • Page 55: Troubleshooting Circuit Diagram - 161Stl

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6.10 Troubleshooting Circuit Diagram - 161STL V1: Details refer to 6.09 A, B and D waveforms. V2: Details refer to 6.09 C and E waveforms. Manual 0-5148 6-13 Troubleshooting...

  • Page 56: 161Stl Connector Diagram

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 6.11 161STL Connector Diagram Troubleshooting 6-14 Manual 0-5148...

  • Page 57: Troubleshooting Circuit Diagram - 201Ts

    TROUBLESHOOTING THERMAL ARC 161STL, 201TS 6.12 Troubleshooting Circuit Diagram - 201TS Manual 0-5148 6-15 Troubleshooting...

  • Page 58: 201Ts Connector Diagram

    THERMAL ARC 161STL, 201TS TROUBLESHOOTING 6.13 201 TS Connector Diagram Troubleshooting 6-16 Manual 0-5148...

  • Page 59: Disassembly Procedure

    DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS SECTION 7: DISASSEMBLY PROCEDURE 7.01 Safety Precautions for Disassembly Read and follow safety information in Section 6.02 before proceeding. Unplug unit before beginning Disassembly procedure. Manual 0-5148 Disassembly Procedure...

  • Page 60: Control Board Removal

    THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE 7.02 Control Board Removal Read and follow safety information in Section 6.02 before proceeding with disassembly Refer to diagram on page 7-3. 1. M4 Screw. Remove 4 screws from Control panel. 2. Disconnect J8 harness from J8 connector.
  • Page 61 DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS SOU/HF/QF POWER CONNECTOR LAYOUT DIAGRAM Control PCB2 Art # A-10164 161STL Control PCB CONNECTOR LAYOUT DIAGRAM POWER SOU/HF/QF Art # A-10165 201TS Control PCB Manual 0-5148 Disassembly Procedure...

  • Page 62: Front Panel Assembly Removal

    THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE 7.03 Front Panel Assembly Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Power supply output Negative 2 Power supply output Positive 3. Output terminal bolts. Unscrew power supply output terminal bolts.
  • Page 63 DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10167 Art # A-10168 Manual 0-5148 Disassembly Procedure...

  • Page 64: Front Panel (Operator Interface) Circuit Board Pc2 Removal

    THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE Art # A-10169 7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. PROCESS Selector Switch Boot Remove the rubber boot from the PROCESS Selector switch by turning the retaining nut counter clockwise.
  • Page 65 DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS 6. Trigger Selector Switch Remove the rubber boot from the Trigger Selector Switch by turning the retaining nut counter-clockwise. 7. Arc Force/Down Slope Control Knob Remove the Arc Force/Down Slope Control Knob by lossening the set screw.

  • Page 66: Back Panel Removal

    THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE Art # A-10172 Art # A-09870 7.05 Back Panel Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. ON/OFF switch 2. Wire from Main PCB1. Disconnect the two wires from PCB1.
  • Page 67 DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10173 Art # A-10174 Manual 0-5148 Disassembly Procedure...
  • Page 68 THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE Art # A-10175 Art # A-10176 Disassembly Procedure 7-10 Manual 0-5148...

  • Page 69: Power Switch S1 And Power Cord Removal

    DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS 7.06 Power Switch S1 and Power Cord Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Input Power Cord connection s to SW1. Remove the stab-on wire connections from SW1.
  • Page 70 THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE Art # A-10178 Art # A-10179 Disassembly Procedure 7-12 Manual 0-5148...

  • Page 71: Base Panel Removal

    DISASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS 7.07 Base Panel Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove PCB1 assembly. 2. Remove Base Panel Screws. 3. Remove Base Panel. Art # A -10180 Manual 0-5148...
  • Page 72 THERMAL ARC 161STL, 201TS DISASSEMBLY PROCEDURE Notes Disassembly Procedure 7-14 Manual 0-5148...

  • Page 73: Assembly Procedures

    ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Base Board 1. Base Panel 2. Panel screws Secure the Main Power PCB1 to the Base Panel with the Panel Screws. 3. Main power PCB1 assembly Art # A- 10181...

  • Page 74: Installing Back Panel

    THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES 8.02 Installing Back Panel 1. Install ON/OFF switch. 2. Install power cord. 3. Reconnect Input Wire on the ON/OFF switch. 4. Reinstall Magnet onto Ground Wire. 5. Install fan. 6. Reconnect power ON/OFF switch to terminals on Main Power PCB.
  • Page 75 ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10183 Art # A-09883 Manual 0-5148 Assembly Procedures...

  • Page 76: Installing Front Panel

    THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES 8.03 Installing Front Panel 1. PCB3 Place PCB1 into front panel. 2. WELD CURRENT potentiometer Turn potentiometer shaft fully clockwise. 3. Arc Force/ Down Slope control potentiometer Turn potentiometer shaft fully clockwise. 4. Potentiometer mounting nut.
  • Page 77 ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10185 Art # A-10186 Manual 0-5148 Assembly Procedures...
  • Page 78 THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES 9. Reinstall output terminals on front panel with 27mm wrench. 10. Reconnect wires to their respective terminals using the bolts. 11. Reconnect Output Terminal Bolts and tighten with 17mm wrench. 12. Reinstall screw. Art # A-10187...
  • Page 79 ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10188 Art # A-10189 Manual 0-5148 Assembly Procedures...

  • Page 80: Installing Main Control Panel And Clear Cover Sheet

    THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES 8.04 Installing Main Control Panel and Clear Cover Sheet 1. Install 4 screws. 2. Plug harness into connector J8. Refer to 7.02. 3. Plug harness into connector J7 4. Plug harness into connector J2.
  • Page 81 ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10190 Manual 0-5148 Assembly Procedures...

  • Page 82: Installing Case

    THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES 8.05 Installing Case 1. Install Case. 2. Install Screws. - Eight (8) screws. 4 on both side panels of case, 2 on front panel, 2 on rear panel. Art # A-10191 Assembly Procedures 8-10...
  • Page 83 ASSEMBLY PROCEDURE THERMAL ARC 161STL, 201TS Art # A-10192 Manual 0-5148 8-11 Assembly Procedures...
  • Page 84 THERMAL ARC 161STL, 201TS ASSEMBLY PROCEDURES Notes Assembly Procedures 8-12 Manual 0-5148...

  • Page 85: Replacement Parts

    REPLACEMENT PARTS THERMAL ARC 161STL, 201TS SECTION 9: REPLACEMENT PARTS 9.01 Hardware List Description Specification Where used Unit Hexagon socket head screw GB/T70.1 M8×14 Handle EACH Cross-recessed round head screw GB/T818 M3×12 Remote socket EACH GB/T845-1985 Cross-recessed tapping screw Base Panel EACH BT4.8*13...

  • Page 86: Replacement Part List - 161Stl

    THERMAL ARC 161STL, 201TS REPLACEMENT PARTS 9.02 Replacement Part List - 161STL Item No Description Part No. Reference Designator Handle W7003040 Panel, Cover W7003200 Rectifier 1000V,50A W7003010 PCB,Control,161STL W7003202 PCB2 Thermostat W7003016 THC1, THC2 Resistor,6 ohm,60W W7003055 PCB,Power,161STL W7003203 PCB1...
  • Page 87 REPLACEMENT PARTS THERMAL ARC 161STL, 201TS Art # A-10022_AB Manual 0-5148 Replacement Parts...

  • Page 88: Replacement Part List - 201Ts

    THERMAL ARC 161STL, 201TS REPLACEMENT PARTS 9.03 Replacement Part List - 201TS Item No Description Part No. Reference Designator Handle W7003040 Panel, Cover W7003200 Rectifier 1000V,50A W7003010 PCB,Control,201TS W7003222 PCB2 Thermostat W7003016 THC1, THC2 Resistor,6 ohm,60W W7003055 PCB,Power,201TS W7003216 PCB1...
  • Page 89 REPLACEMENT PARTS THERMAL ARC 161STL, 201TS Art # A-10104_AB Manual 0-5148 Replacement Parts...
  • Page 90 THERMAL ARC 161STL, 201TS REPLACEMENT PARTS Notes Replacement Parts Manual 0-5148...

  • Page 91: Accessories

    ACCESSORIES THERMAL ARC 161STL, 201TS SECTION 10: ACCESSORIES Description Part Number 17 style TIG Torch with 12.5ft lead, finger remote control, 50mm dinse connection and W4012701 accessory kit VICTOR AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection 0781-4169...
  • Page 92 THERMAL ARC 161STL, 201TS ACCESSORIES Notes Accessories 10-2 Manual 0-5148...

  • Page 93: Limited Warranty

    No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the product.
  • Page 94 WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. January 2009 SAFETY EQUIPMENT ARRANTY ERIOD ABOR Auto-Darkening Welding Helmet (Electronic Lens) 2 year 2 year Harness Assembly 1 Month 1 Month ENGINE DRIVEN WELDERS...
  • Page 96 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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