Thermal Arc 161 STL 201 Ts Inverter Welder SM PDF

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:
50Hz
60
50Hz
60
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in the industry. This product is backed by our extensive warranty and world-
wide service network. To locate your nearest distributor or service agency call
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This Service 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
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The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for Victor
Technologies International, Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing, Construction,
Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,

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to achieve a safer working environment within the welding industry.
! WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manu-
facturer assumes no liability for its use.
Service Manual Number 0-5148 for:

Thermal Arc 161 STL Power Source Arc Welder Part No. W1003700
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.
16052 Swingley Ridge Road,
Suite 300 St, Louis, Mo 63017
USA
www.thermalarc.com
Copyright © 2011,2012 by
Victor Technologies International, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Publication Date: June 15, 2011

Revision AC Date: December 03, 2012
Record the following information for Warranty purposes:
Where Purchased: _____________________________________
Purchase Date: _____________________________________
Equipment Serial #: _____________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01 Arc Welding Hazards........................................................................................ 1-1
1.02 General Safety Information for Victor CS Regulator......................................... 1-4
1.03 Principal Safety Standards............................................................................... 1-5
1.04 Symbol Chart................................................................................................... 1-6
1.05 Servicing Hazards............................................................................................ 1-7
1.06 EMF Information.............................................................................................. 1-8
SECTION 2:
INTRODUCTION....................................................................................... 2-1
2.01 How to Use This Manual.................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt of Equipment....................................................................................... 2-1
2.04 Description...................................................................................................... 2-1
2.05 Transportation Methods................................................................................... 2-1
SECTION 3:
SAFETY AND INSTALLATION........................................................................ 3-1
3.01 Duty Cycle........................................................................................................ 3-1
3.02 Specifications - 161STL................................................................................... 3-3
3.03 Specifications -201TS...................................................................................... 3-4
3.04 Environment.................................................................................................... 3-5
3.05 Location........................................................................................................... 3-5
3.06 Electrical Input Connections............................................................................ 3-5
3.07 Electromagnetic Compatibility......................................................................... 3-8
3.08 Volt-Ampere Curves....................................................................................... 3-10
SECTION 4:
OPERATION............................................................................................ 4-1
4.01 Front Panel...................................................................................................... 4-1
4.02 Setup for Welding............................................................................................ 4-5
4.03 Stick (SMAW) Setup........................................................................................ 4-6
4.04 LIFT TIG (GTAW) Setup................................................................................... 4-7
4.05 HF TIG (GTAW) Setup (201TS only)................................................................. 4-9
4.06 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
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............................................................................................. 6-5
6.07 DC Bus Voltage Check..................................................................................... 6-8
6.08 Installing Clear Cover Sheet............................................................................. 6-9
6.09 Waveforms for Section 6-10.......................................................................... 6-10
6.10 Troubleshooting Circuit Diagram - 161STL.................................................... 6-13
6.11 161STL Connector Diagram........................................................................... 6-14
6.12 Troubleshooting Circuit Diagram - 201TS...................................................... 6-15
6.13 201TS Connector Diagram............................................................................. 6-16
SECTION 7:
DISASSEMBLY PROCEDURE........................................................................ 7-1
7.01 Safety Precautions for Disassembly................................................................ 7-1
7.02 Control Board Removal.................................................................................... 7-2
7.03 Front Panel Assembly Removal....................................................................... 7-4
7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal.......................... 7-6
7.05 Back Panel Removal........................................................................................ 7-8
7.06 Power Switch S1 and Power Cord Removal.................................................. 7-11
7.07 Base Panel Removal...................................................................................... 7-13
SECTION 8:
ASSEMBLY PROCEDURES........................................................................... 8-1
8.01 Installing Base Board....................................................................................... 8-1
8.02 Installing Back Panel........................................................................................ 8-2
8.03 Installing Front Panel....................................................................................... 8-4
8.04 Installing Main Control Panel and Clear Cover Sheet....................................... 8-8
8.05 Installing Case............................................................................................... 8-10
SECTION 9:
REPLACEMENT PARTS............................................................................... 9-1
9.01 Hardware List ................................................................................................. 9-1
9.02 Replacement Part List - 161STL...................................................................... 9-2
9.03 Replacement Part List - 201TS........................................................................ 9-4
SECTION 10:
ACCESSORIES........................................................................................10-1
LIMITED WARRANTY
WARRANTY SCHEDULE
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.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards 8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
WARNING
11. Do not touch electrode while in contact with the work (ground)
ELECTRIC SHOCK can kill. circuit.
Touching live electrical parts can cause fatal shocks or 12. Use only well-maintained equipment. Repair or replace damaged
severe burns. The electrode and work circuit is electri- parts at once.
cally live whenever the output is on. The input power
circuit and machine internal circuits are also live when 13. In confined spaces or damp locations, do not use a welder with AC
power is on. In semi-automatic or automatic wire weld- output unless it is equipped with a voltage reducer. Use equipment
ing, the wire, wire reel, drive roll housing, and all metal with DC output.
parts touching the welding wire are electrically live. 14. Wear a safety harness to prevent falling if working above floor
Incorrectly installed or improperly grounded equipment level.
is a hazard.
15. Keep all panels and covers securely in place.
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 WARNING
or covers.
ARC RAYS can burn eyes and skin; NOISE can damage
4. Disconnect input power or stop engine before installing or hearing. Arc rays from the welding process produce
servicing this equipment. Lock input power disconnect switch intense heat and strong ultraviolet rays that can burn
open, or remove line fuses so power cannot be turned on eyes and skin. Noise from some processes can damage
accidentally. hearing.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes. 1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
6. Turn off all equipment when not in use. Disconnect power to eyes when welding or watching.
equipment if it will be left unattended or out of service.
2. Wear approved safety glasses. Side shields recommended.
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not 3. Use protective screens or barriers to protect others from flash and
touch holders connected to two welding machines at the same glare; warn others not to watch the arc.
time or touch other people with the holder or electrode. 4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Manual 0-5148 1-1 Safety Instructions and Warnings

THERMAL ARC 161STL, 201TS SAFETY INSTRUCTIONS AND WARNINGS
WARNING WARNING
FUMES AND GASES can be hazardous to your health. WELDING can cause fire or explosion.
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. sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
1. Keep your head out of the fumes. Do not breathe the fumes. contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases. 1. Protect yourself and others from flying sparks and hot metal.
3. If ventilation is poor, use an approved air-supplied respirator. 2. Do not weld where flying sparks can strike flammable material.
4. Read the Material Safety Data Sheets (MSDSs) and the man- 3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
ufacturer’s instruction for metals, consumables, coatings, and If this is not possible, tightly cover them with approved covers.
cleaners.
4. Be alert that welding sparks and hot materials from welding can
5. Work in a confined space only if it is well ventilated, or while wear- easily go through small cracks and openings to adjacent areas.
ing an air-supplied respirator. Shielding gases used for welding
can displace air causing injury or death. Be sure the breathing air 5. Watch for fire, and keep a fire extinguisher nearby.
is safe.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
6. Do not weld in locations near degreasing, cleaning, or spraying can cause fire on the hidden side.
operations. The heat and rays of the arc can react with vapors to
7. Do not weld on closed containers such as tanks or drums.
form highly toxic and irritating gases.
8. Connect work cable to the work as close to the welding area as
7. Do not weld on coated metals, such as galvanized, lead, or cad-
practical to prevent welding current from traveling long, possibly
mium plated steel, unless the coating is removed from the weld
unknown paths and causing electric shock and fire hazards.
area, the area is well ventilated, and if necessary, while wearing
an air-supplied respirator. The coatings and any metals containing 9. Do not use welder to thaw frozen pipes.
these elements can give off toxic fumes if welded.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.
Electrode Size Filter Electrode Size Filter

Welding or Cutting Welding or Cutting
Metal Thickness Shade Metal Thickness Shade
Operation Operation
or Welding Current No. or Welding Current No.
Gas metal-arc
Torch soldering 2
welding (MIG)
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding Under 5/32 in., 4 mm 10 Heavy 14
(stick) electrodes
5/32 to 1/4 in.,
12 Plasma arc cutting
4 to 6.4 mm
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Safety Instructions and Warnings 1-2 Manual 0-5148
WARNING WARNING
FLYING SPARKS AND HOT METAL can cause injury. ENGINE FUEL can cause fire or explosion.
Chipping and grinding cause flying metal. As welds cool, Engine fuel is highly flammable.
they can throw off slag.
1. Stop engine before checking or adding fuel.
1. Wear approved face shield or safety goggles. Side shields 2. Do not add fuel while smoking or if unit is near any sparks or open
recommended. flames.
2. Wear proper body protection to protect skin. 3. Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
WARNING 5. Do not spill fuel. If fuel is spilled, clean up before starting
CYLINDERS can explode if damaged. engine.
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. WARNING
1. Protect compressed gas cylinders from excessive heat, mechanical MOVING PARTS can cause injury.
shocks, and arcs.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
2. Install and secure cylinders in an upright position by chaining and catch loose clothing.
them to a stationary support or equipment cylinder rack to prevent
1. Keep all doors, panels, covers, and guards closed and
falling or tipping.
securely in place.
3. Keep cylinders away from any welding or other electrical
2. Stop engine before installing or connecting unit.
circuits.
3. Have only qualified people remove guards or covers for
4. Never allow a welding electrode to touch any cylinder.
maintenance and troubleshooting as necessary.
5. Use only correct shielding gas cylinders, regulators, hoses, and
4. To prevent accidental starting during servicing, disconnect
fittings designed for the specific application; maintain them and
negative (-) battery cable from battery.
associated parts in good condition.
5. Keep hands, hair, loose clothing, and tools away from moving
6. Turn face away from valve outlet when opening cylinder valve.
parts.
7. Keep protective cap in place over valve except when cylinder is in
6. Reinstall panels or guards and close doors when servicing
use or connected for use.
is finished and before starting engine.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
WARNING
! WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Engines can be dangerous. Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
WARNING
3. Do not allow tools to cause sparks when working on a battery.
ENGINE EXHAUST GASES can kill.
4. Do not use welder to charge batteries or jump start vehicles.
Engines produce harmful exhaust gases. 5. Observe correct polarity (+ and –) on batteries.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.

1.02 General Safety Information for
Victor CS Regulator
WARNING
A Fire Prevention
STEAM AND PRESSURIZED HOT COOLANT can burn
Welding and cutting operations use fire or combustion as a basic
face, eyes, and skin.
tool. The process is very useful when properly controlled. However,
The coolant in the radiator can be very hot and under it can be extremely destructive if not performed correctly in the proper
pressure. environment.
1. The work area must have a fireproof floor.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool. 2. Work benches or tables used during welding or cutting
operations must have fireproof tops.
2. Wear gloves and put a rag over cap area when removing cap.
3. Use heat resistant shields or other approved material to pro-
3. Allow pressure to escape before completely removing cap.
tect nearby walls or unprotected flooring from sparks and hot
NOTE metal.
Considerations About Welding And The Effects of Low 4. Keep an approved fire extinguisher of the proper size and
Frequency Electric and Magnetic Fields type in the work area. Inspect it regularly to ensure that it
is in proper working order. Know how to use the fire extin
The following is a quotation from the General Conclusions Section of guisher.
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper, 5. Move combustible materials away from the work site. If you
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May can not move them, protect them with fireproof covers.
1989): “...there is now a very large volume of scientific findings based
!
on experiments at the cellular level and from studies with animals
and people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most WARNING
of this work is of very high quality, the results are complex. Current
NEVER perform welding, heating, or cutting operations
scientific understanding does not yet allow us to interpret the evidence
on a container that has held toxic, combustible or
in a single coherent framework. Even more frustrating, it does not
flammable liquids, or vapors. NEVER perform welding,
yet allow us to draw definite conclusions about questions of possible
heating, or cutting operations in an area containing com-
risk or to offer clear science-based advice on strategies to minimize
bustible vapors, flammable liquids, or explosive dust.
or avoid potential risks.”
B Housekeeping
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them. ! WARNING
2. Arrange cables to one side and away from the operator.
NEVER allow oxygen to contact grease, oil, or other
3. Do not coil or drape cable around the body. flammable substances. Although oxygen by itself will not
burn, these substances become highly explosive. They
4. Keep welding power source and cables as far away from body can ignite and burn violently in the presence of oxygen.
as practical.
Keep ALL apparatus clean and free of grease, oil and other flammable
substances.
C Ventilation
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
! WARNING
Adequately ventilate welding, heating, and cutting work
areas to prevent accumulation of explosive or toxic
concentrations of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes. Use respira-
tory protection equipment in these circumstances. When
welding/brazing, read and understand the Material Safety
Data Sheet for the welding/brazing alloy.

D Personal Protection 3. Store empty cylinders away from full cylinders. Mark them
Gas flames produce infrared radiation which may have a harmful effect “EMPTY” and close the cylinder valve.
on the skin and especially on the eyes. Select goggles or a mask with 4. NEVER use compressed gas cylinders without a pressure
tempered lenses, shaded 4 or darker, to protect your eyes from injury reducing regulator attached to the cylinder valve.
and provide good visibility of the work.
5. Inspect the cylinder valve for oil, grease, and damaged
Always wear protective gloves and flame-resistant clothing to protect skin parts.
and clothing from sparks and slag. Keep collars, sleeves, and pockets
buttoned. DO NOT roll up sleeves or cuff pants.
When working in a non-welding or cutting environment, always wear
suitable eye protection or face shield.
! WARNING
DO NOT use the cylinder if you find oil, grease or dam-
! WARNING
aged parts. Inform your gas supplier of this condition
immediately.
6. Momentarily open and close (called “cracking”) the cylinder
Practice the following safety and operation precautions
valve to dislodge any dust or dirt that may be present in the
EVERY TIME you use pressure regulation equipment.
valve.
Deviation from the following safety and operation
instructions can result in fire, explosion, damage to
equipment, or injury to the operator.
CAUTION
E Compressed Gas Cylinders
The Department of Transportation (DOT) approves the design and When cracking the cylinder valve, DO NOT stand directly
manufacture of cylinders that contain gases used for welding or cut- in front of the cylinder valve. Always perform cracking in
ting operations. a well ventilated area. If an acetylene cylinder sprays a
mist when cracked, let it stand for 15 minutes. Then, try
1. Place the cylinder (Figure 1-1) where you will use it. Keep to crack the cylinder valve again. If this problem persists,
the cylinder in a vertical position. Secure it to a cart, wall, work contact your gas supplier.
bench, post, etc.
1.03 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Figure 1-1: Gas Cylinders Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
! WARNING
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
Cylinders are highly pressurized. Handle with care. from Compressed Gas Association, 1235 Jefferson Davis Highway,
Serious accidents can result from improper handling Suite 501, Arlington, VA 22202.
or misuse of compressed gas cylinders DO NOT drop
the cylinder, knock it over, or expose it to excessive Code for Safety in Welding and Cutting, CSA Standard W117.2, from
heat, flames or sparks. DO NOT strike it against other Canadian Standards Association, Standards Sales, 178 Rexdale
cylinders. Contact your gas supplier or refer to CGA P-1 Boulevard, Rexdale, Ontario, Canada M9W 1R3.
“Safe Handling of Compressed Gases in Containers”
Safe Practices for Occupation and Educational Eye and Face Protection,
publication.
ANSI Standard Z87.1, from American National Standards Institute,
NOTE 1430 Broadway, New York, NY 10018.
CGA P-1 publication is available by writing the Com- Cutting and Welding Processes, NFPA Standard 51B, from National Fire
pressed Gas Association, 4221 Walney Road, 5th Floor, Protection Association, Batterymarch Park, Quincy, MA 02269.
Chantilly,VA 20151-2923
2. Place the valve protection cap on the cylinder whenever
moving it, placing it in storage, or not using it. Never drag or
roll cylinders in any way. Use a suitable hand truck to move
cylinders.

1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On Single Phase Wire Feed Function
Wire Feed Towards

Off Three Phase Workpiece With
Output Voltage Off.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier
Increase/Decrease Remote Purging Of Gas
X
Continuous Weld
Circuit Breaker Duty Cycle
Mode
AC Auxiliary Power % Percentage Spot Weld Mode
Fuse Panel/Local Spot Time

t
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
Gas Metal Arc

Voltage t2
Postflow Time
Welding (GMAW)
Gas Tungsten Arc 2 Step Trigger

Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)
Negative Constant Current 4 Step Trigger

Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive
Or Constant Potential hold for preflow.
Direct Current (DC) High Temperature

t Burnback Time
Protective Earth
Fault Indication
(Ground) IPM Inches Per Minute
Line Arc Force

MPM Meters Per Minute
Line Connection Touch Start (GTAW)

S See Note
Auxiliary Power Variable Inductance See Note
115V 15A Receptacle Rating-

V Voltage Input
Auxiliary Power
Art # A-04130_AB
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
1.05 Servicing Hazards
WARNING
! WARNING FLYING METAL or DIRT can injure eyes.
The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during
manual to call attention to and identify possible hazards. servicing.
When you see the symbol, watch out, and follow the • Be careful not to short metal tools, parts, or wires together
related instructions to avoid the hazard. during testing and servicing.
Only qualified persons should test, maintain, and repair
this unit.
Only qualified persons should test, maintain, and repair WARNING
this unit. HOT PARTS can cause sever burns.
• Do not touch hot parts bare handed.

• Allow cooling period before working on equipment.
WARNING
• To handle not parts, use proper tools and/or wear heavy, insu-
ELECTRIC SHOCK can kill. lated welding gloves and clothing to prevent burns.
• Do not touch live electrical parts.
• Turn Off welding power source and wire feeder and disconnect
and lockout input power using line disconnect switch, circuit WARNING
breakers, or by removing plug from receptacle, or stop engine
EXPLODING PARTS can cause injury.
before servicing unless the procedure specifically requires an
energized unit. • Failed parts can explode or cause other parts to explode when
• Insulate yourself from ground by standing or working on power is applied to inverters.
dry insulating mats big enough to prevent contact with the • Always wear a face shield and long sleeves when servicing
ground. inverters.
• Do not leave live unit unattended.
• If this procedure requires and energized unit, have only person-
nel familiar with and following standard safety practices do the WARNING
job.
• When testing a live unit, use the one-hand method. Do not put SHOCK HAZARD from testing.
both hands inside unit. Keep one hand free. • Turn Off welding power source and wire feeder or stop engine
• Disconnect input power conductors from de-energized supply before making or changing meter lead connections.
line BEFORE moving a welding power source. • Use at least one meter lead that has a self-retaining spring clip
SIGNIFICANT DC VOLTAGE exists after removal of input power such as an alligator clip.
on inverters. • Read instructions for test equipment.
• Turn Off inverters, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section
before touching any parts.
WARNING
FALLING UNIT can cause injury.
WARNING • Use lifting eye to lift unit only, NOT running gear, gas cylinders,
STATIC (ESD) can damage PC boards. or any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• Put on grounded wrist strap BEFORE handling boards or parts.
• If using lift forks to move unit, be sure forks are long enough
• Use proper static-proof bags and boxes to store, move, or ship to extend beyond opposite side of unit.
PC boards.
WARNING
WARNING
MOVING PARTS can cause injury,
FIRE OR EXPLOSION hazard.
• Keep away from moving parts such as fans.
• Do not place unit on, over, or near combustible surfaces.
• Keep away from pinch points such as drive rolls.
• Do not service unit near flammables.
• Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
1.06 EMF Information
• Keep hands, hair, loose clothing, and tools away from moving Considerations About Welding And The Effects Of Low Frequency
parts. Electric And Magnetic Fields
• 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. tromagnetic fields. There has been and still is some concern about
such fields. However, after examining more than 500 studies span-
ning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: “The body of evidence,
WARNING in the committee’s judgment, has not demonstrated that exposure to
MAGNETIC FIELDS can affect Implanted Medical De- power-frequency electric and magnetic fields is a human-health haz-
vices. ard.” However, studies are still going forth and evidence continues to
be examined. Until the final conclusions of the research are reached,
• Wearers of Pacemakers and other Implanted Medical Devices you may wish to minimize your exposure to electromagnetic fields
should keep away from servicing areas until consulting their when welding or cutting.
doctor and the device manufacturer.
To reduce magnetic fields in the workplace, use the following pro-
cedures:
1. Keep cables close together by twisting or taping them, or using a
WARNING cable cover.
OVERUSE can cause OVERHEATING. 2. Arrange cables to one side and away from the operator.
• Allow cooling period; follow rated duty cycle. 3. Do not coil or drape cables around your body.
• Reduce current or reduce duty cycle before starting to weld 4. Keep welding power source and cables as far away from operator
again. as practical.
• Do not block or filter airflow to unit.
5. Connect work clamp to workpiece as close to the weld as pos-
sible.
About Implanted Medical Devices:
WARNING
Implanted Medical Device wearers should consult their doctor and
H.F. RADIATION can cause interference. the device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating opera-
• High-frequency (H.F.) can interfere with radio navigation, safety tions. If cleared by your doctor, then following the above procedures
services, computers, and communications equipment. is recommended.
• Have only qualified persons familiar with electronic equipment
install, test, and service H.F. producing units.
• The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
• If notified by the FCC about interference, stop using the equip-
ment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding
to minimize the possibility of interference.
! WARNING
READ INSTRUCTIONS.
• Use Testing Booklet (Part No. 150 853) when servicing this unit.
• Consult the Owner’s Manual for welding safety precautions.
• Use only genuine replacement parts from the manufacturer.

INTRODUCTION tHERMAL ARC 161STL, 201ts
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual 2.03 Receipt of Equipment
This Manual usually applies to the part numbers listed on When you receive the equipment, check it against the
page i. To ensure safe operation, read the entire manual, invoice to make sure it is complete and inspect the
including the chapter on safety instructions and warnings. equipment for possible damage due to shipping. If there is
Throughout this manual, the word WARNING, CAUTION any damage, notify the carrier immediately to file a claim.
and NOTE may appear. Pay particular attention to the in- Furnish complete information concerning damage claims
formation provided under these headings. These special or shipping errors to the location in your area listed in the
annotations are easily recognized as follows: inside back cover of this manual. Include all equipment
identification numbers as described above along with a
! WARNING
full description of the parts in error.
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
offers stable TIG welding characteristics with an optimized
CAUTION Lift Start TIG sequence to initiate the welding arc when
Refers to possible equipment damage. Cau- used with a suitable TIG torch and shielding gas.
tions will be shown in bold type. The Thermal Arc 201TS is compact inverter welding
NOTE machine has infinitely adjustable welding current from
Offers helpful information concerning certain 10 to 200 amps. It has a LIFT TIG (GTAW) and HF TIG
operating procedures. Notes will be shown (GTAW) welding modes that offers stable TIG welding
in italics characteristics with an optimized start TIG sequence to
initiate the welding arc when used with a suitable TIG
You will also notice icons from the safety section appear-
torch and shielding gas.
ing throughout the manual. These are to advise you of
specific types of hazards or cautions related to the portion Both models have advanced TIG features including 8 Pin
of information that follows. Some may have multiple Amp Plug for remote control devices, down slope, 2T /
hazards that apply and would look something like this: 4T controls, and gas solenoid operation. They also have
STICK (SMAW) welding mode which uses standard gen-
eral purpose STICK (SMAW) 3/32” (2.5mm) electrodes
for light gauge work, generally less than 1/8” (3.2mm)
thick and STICK (SMAW) 1/8” (3.2mm) electrodes for
heavier material.
2.02 Equipment Identification
The unit’s identification number (specification or part 2.05 Transportation Methods
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 ! Disconnect input power
identified only by the specification or part number printed
conductors from de-energized supply line before moving
on the shipping container. Record these numbers for
the welding power source.
future reference.
Lift unit with handle on top of case. Use handcart or similar
device of adequate capacity. If using a fork lift vehicle,
secure the unit on a proper skid before transporting.
Manual 0-5148 2-1 Introduction

THERMAL ARC 161STL, 201ts INTRODUCTION
Notes
Introduction 2-2 Manual 0-5148

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. This means that it has been designed and built to provide the rated amperage (160A) for
3 minutes, i.e. arc welding time, out of every 10 minute period (30% of 10 minutes is 3 minutes). During the other 7
minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.
230VAC Input

Lift TIG
Duty Cycle (percentage)@40˚C

Stick

AMPS
Art # A-10193
115VAC Input
120
Duty Cycle (percentage)@40ºC
100
Lift TIG
80
60
40
Stick
20
0
0 20 40 60 80 100 120 140 160 180
AMPS
Art # A-10194
Figure 3-1: 161STL Duty Cycle
Manual 0-5148 3-1 Safety and Installation

THERMAL ARC 161STL, 201ts SAFETY AND INSTALLATION
230VAC Input
120
100
Lift TIG/HF TIG
Duty Cycle (percentage)@ 40˚C
80
60
Stick
40
20
0
0 50 100 150 200 250
AMPS
Art # A-10145
115VAC Input
120
100
Duty Cycle (percentage)@40˚C
Lift TIG/HF TIG

80
60
40
Stick
20
0
0 50 100 150 200 250
AMPS
Art # A-10157
Figure 3-2: 201TS Duty Cycle
Safety and Installation 3-2 Manual 0-5148

3.02 Specifications - 161STL
Power Source Part Number W1003700
Mains Power
Nominal Supply Voltage AC 115V AC 208/230V
Number of Phases Single Phase Single Phase
Input Voltage Range AC 104 - 127V AC 187- 253V
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Effective Input Current (l1eff) 20 Amps 16 Amps
Maximum Input Current (l1 max) ∆ 28.6 Amps ∆ 25 Amps
Single Phase Generator Requirements [Continuous rating 5 KVA 6 KVA
at nominal supply voltage with maximum output for STICK
(SMAW) welding]
Welding Output
Welding Current Range Stick: 10 - 125 Amps Stick:/TIG:
TIG: 10 - 160 Amps 10 - 160 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min. 100A @ 45%, 24.0V 160A @ 30%, 26.4V
(Quoted figures refer to STICK (SMAW) output) 95A @ 60%, 23.8V 120A @ 60%, 24.8V
80A @ 100%, 23.2V 100A @ 100%, 24.0V
Rated Input Current (A) 28.6A 25A
for STICK (SMAW) Welding Io = 100A @ 24.0V Io = 160A @ 26.4V
Rated Input Current (A) 28.6A 15.5A
for LIFT TIG (GTAW) Welding Io = 150A @ 16.4V Io = 160A @ 16.4V
Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 45% 26.4V, 160A @ 30%
Rated Output for LIFT TIG (GTAW) Welding 16.0V, 150A @ 35% 16.4V, 160A @ 30%
Duty Cycle (%) 45% @ 100A 30% @ 160A
Welder Type Inverter Power Source
Output Terminal Type Heavy Duty DinseTM 50
Classification
Protection Class IP23S
Standards EN 60974-1
EN50199
Cooling Method Fan Cooled
Dimensions and Weight
Welding Power Source Mass 21.6 lb. (9.8 kg)
Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆ The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes
and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent
of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code)
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously
sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications
due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location
and conditions and local power grid supply conditions..

3.03 Specifications -201TS
Power Source Part Number W1003800
Mains Power
Nominal Supply Voltage AC 115V AC 208/230V
Number of Phases Single Phase Single Phase
Input Voltage Range AC 104- 127V AC 187- 253V
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Effective Input Current (l1eff) 20 Amps 16 Amps
Maximum Input Current (l1 max) ∆ 28.6 Amps ∆ 32 Amps
Single Phase Generator Requirements [Continuous rating at 5 KVA 6 KVA
nominal supply voltage with maximum output for STICK (SMAW)
welding]
Welding Output
Welding Current Range Stick: 10 - 125 Amps Stick/TIG:
TIG: 10 - 160 Amps 10 - 200 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min. 100A @ 45%, 24.0V 200A @ 20%, 28V
(Quoted figures refer to STICK (SMAW) output) 95A @ 60%, 23.8V 120A @ 60%, 24.8V
80A @ 100%, 23.2V 100A @ 100%, 24.0V
Rated Input Current (A) 28.6A 32A
for STICK (SMAW) Welding Io = 100A @ 24.0V Io = 200A @ 28V
Rated Input Current (A) 28.6A 20.6A
for LIFT TIG/HF TIG (GTAW) Welding Io = 150A @ 16.0V Io = 200A @ 18V
Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 45% 28V, 200A @ 20%
Rated Output for LIFT TIG/HF TIG (GTAW) Welding 16.0V, 150A @ 35% 18V, 200A @ 25%
Duty Cycle (%) 45% @ 100A 20% @ 200A
Welder Type Inverter Power Source
Output Terminal Type Heavy Duty DinseTM 50
Classification
Protection Class IP23S
Standards EN 60974-1
EN50199
Cooling Method Fan Cooled
Dimensions and Weight
Welding Power Source Mass 22 lb. (10 kg)
Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 17.7”
(H230mm x W135mm x D450mm)
∆ The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes
and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent
of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code)
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously
sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications
due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location
and conditions and local power grid supply conditions.
3.04 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 conductive elements, and in which there is a high risk of unavoidable
or accidental contact by the operator.
C. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human
body and the insulation properties of accessories.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased hazard, have been insulated.
3.05 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between 14°F (-10°C) to 104° F (40° C).
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air flow for cooling
! WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.06 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.
DO NOT TOUCH live electrical parts.

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.
• Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one
of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility
for information about the type of electrical service available, how proper connections should be made, and inspection
required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power
from the welding power supply whenever necessary to inspect or service the unit.
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3-3:
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.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.
3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.
Input Voltage Circuit Breaker or Fuse Size
115V 30A
208-230V 50A
Table 3-1: Fuse Guide
CAUTION
The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.
208-230V, 50A, 1Ø
Welding Power Supply
120 V, 20A, 1Ø
The Adapters enable

connection to all these
power outlets
120 V, 15A, 1Ø
Primary Power Cable

Art# A-09789
Figure 3-3: Electrical Input Connections

Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides
pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors
have charged to operating voltage (after approximately 5 seconds)
NOTE
Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.
Model Primary Supply Lead Minimum Primary Current & Duty Cycle
Size (Factory Fitted) Current Circuit Size LIFT TIG/ HF TIG STICK (SMAW)
(Vin/Amps) (GTAW)
115V/30A - 100A @ 45%
Thermal Arc 115V/30A 150A @ 35% -
12 AWG (3.3mm²)
161 STL 208-230V/25A - 160A @ 30%
208-230V/15A 160A @ 30% -
115V/30A - 100A @ 45%
Thermal Arc 115V/30A 150A @ 35% -
12 AWG (3.3mm²)
201 TS 208-230V/25A - 200A @ 20%
208-230V/25A 200A @ 25% -
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

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
WARNING beyond the boundaries of the premises.
Extra precautions for Electromagnetic C. Methods of Reducing Electromagnetic Emissions

Compatibility may be required when this 1. Mains Supply
Welding Power Source is used in a domestic
situation. Welding equipment should be connected to the
mains supply according to the manufacturer’s
A. Installation and Use - Users Responsibility recommendations. If interference occurs, it may be
necessary to take additional precautions such as
The user is responsible for installing and using the welding filtering of the mains supply. Consideration should
equipment according to the manufacturer’s instructions. be given to shielding the supply cable of permanently
If electromagnetic disturbances are detected then it shall installed welding equipment in metallic conduit or
be the responsibility of the user of the welding equipment equivalent. Shielding should be electrically continuous
to resolve the situation with the technical assistance of throughout its length. The shielding should be
the manufacturer. In some cases this remedial action connected to the Welding Power Source so that good
may be as simple as earthing the welding circuit, see electrical contact is maintained between the conduit
NOTE below. In other cases it could involve constructing and the Welding Power Source enclosure.
an electromagnetic screen enclosing the Welding Power
Source and the work, complete with associated input 2. Maintenance of Welding Equipment
filters. In all cases, electromagnetic disturbances shall be The welding equipment should be routinely maintained
reduced to the point where they are no longer Trouble- according to the manufacturer’s recommendations. All
some. access and service doors and covers should be closed
B. Assessment of Area and properly fastened when the welding equipment
is in operation. The welding equipment should not
Before installing welding equipment, the user shall make be modified in any way except for those changes
an assessment of potential electromagnetic problems in and adjustments covered in the manufacturer’s
the surrounding area. The following shall be taken into instructions. In particular, the spark gaps of arc
account. striking and stabilizing devices should be adjusted
and maintained according to the manufacturer’s
1. Other supply cables, control cables, signaling and
recommendation
telephone cables; above, below and adjacent to the
welding equipment. 3. Welding Cables
2. Radio and television transmitters and receivers. The welding cables should be kept as short as possible
and should be positioned close together, running at or
3. Computer and other control equipment.
close to the floor level.
4. Safety critical equipment, e.g. guarding of industrial
4. Equipotential Bonding
equipment.
Bonding of all metallic components in the welding
5. The health of people around, e.g. the use of pace-
installation and adjacent to it should be considered.
makers and hearing aids.
However, metallic components bonded to the work
6. Equipment used for calibration and measurement. piece will increase the risk that the operator could
receive a shock by touching the metallic components
7. The time of day that welding or other activities are to and the electrode at the same time. The operator
be carried out. should be insulated from all such bonded metallic
8. The immunity of other equipment in the environment: components.
the user shall ensure that other equipment being used
in the environment is compatible: this may require
additional protection measures.

5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and
position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk
of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to
earth should be made by direct connection to the work piece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems
of interference. Screening the entire welding installation may be considered for special applications.

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
80
70
Lift TIG Max
60
50
VOLTS
40
Stick Max
30 A-09949
20
10
0
0 50 100 150 200
AMPS
Art # A-10195
115VAC Input
80
70
60
Lift TIG Max
50
VOLTS
40
30 Stick Max
20
10
0
0 50 100 150 200
AMPS
Art # A-10196
Figure 3-4: 161STL Volt-Ampere Curves

230VAC Input
80
70
60
50
Stick Max
VOLTS
40
30
Lift TIG Max
20
10
0
0 50 100 150 200 250
AMPS
Art # A-10158
115VAC Input
80
70
60
Lift Tig Max
50
VOLTS
40
Stick Max
30
20
10
0
0 50 100 150 200
AMPS
Art # A-10159
Figure 3-4: 201TS Volt-Ampere Curves

Notes

OPERATION THERMAL ARC 161sTL, 201TS
SECTION 4:
OPERATION
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold the electrode. The welding current range values should be used as a
guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies
between different classes of electrode, welding current at any one setting would vary according to the type of electrode
in use. The operator should use the welding current range values as a guide then fine tune the welding current to suit
the specific application. Refer to the electrode manufacture's literature for further information.
4.01 Front Panel
(C) Trigger Mode Selection Switch
(A) Power On Indicator (D) Process Selection Switch
(F) Arc Force/Down

Slope Control
(B) Fault Indicator
(E) Welding Current

Control
(G) Gas Outlet (I) 8 Pin Control Socket
Negative Output Terminal Positive Output Terminal
Art # A-09786_AC
Figure 4-1: Thermal Arc 161STL Controls
Manual 0-5148 4-1 Operation

THERMAL ARC 161STL, 201TS OPERATION
(C) Trigger Mode Selection Switch
(A) Power On Indicator (D) Process Selection Switch
(F) Arc Force/Down

Slope Control
(B) Fault Indicator
(E) Welding Current

Control
(G) Gas Outlet (I) 8 Pin Control Socket
Negative Output Terminal Positive Output Terminal
Art # A-10097
Figure 4-2: Thermal Arc 201TS Controls
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.
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
The welding power source is protected by a self resetting thermostat and over primary current protection devices.
Welding can not take place if the FAULT Indicator lights up continuously or is flashing.
Thermostat Protection
If the Fault Indicator lights up continuously then the duty cycle of the power source has been exceeded. Leave the
power on and wait for the 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 4-2 Manual 0-5148

C. TRIGGER Mode Switch (LIFT TIG Mode Only) F. Arc Force/Down Slope Control
2T (Normal) Mode Arc Force is effective when in STICK (SMAW) Mode only.
Arc Force control provides an adjustable amount of Arc
Press the TIG Torch Trigger Switch or Foot Control and
Force (or “dig”) control. This feature can be particularly
hold depressed to weld. Release the TIG Torch Trigger
beneficial in providing the operator the ability to com-
Switch or Foot Control to stop welding. Down Slope
pensate for variability in joint fit-up in certain situations
operates in LIFT TIG (GTAW) mode only. While welding
with particular electrodes. In general increasing the Arc
if the TIG Torch Trigger Switch is released, the welding
Force control toward ‘10’ (maximum Arc Force) allows
current ramps down to zero current over a defined period
greater penetration control to be achieved. Down Slope
of time. The time period is determined by the Down Slope
operates in TIG mode only. It is used to set the time for
Control Knob (F).
weld current to ramp down. Refer to Item C (Trigger
4T (Latch) Mode Mode Selection Switch) for further information regarding
Downslope operation.
This mode of welding is mainly used for long weld runs.
The operator need only to press the TIG Torch Trigger G. Gas Outlet
Switch to activate and then release the TIG Torch Trig-
The Gas Outlet is a 5/8”-18 UNF female gas fitting and is
ger Switch to continue to weld, then press the TIG Torch
utilized for the connection of a suitable TIG Torch.
Trigger Switch again and release the TIG Torch Trigger
Switch to stop welding. This eliminates the need for the H. Post Gas Flow (weld current dependant)
operator to depress the TIG Torch Trigger Switch for the
Post Gas Flow is the time Gas flows after the arc has
complete length of the weld. The 4T mode incorporates a
extinguished. The gas flow time is proportional to weld
current slope function which includes a fixed current up
current. This is used to cool and reduce oxidization of the
slope of 1 second and an adjustable current down slope.
Tungsten Electrode. For example if the Welding Current
Current slope operates in TIG Mode only. Up slope is not
is set to 10 amps the Post Gas Flow time will be approxi-
adjustable and activates automatically in 4T mode when
mately 3 seconds. For a Welding Current set to 160 Amps
the TIG torch trigger is depressed. To activate the Down
the Post Gas Flow time will be approximately 10 seconds.
Slope function in 4T mode while welding, the TIG Torch
The Post Gas Flow time cannot be adjusted independently
Trigger Switch must be depressed and held while welding
of the Welding Current.
which will ramp the Welding Current down to zero over
a defined period of time. The time period is determined
by the Down Slope Control Knob (F). At any time while
welding if the TIG Torch Trigger Switch is depressed and
released the arc will extinguish immediately.
D. Process Selection Switch
161STL
Switches between STICK (SMAW) and LIFT TIG (GTAW)
modes. Refer to Section 4.03 Setup for STICK (SMAW)
Welding and 4.04 Setup for TIG Welding.
201TS
Switches between STICK (SMAW), LIFT TIG (GTAW) and
HF TIG (GTAW) modes. Refer to Section 4.03 Setup for
STICK (SMAW) Welding, 4.04 Setup for LIFT TIG (GTAW)
Welding and 4.05 Setup for HF TIG (GTAW)Welding.
E. Welding Current Control
The welding current is increased by turning the Weld
Current Control Knob clockwise or decreased by turn-
ing the Weld Current Control Knob anticlockwise. The
welding current should be set according to the specific
application. Refer to application notes in this section for
further information.
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.
12345678 2 1
5 4 3
8 7 6
5k Ohms
Front View of 8 Pin Socket
Art # A-09815_AB
Plug Pin Function

1
2 Torch Switch Input (24V) to energize
weld current. (connect pin 2&3 to turn on
welding current)
3 Torch Switch Input (0V) to energize weld
current. (connect pin 2&3 to turn on
welding current)
4
5 5k ohm (maximum) connection to 5k ohm
remote control potentiometer
6 Zero ohm (minimum) connection to 5k
ohm remote control potentiometer
7 Wiper arm connection to 5k ohm remote
control potentiometer
8
NOTE
Remote Welding Current Control is available through the front panel of this unit. The remote will only go to the maximum value
that is set at the panel. If the panel is set to 100 amps, the remote can't go above 100 amps when fully adjusted.
J. ON/OFF Switch (located on rear panel not shown)

This switch controls the Mains Supply Voltage to the Power Source.

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. The welding current range values should be used as a guide only. Current delivered to the
arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes
of electrodes, welding current at any one setting would vary according to the type of electrode in use. The
operator should use the welding current range values as a guide then fine tune the welding current to suit
the application.
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder make
sure the Primary power supply is switched off.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.

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)
200A
Art#:A-09784
Figure 4-3: Setup for STICK (SMAW) Welding
STICK (SMAW) Mode Sequence of Operation
CAUTION
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the work lead 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 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.
6. Set the weld current control knob to the desired amperage.
7. Set the ARC FORCE CONTROL knob to 2.
Minimum (0) provides a soft arc, low spatter & low penetration.
Medium (2) provides a normal arc, improved fusion & normal penetration.
Maximum (10) provides a hard arc & deep penetration.
8. Install a stick electrode in the electrode holder.
9. You are now ready to begin STICK Welding
NOTE
Gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work
piece while holding a consistent arc length above base metal.
4.04 LIFT TIG (GTAW) Setup

Switch to LIFT TIG.
Switch to 2T/4T
Set Welding Current

as specified by the
Set DOWN Slope
Electrode Manufacturer.
Secure the gas cylinder in an Positive Output

upright position by chaining it Terminal
Negative
to a stationary support to prevent (Dinse™ 50)
Output
falling or tipping.
Terminal
(Dinse™ 50)
Art # A-09785_AB
Figure 4-4: Setup for LIFT TIG (GTAW) Welding

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
CAUTION grinding wheel is turning.
Before any welding is to begin, be sure to 13. Install the tungsten with approximately 1/8” to ¼”
wear all appropriate and recommended safety sticking out from the gas cup, ensuring you have
equipment. correct sized collet.
1. Switch the ON/OFF Switch (located on the rear panel) 14. Tighten the back cap then open the valve on the
to OFF. torch.
2. Connect the work lead to positive output terminal. It 15. Plug the power cable into the appropriate outlet, and
is essential that the male plug is inserted and turned turn the switch to the “ON” position. The power L.E.D.
fully clockwise until connector locks in place to achieve light should illuminate.11. Set the “Process Selection
reliable electrical connection. Switch” to LIFT TIG
3. Connect the TIG torch as follows: 16. You are now ready to begin TIG Welding.
a) Place the power cable into the negative output ter-

minal. It is essential that the male plug is inserted
and turned fully clockwise until connector locks
in place to achieve reliable electrical connection;
b) Place the 8 pin plug into the 8 pin socket. To make
connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
c) Place the TIG torch gas hose to the gas outlet
and tighten with a wrench. Caution: DO NOT over
tighten.
4. Using a secured Argon cylinder, slowly crack open then
close the cylinder valve while standing off to the side
of the valve. This will remove any debris that may be
around the valve & regulator seat area.
5. Install the regulator (for details of VICTOR regulator,
please refer to 3.08 ) and tighten with a wrench.
6. Connect one end of the supplied gas hose to the outlet
of the Argon regulator and tighten with a wrench. Cau-
tion: DO NOT over tighten.
7. Connect the other end of the supplied gas hose to
the gas inlet fitting on the rear panel of the welder
tighten.
8. Open the Argon Cylinder Valve to the fully open posi-
tion.
9. Connect the ground (work) clamp to your work
piece.
10. Set the DOWN SLOPE control knob to the desire weld
current ramp down time. Refer to Section 4.01.
11. Set the weld current control knob to the desired am-
perage.
4.05 HF TIG (GTAW) Setup (201TS only)

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 Positive Output

upright position by chaining it Terminal
Negative
to a stationary support to prevent (Dinse™ 50)
Output
falling or tipping.
Terminal
(Dinse™ 50)
Art # A-10100_AB
Figure 4-5: Setup for HF TIG (GTAW) Welding of 201TS
HF TIG (GTAW) Sequence of Operation
CAUTION
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the ground (work) clamp cable to positive output terminal. It is essential that the male plug is inserted
and turned fully clockwise until connector locks in place to achieve reliable electrical connection.

3. Connect the TIG torch as follows: 4.06 Welding Current Control
a) Place the power cable into the negative output ter- Explanation
minal. It is essential that the male plug is inserted
and turned fully clockwise until connector locks 15 Amp Outlet
in place to achieve reliable electrical connection; The mains power 15 Amp circuit breaker or fuse should
b) Place the 8 pin plug into the 8 pin socket. To make not trip at this Weld Current value when STICK welding.
connections, align keyway, insert plug, and rotate The environmental conditions that may cause the mains
threaded collar fully clockwise. power 15 Amp circuit breaker or fuse to trip are:
c) Place the TIG torch gas hose to the gas outlet a) High ambient temperature
tighten. b) Worn parts in circuit breaker
4. Using a secured Argon cylinder, slowly crack open then c) Using an extension cable
close the cylinder valve while standing off to the side
d) Low line mains power voltage
of the valve. This will remove any debris that may be
around the valve & regulator seat area. 20 Amp Outlet
5. Install the regulator (for details of VICTOR regulator, The mains power 20 Amp circuit breaker or fuse should
please refer to 3.09 ) and tighten with a wrench. not trip at this Weld Current value when STICK welding.
6. Connect one end of the supplied gas hose to the outlet The environmental conditions that may cause the mains
of the Argon regulator and tighten with a wrench. Cau- power 20 Amp circuit breaker or fuse to trip are:
tion: DO NOT over tighten.
a) High ambient temperature
7. Connect the other end of the supplied gas hose to the
gas inlet fitting on the rear panel of the welder and b) Worn parts in circuit breaker
tighten with a wrench. Caution: DO NOT over tighten. c) Using an extension cable
8. Open the Argon Cylinder Valve to the fully open posi- d) Low line mains power voltage
tion.
Output Scale for 115V
9. Connect the ground (work) clamp to your work
piece.
10. Set the DOWN SLOPE control knob to the desire weld The inside number scale identifies the available
current ramp down time. Refer to Section 4.01. output weld current for STICK or LIFT TIG weld modes.
11. Set the weld current control knob to the desired STICK Mode: Identifies the STICK weld point for 15
amperage. Amp outlet.
Identifies the STICK weld point for 20
12. The tungsten must be ground to a blunt point in or-
Amp outlet.
der to achieve optimum welding results. It is critical
to grind the tungsten electrode in the direction the Exceeding these points will cause nui-
grinding wheel is turning. sance tripping of the circuit breaker or
fuse.
13. Install the tungsten with approximately 1/8” to ¼”
sticking out from the gas cup, ensuring you have LIFT TIG Mode/HF TIG Mode: A 15 Amp outlet is ca-
correct sized collet. pable of supplying enough input power
for all TIG (GTAW) output weld current
14. Tighten the back cap then open the valve on the torch. values.
15. Plug the power cable into the appropriate outlet, and Nuisance tripping should not occur on a 15 Amp outlet.
turn the switch to the “ON” position. The power L.E.D. Output Scale for 208/230V
light should illuminate. Set the “Process Selection
Switch” to HF TIG The outside number scale identifies the available output
weld current for STICK or LIFT TIG /HF TIG weld modes.
16. You are now ready to begin HF TIG Welding.
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.

Art# A-09787
Figure 4-6: Current Control for 161STL
15 Amp Outlet
20 Amp Outlet
Figure 4-9: Regulator to Cylinder Valve
1. Before opening the cylinder valve, turn the regula-
Output Scale for 230V tor adjusting screw counter-clockwise until there
Art # A-10098
is no pressure on the adjusting spring and the
screw turns freely.
Figure 4-7: Current Control for 201TS Art # A-09845
4.07 Victor Regulator

! WARNING
Stand to the side of the cylinder opposite the
Flow gauge regulator (Figure 4-8) attached to the cylinder regulator when opening the cylinder valve.
valve reduce high cylinder pressures to suitable low work- Keep the cylinder valve between you and the
ing pressures for welding, cutting, and other applications. regulator. For your safety, NEVER STAND IN
HIGH PRESSURE FRONT OF OR BEHIND A REGULATOR WHEN
FLOW GAUGE
GAUGE (SUPPLY)
OPENING THE CYLINDER VALVE!
2. Slowly and carefully open the cylinder valve (Fig-

ure 4-10) until the maximum pressure shows on
INLET the high pressure gauge.
CONNECTION
OUTLET
CONNECTION
PRESSURE
ADJUSTING
A-09414_AB
SCREW
Figure 4-8: Victor CS Regulator

4.09 Lift Start TIG with the Thermal Arc
161STL
Make sure that you have the appropriate shielding gas
set up, attach the shielding gas hose from the torch to a
flow meter regulator on the cylinder. In this case we will
be using Argon set at a flow rate of around 20 CFH. You
will need to use a TIG torch that has a gas valve, and is
properly adjusted. (Tungsten, Collet, Collet body, nozzle,
and back cap).
1. Attach the TIG torch lead to the (-) terminal of the
power supply.
2. Attach the work lead with ground camp to the (+)
terminal of the power source, and your work piece.
Art # A-09828
Figure 4-10: Open Cylinder Valve NOTE

About tungsten selection for this power
3. On all cylinders, except acetylene, open the valve supply, a 2% Thoriated tungsten is generally
completely to seal the valve packing. On gaugeless used for DC straight polarity welding. Point
regulators, the indicator will register the cylinder the tungsten by grinding a taper on it about
contents open. 2½ times the diameter of the tungsten used
and grind a slight flat on the end, this will help
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. and close the valve.
1. Be sure that there is a valve in the downstream 2. Turn on the power supply. The switch is located
equipment to turn off the gas flow. on the rear panel.
2. With the cylinder valve open, adjust the regulator 3. Set the weld process to lift TIG. Set the anticipated
to deliver the maximum required delivery flow amperage needed for the weld on the panel and
rate. turn on the torch valve, touch the tungsten to the
3. Close the cylinder valve. Watch to see if the high work, as you lift the tungsten off the work, the arc
pressure or contents gauge drops, if it does you will start.
have a leak in the connection between the regula- NOTE
tor and the cylinder.
An alternate method is to set the edge of the
4. Once leak testing has been performed and there gas cup on the work piece. Rotate the torch so
are no leaks in the system, slowly open the cylin- the tungsten comes in contact with the work.
der valve and proceed. Roll the torch back to lift the tungsten off the
work and the arc will start.
! WARNING
If a leak has been detected anywhere in the
system, discontinue use and have the system
repaired. DO NOT use leaking equipment. Do
not attempt to repair a leaking system while
the system is under pressure.

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. The higher frequency AC then goes on to
a much smaller main transformer than in a conventional power supply. The AC is then rectified to extremely smooth
DC. The diagram to the below shows the basic electrical wiring of a DC output inverter power supply.
Inverter Technology - Summary
Rectifier Filter IGBT Transformer Rectifier Inductor
AC-50/60Hz DC-Rippled DC-Smooth AC-23KHz AC-23KHz DC- Rippled DC-Smooth

High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage
Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage
Art # A-09846
Manual 0-5148 5-1 Theory of Operation

THERMAL ARC 161Stl, 201ts THEORY OF OPERATION
Notes
Theory of Operation 5-2 Manual 0-5148

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.
Replace front panel PCB3
Over Temp Indicator on Duty Cycle has been exceeded. Reduce weld time and allow Power Supply to cool.
Check thermostat wire connections. If the connection is properly inserted and
Over Temp Indicator is still on after short-circuit thermostat, replace control panel,
otherwise replace thermostat. (the value of thermostat is 75ºC).
Power Indicator ON, Fan Check fan for obstruction.
does not run Check whether J12connector on main board PCB1 is plugged in properly. Check for
+24V±10% on pins 1 and pin 2 of J12 connector.
If both above are ok, replace fan.
No Gas Flow In Lift Tig / Check process switch on front panel to determine whether it is functioning properly.
HF Tig Mode And put it to Lift Tig or HF Tig mode.
Make sure pin3 and pin4 of J12connector on main board PCB1 is +24V±10%
Replace gas solenoid
ON/OFF Indicator blinks Step 1. Make sure the voltage between pin 1 and pin2 of J11 connector on main
power PCB1 is - 24VDC±10%, and the voltage between pin 2 and 3 is +24VDC±10%.
Step 2. If above voltage is correct, please replace front panel PCB3.
Step 3. If above voltage is incorrect, disconnect the harness of J11 connector and
re-measure according to step 1. If still incorrect replace Main Power PCB 1
Cannot adjust Weld Check Control panel PCB 3 J26 connector and Remote control PCB4 J27 connector
Current to make sure they are properly inserted.
Check Current Control Potentiometer for an adjustment of 0 to 4.8vdc from Min to
Max on Front Panel PCB3. Pin1=Min, Pin2=Wiper, Pin3=Max. If adjustment cannot
be made correctly replace Front Panel PCB3.
No Open Circuit voltage Check process switch on front panel to determine whether it is functioning properly.
Check the Bus voltage on Main Power PCB1 . It should read 385VDC (see 6.05)
Turn Powersupply off and remove Mains Power. Check Input IGBT’s and Output
Diodes (see 6.06.2 and 6.06.5). If it is incorrect, replace main power PCB1.
If above is OK, replace control PCB2.
Low Weld output If input mains is 230VAC and output is limited to 125Amps output, check Front panel
PCB3 J25 connector and Main Power PCB1 J16 connector . If they are properly
inserted, replace Control PCB2
High Weld Output If input is 115V, output is near 160A, check whether it is shorted between pin1 and
pin 3 on IN JC connector on main power board. If it is not, replace control board.
No HF in HF TIG mode Make sure the process switch is functioning properly, and put it to HF TIG mode.
Check TIG torch Switch for continuity. Also check wire harness on 8 pin remote
connection. If OK, measure on (PCB1) J17 pins1 and 3 for 15vdc when troch switch
is depressed.
Check the wire of HF arc starter is connection properly.
Replace the main power PCB1
Manual 0-5148 6-1 Troubleshooting
!
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.
! Check DC bus voltage according to Section 6.07 after removing case.
! Before troubleshooting or applying power to unit, complete the following checks to avoid causing further
damage.
6.03 Tools Needed for Troubleshooting and Servicing
Art # A-09849
Troubleshooting 6-2 Manual 0-5148

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.
2 A-09951
A-09952

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

1. Clear protective sheet
Take out clear protective sheet.
1
Art # A-10160

6.06 Pre-Power Check
Measure Points for following tests
3
1
16
4
15
17
10 18
2
14
9
13
Art # A-10161
12
11
8
7
6
5


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.
Positive Probe Negative Probe

Measure Point 2 Measure Point 1
If reading is out of voltage drop range, disconnect two parallel rectifiers and measure separately to determine
faulty rectifier and replace it.
2. Measurement of Main IGBT
Set multimeter to diode mode. Diode voltage drop reading shuld be in the range of 0.200-0.600V.

If reading is out of voltage drop range, replace main board.
3. Measurement of PFC IGBT
Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200-0.600V.


4. Measurement of Boost Diode


5. Measurement of Output Diode

If reading is out of voltage drop range, replace main PCB1.

6. Measurement of In Rush Resistor R1.
Set multimeter to Ohm mode. Ohm reading should be 4Ω±5%.

If reading is not 4ohms within ±5%, replace Resistor R1.
7. Power Switch S1 Continuity Check
Art # A-09854_AB

1. ON/OFF switch
Place ON/OFF switch in ON position. Measure the two top terminals for continuity. Then check the two bottom
terminals for same result. If either test is faulty, replace ON/OFF switch.

6.07 DC Bus Voltage Check
! Warning: Measure DC voltage reading with multimeter before inspection. Set multimeter to DC voltage mode.

1. DC Positive
2. DC Negative
Check and make sure input capacitors are discharged and voltage is near 0 VDC. When powered up voltage
should read 385 VDC.
1 2 Art # A-10162

6.08 Installing Clear Cover Sheet

1. Replace the clear protective sheet.
1
Art # A-10160

6.09 Waveforms for Section 6-10
A. OCV Waveform of Transformer primary
Art # A-09858

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

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

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.
INPUT 230VAC/115VAC
50/60Hz
Art # A-10280

6.11 161STL Connector Diagram

6.12 Troubleshooting Circuit Diagram - 201TS
INPUT 230VAC/115VAC
50/60Hz
Art # A-11277

J1,J10 J29 J20
J5,J13
1 7 1 8 1 6
1 5
J9,J12,J26,J27 J2,J11,J14,J17,J28 J3,J4,J23,J15,J16,J21,J25 J6, ,J22,J18 J7,J19 J30

J8,J24
1 4 1 2 3 1 2
1 2 1 2 1 2
1 5
10 6
CONNECTOR KEY
6.13 201 TS Connector Diagram
J1 +15
J2 power
J3 OT2
J4 OT1
J5 SOU/HF/QF
J6 GUN
J7 WV
J8 MB
J9 WA
Troubleshooting 6-16
J10 IN
J11 DY2
J12 FJ/QF
J13 DY1
J14 JC3
J15 OC2
J16 JC
J17 SWIN
J18 SWOUT
J19 WVOUT
J20 JC2
J21 JC1
J22 RX24
J23 OC1
J24 J1
J25 JC
J26 J-MB
J27 J-RC
J28 GUN1
J29 R-G
J30 HF OUT
Art # A-11278 201

Manual 0-5148
disassembly procedure
! THERMAL ARC 161stl, 201TS
SECTION 7:
DISASSEMBLY PROCEDURE
7.01 Safety Precautions for Disassembly

Unplug unit before beginning Disassembly procedure.
Manual 0-5148 7-1 Disassembly Procedure

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.
3 Disconnect J7 harness from J7 connector.
Ensure to unplug all harness from the main control PCB.
3 2 1
Art # A-10163
7 8 4 9 10
Disassembly Procedure 7-2 Manual 0-5148

disassembly procedure THERMAL ARC 161stl, 201TS
3 2 1
NO
J7 MB J8 J9 WA
WV
J6 GUN
J5 SOU/HF/QF
OT2 J4 J3 OT1 POWER J2 J1

CONNECTOR LAYOUT DIAGRAM
Control PCB2 Art # A-10164
161STL Control PCB
CONNECTOR LAYOUT DIAGRAM

J1 J2 POWER OT1 J3 J4 OT2
SOU/HF/QF J5
GUN
J6
WA J9 MB J8 J7 WV
3 2 1 Art # A-10165
201TS Control PCB

7.03 Front Panel Assembly Removal
1. Power supply output Negative
2 Power supply output Positive
3. Output terminal bolts. Unscrew power supply output terminal bolts.
4. Disconnect the harness from Front Panel PCB3.
Art # A-10166
1
2

Art # A-10167
Art # A-10168

Art # A-10169
7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal
1. PROCESS Selector Switch Boot
Remove the rubber boot from the PROCESS Selector switch by turning the retaining nut counter clockwise.
2. WELD CURRENT Control Knob
Remove the WELD CURRENT KNOB by loosening the set screw.
3. WELD CURRENT control mounting nut
Remove mounting nut.
4. Front Panel PCB3
Remove the Front Panel PCB3 from the panel.
5. Panel mounting screw
Remove screw.

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.
8. Arc Force/Down slope Control Knob mounting nut
Remove mounting nut.
9. Remote Control PCB4
Remove the Remote Control PCB4.
2 7
Art # A-10170
3 8
Art # A-10171

Art # A-10172
Art # A-09870
7.05 Back Panel Removal
1. ON/OFF switch
2. Wire from Main PCB1.
Disconnect the two wires from PCB1.
3. Rear panel mounting SCREW.
Remove screw holding rear panel to chassis.
4. Ground wire screw.
Disconnect Input cord ground wire from Main Power PCB1 using a 1/4" wench.
5. Disconnect harness from J8 connector on Control PCB2 and carefully lift the wire free from the unit.
Refer to diagram on page 7-3.
6. Disconnect harness from J12 connector on Control PCB2 and carefully lift the wires free from the unit.
Art # A-10173
Art # A-10174

Art # A-10175
Art # A-10176

7.06 Power Switch S1 and Power Cord Removal
1. Input Power Cord connection s to SW1.
Remove the stab-on wire connections from SW1.
2. SW1 locking tabs
Squeeze the locking tabs and push SW1 out from the rear panel.
3. Input Power Cord.
4. Strain relief screws
Remove the two (2) screws from the strain relief.
5 Input Power Cord ground wire filter.
Cut the tie-wrap and remove the magnet from the ground wire.
Pull the Input Power Cord out. It may be necessary to use a flat blade screw driver against the strain relief
tabs, prying outward (Internal side if strain relief) to help remove the cord.
6. Pull out the Input Power Cord.
7. Remove fan.
Art# A-10177

1 3
Art # A-10178
Art # A-10179
2

7.07 Base Panel Removal
1. Remove PCB1 assembly.
2. Remove Base Panel Screws.
3. Remove Base Panel.
Art # A -10180

Notes

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
2
Art # A- 10181
Manual 0-5148 8-1 Assembly Procedures

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.
7. Reconnect Ground Wire to Main PCB.
8. Reconnect Rear Panel screws.
Art # A-10182
Assembly Procedures 8-2 Manual 0-5148

Art # A-10183
8
Art # A-09883

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.
Install nut and tighten.
5. WELD CURRENT knob
Install knob onto potentiometer shaft. Align the knob pointer to line up with maximum current calibration mark
on the panel, then tighten the set screw.
6. Arc Force/ Down Slope Control knob
Install knob onto potentiometer shaft, align the knob pointer to line up with maximum mark on the panel, then
tighten the set screw.
7. PROCESS selector switch boot.
Install boot over the switch and tighten nut onto switch.
8. Trigger Selector Switch boot
Install boot over the switch and tighten nut onto switch.
2
Art # A-10184
3

Art # A-10185
8 7
Art # A-10186
6
5

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

11
Art # A-10188
10
12
Art # A-10189

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.
8 Plug harness into connector J3
9 Plug harness into connector J9
10. Plug harness into connector J1
Verify harness connections with the system schematic to insure all connections are correct.
11. Install clear protective sheet.
3 2 1
Art # A-10163
7 8 4 9 10

11
Art # A-10190

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.
2
Art # A-10191

Art # A-10192

Notes

replacement parts THERMAL ARC 161stl, 201TS
SECTION 9:
REPLACEMENT PARTS
9.01 Hardware List
Description Specification Where used QTY Unit
Hexagon socket head screw GB/T70.1 M8×14 Handle 2 EACH

Cross-recessed round head screw GB/T818 M3×12 Remote socket 4 EACH
GB/T845-1985
Cross-recessed tapping screw Base Panel 2 EACH
BT4.8*13
Cross-head pan head tapping GB/T13806.2
Bracket 3 EACH
screw AST4.2×13
Base Panel, Solenoid
locking washer, external serrated GB862.2-87 4 4 EACH
valve,
Screw, spring washer, flat washer M4×16 Rectifier bridge 2 EACH
Solenoid valve, base
Flat washer 4*10 5 EACH
panel, Case
Cross-recessed round head screw GB/T818 M5×12 Power Cord 2 EACH
Cross-recessed pan screw GB/T818 M3×25 Fan 4 EACH
Nut GB/T6170 M3 Fan, plug 8 EACH
Nut GB/T6170 M4 Ground 1 EACH
Front Panel, Rear
Cross-recessed pan head screw GB/T818 M4×10 8 EACH
Panel, and Case
Plastic screw PF-408 Control PCB 3 EACH
Plastic screw DN-4 Control PCB 4 EACH
Manual 0-5148 9-1 Replacement Parts

THERMAL ARC 161Stl, 201TS replacement parts
9.02 Replacement Part List - 161STL
Item No Description Part No. Reference Designator

1 Handle W7003040
2 Panel, Cover W7003200
3 Rectifier 1000V,50A W7003010
4 PCB,Control,161STL W7003202 PCB2
5 Thermostat W7003016 THC1, THC2
6 Resistor,6 ohm,60W W7003055 R1
7 PCB,Power,161STL W7003203 PCB1
8 Insulation Sheet W7003214
9 PCB,Front Control,161STL W7003204 PCB3
10 Front Panel W7003205
11 Front Panel Label W7003206
12 Rubber Boot W7003064
13 Knob, control, Red, 21 ODx6 ID W7003079
14 Output Terminal, 50mm dinse W7003020
15 Socket,8 Pin,w/cable,161STL-201TS W7003220
16 Connector,Gas Outlet,161STL-201TS W7003212
17 Output Inductor Magnetic Core W7003210
18 Gas Solenoid W7003033
19 Base Panel W7003209
20 Fan,24V DC W7003090
21 Rear Panel W7003201
22 Connector,Gas Inlet,161STL-201TS W7003215
23 ON/OFF Switch W7003053 SW1
24 Current Sensor, 161-201TS W7003076 Current Sensor
25 Cable Cord,12AWG,10ft,6-50P W7003052
26 PCB,Remote,161STL-201TS W7003221 PCB4
Replacement Parts 9-2 Manual 0-5148

23
22
25
3
21
4
7
5
20 6 8
10
11
12

13
19
14
Art # A-10022_AB 18 17 16 15
26

9.03 Replacement Part List - 201TS
Item No Description Part No. Reference Designator
1 Handle W7003040
2 Panel, Cover W7003200
3 Rectifier 1000V,50A W7003010
4 PCB,Control,201TS W7003222 PCB2
5 Thermostat W7003016 THC1, THC2
6 Resistor,6 ohm,60W W7003055 R1
7 PCB,Power,201TS W7003216 PCB1
8 Insulation Sheet W7003214
9 Points,HF Starter,201TS W7003034
10 Output Inductor Magnetic Core W7003210
11 Front Control PCB3 W7003218 PCB3
12 Front Panel W7003205
13 Front Panel Label W7003219
14 Rubber Boot W7003064
15 Knob, control, Red, 21 ODx6 ID W7003079
16 Connector,Gas Outlet,161STL-201TS W7003212
17 Output Terminal, 50mm dinse W7003020
18 Socket,8 Pin,cable,161STL-201TS W7003220
19 Gas Solenoid W7003033
20 Current Sensor, 161-201TS W7003076 Current Sensor
21 Base Panel W7003209
22 Fan,24V DC W7003090
23 Rear Panel W7003201
24 Cable Cord,12AWG,10ft,6-50P W7003052
25 Connector,Gas Inlet,161STL-201TS W7003215
26 ON/OFF Switch W7003053 SW1
27 PCB,Remote,161STL-201TS W7003221 PCB4

26
25
4
24 7
55 8 9
6
23 10
22
11
12
13
14
15
16
17
20
Art # A-10104_AB 18
21 19
27

Notes

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
Power Adapter-230V,50A Socket (Nema 6-50R) to 115V, 15A Plug (Nema 5-15P) W4014000
USA Graphics Auto-Darkening welding helment, spare cover lens and operating manual W4011700
Canadian Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4011800
Claret Color Auto-Darkening welding helmet, spare cover lens and operating manual W4011900
Black Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4012000
Manual 0-5148 10-1 Accessories

THERMAL ARC 161Stl, 201TS accessories
Notes
Accessories 10-2 Manual 0-5148

LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
January 2009
LIMITED WARRANTY: Thermal Arc®, Inc., A Victor Technologies Company (“Thermal Arc”),
warrants to customers of authorized distributors (“Purchaser”) that its products will be free of
defects in workmanship or material. Should any failure to conform to this warranty appear within
the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation
that the product has been stored, installed, operated, and maintained in accordance with
Thermal Arc’s specifications, instructions, recommendations and recognized standard industry
practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects
by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of
the product determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of merchantability,
fitness for any particular purpose, or other warranty of quality, whether
express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,
incidental, or consequential damages, including but not limited to lost profits and business
interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of
Thermal Arc with respect to any contract, or anything done in connection therewith such as the
performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by Thermal Arc, whether arising out of contract, tort, including
negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the
goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this warranty in
any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.
Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment
of thermal’s obligations to purchaser with respect to the product.
This warranty is void, and seller bears no liability hereunder, if purchaser used replacement
parts or accessories which, in Thermal Arc’s sole judgment, impaired the safety or performance
of any Thermal Arc product. Purchaser’s rights under this warranty are void if the product is sold
to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the authorized
distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal
Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s
discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this
warranty. Transportation charges to send products to an authorized warranty repair facility
shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s
risk and expense. This warranty dated January 1st 2009 supersedes all previous Thermal Arc
warranties. Thermal Arc® is a Registered Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
January 2009
SAFETY EQUIPMENT WARRANTY PERIOD LABOR
Auto-Darkening Welding Helmet (Electronic Lens) 2 year 2 year
Harness Assembly 1 Month 1 Month
ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors ..................................................................................................... 3 years 3 years
Original Main Power Rectifiers, Control P.C. Boards ....................................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays, switches,
1 year
contactors, solenoids, fans, power switch semi-conductors ............................................................................. 1 year
Engines and associated components are NOT warranted by Thermal Arc, although most are
warranted by the engine manufacturer ............................................................................................. See the Engine Manufactures’ Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor................................................................................................ 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ..................................... 3 years 3 years
contactors, solenoids, fans, electric motors. ..................................................................................................... 1 year 1 year
TIG (GTAW) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400MST, 300MST, 400MSTP
Original Main Power Magnetics ........................................................................................................................ 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ..................................... 3 years 3 years
contactors, solenoids, fans, electric motors. ..................................................................................................... 1 year 1 year
PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150
Original Main Power Magnetics ....................................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................................... 3 years 3 years
Welding Console, Weld Controller, Weld Timer............................................................................................... 3 years 3 years
contactors, solenoids, fans, electric motors, Coolant Recirculator.................................................................... 1 year 1 year
STICK (SMAW) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Thermal Arc 95S
Original Main Power Magnetics ......................................................................................................................... 1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards ......................................................................................... 1 year 1 year
contactors, solenoids, fans,............................................................................................................................... 1 year 1 year
161S, 161STL, 201TS
Original Main Power Magnetics 3 years 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years
All other original circuits and components including, but not limited to, relays, switches, 1 year 1 year
contactors, solenoids, fans
160S, 300S, 400S
Original Main Power Magnetics ........................................................................................................................ 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards ........................................................................................ 3 years 3 years
contactors, solenoids, fans, power switch semi-conductors ............................................................................. 1 year 1 year
GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR
Water Recirculators ........................................................................................................................................... 1 year 1 year
Plasma Welding Torches .................................................................................................................................180 days 180 days
Gas Regulators (Supplied with power sources)...............................................................................................180 days Nil
MIG and TIG Torches (Supplied with power sources) ......................................................................................90 days Nil
Replacement repair parts..................................................................................................................................90 days Nil
MIG, TIG and Plasma welding torch consumable items .......................................................................................Nil Nil
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph: 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada

Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph: +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph: 6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph: +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812
TECHNOLOGIES ™
I n n o v atio n to S hape the W orld ™
U.S. Customer Care: 800-426-1888 / fax 800-535-0557 • Canada Customer Care: 905-827-4515 / fax 800-588-1714
International Customer Care: 940-381-1212 / fax 940-483-8178
© 2012 Victor Technologies International, Inc. victortechnologies.com .

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161 STL

201 Ts Inverter Arc Welder

Revision: AC Issue Date: Dec. 03, 2012 Manual No.: 0-5148

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-leading,

Above all, we are committed to develop technologically advanced products

Service Manual Number 0-5148 for:

® All rights reserved.

Publication Date: June 15, 2011

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________

Manual 0-5148 1-1 Safety Instructions and Warnings

Eye protection filter shade selector for welding or cutting

Electrode Size Filter Electrode Size Filter

Shielding gas cylinders contain gas under high pressure.

Manual 0-5148 1-3 Safety Instructions and Warnings

Safety Instructions and Warnings 1-4 Manual 0-5148

1.03 Principal Safety Standards

Manual 0-5148 1-5 Safety Instructions and Warnings

On Single Phase Wire Feed Function

Wire Feed Towards

Increase/Decrease Remote Purging Of Gas

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time

Gas Metal Arc

Gas Tungsten Arc 2 Step Trigger

Negative Constant Current 4 Step Trigger

Direct Current (DC) High Temperature

Line Arc Force

Line Connection Touch Start (GTAW)

Auxiliary Power Variable Inductance See Note

115V 15A Receptacle Rating-

• Do not touch hot parts bare handed.

Safety Instructions and Warnings 1-8 Manual 0-5148

Manual 0-5148 2-1 Introduction

Introduction 2-2 Manual 0-5148

Figure 3-1: 161STL Duty Cycle

Manual 0-5148 3-1 Safety and Installation

Lift TIG/HF TIG

Safety and Installation 3-2 Manual 0-5148

Manual 0-5148 3-3 Safety and Installation

3.06 Electrical Input Connections

DO NOT TOUCH live electrical parts.

Manual 0-5148 3-5 Safety and Installation

Welding Power Supply

The Adapters enable

Primary Power Cable

Figure 3-3: Electrical Input Connections

Manual 0-5148 3-7 Safety and Installation

Extra precautions for Electromagnetic C. Methods of Reducing Electromagnetic Emissions

Safety and Installation 3-8 Manual 0-5148

Manual 0-5148 3-9 Safety and Installation

Figure 3-4: 161STL Volt-Ampere Curves

Safety and Installation 3-10 Manual 0-5148

Figure 3-4: 201TS Volt-Ampere Curves

Manual 0-5148 3-11 Safety and Installation

Safety and Installation 3-12 Manual 0-5148

4.01 Front Panel

(C) Trigger Mode Selection Switch

(A) Power On Indicator (D) Process Selection Switch

(F) Arc Force/Down