AOTAI Dura ARC160 Instruction Manual
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AOTAI Dura ARC160 Instruction Manual

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Dear Customer
This instruction manual will help you get to know your new machine. Read the
manual carefully and you will soon be familiar with all the great features of your
new product. Meanwhile, please remember safety rules and operate as
instructed.
If you treat your product carefully, this definitely helps to prolong its enduring
quality and reliability-things which are both essential prerequisites for getting
outstanding results.
Production specification may change without advance notice.
The model you purchase is for:
Please find corresponding models from the "Contents".
Important:
Please take special note of safety rules and operate as instruction in case of
damage and serious injury.
Dura ARC160
Dura ARC160II
Dura ARC200
Dura ARC200II
Dura ARC250
1

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Summary of Contents for AOTAI Dura ARC160

  • Page 1 If you treat your product carefully, this definitely helps to prolong its enduring quality and reliability-things which are both essential prerequisites for getting outstanding results. Production specification may change without advance notice. The model you purchase is for: Dura ARC160 Dura ARC160II Dura ARC200 Dura ARC200II Dura ARC250 Please find corresponding models from the “Contents”.

  • Page 2: Safety Rules

    Safety Rules “Danger” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. “Warning!” indicates a possible hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are explained in the text. “Caution”...
  • Page 3 occasion when there is a high risk of unavoidable or accidental contact with the work piece or ground. Must use additional safety precautions: semiautomatic DC constant voltage (wire) welder, DC manual (Stick) welder and AC welder with reduced open- load voltage. Maintain the electrode holder, ground clamp, welding cable and welding machine in good, safe operating condition.
  • Page 4 Welding and cutting sparks can cause fire or explosion. When not welding, make sure the electrode circuit is not touching the work or ground. Accidental contact can cause sparks, explosion, overheating, or fire. Make sure the area is safe before doing any welding.
  • Page 5 fittings, etc. should be suitable for the application and maintained in good condition. Open the cylinder valve slowly and keep your head and face away from the cylinder valve outlet. Valve protection caps should be kept in place over valve expect when the cylinder is in use or connected for use.

  • Page 6: Table Of Contents

    1-4 Duty cycle 1-5 Applications 2-BEFORE COMMISSIONING 2-1 Utilization for intended purpose only 2-2 Machines set-up regulations Power source connection Welding cables instruction 3-DURA ARC160/160II/200/ 200II/ 3-1 System components 3-2 Standard equipments for welding 3-3 Control panel 3-4 Interface 3-5 Rear panel...

  • Page 7: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features Dura ARC160/160II/200/250/200II welding machine is suitable for DC SMAW , simple TIG process, which can weld carbon steel, stainless steel, copper, titanium, etc. Because of the ideal static characteristic and dynamic characteristics, machines highlights are as follows:...

  • Page 8: Duty Cycle

    Reduce amperage or duty cycle before welding. NOTE! Exceeding duty cycle can damage unit and void warranty. Dura ARC250 Dura ARC200/200Ⅱ Dura ARC160/160Ⅱ % DUTY C YCLE Fig. 1-4-1: Duty Cycle (at 40 C) 1-5 Applications The ARC series can weld most of the metal materials absolutely including the welding of carbon steel, stainless steel, etc.

  • Page 9: 2-Before Commissioning

    2 - BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the machine until you have read "Safety rules". 2-1 Utilization for intended purpose only The power source may only be used for SMAW and Simple TIG welding. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose".

  • Page 10: 3-Dura Arc160/160Ii/200/ 200Ii/ 250

    3–DURA ARC160/160II/200/ 200II/ 3-1 System components Welding cable Ground cable Power source Fig. 3-1-1: System components 3-2 Basic equipments for welding - Power source - Ground cable - Electrode holder - Electrode 3-3 Control panel Note! Your machine has certain functions that are not in accordance with this operating manual, or vice versa.

  • Page 11: Interface

    WELDING CURRENT(A) Fig. 3-3-1: Control panel 1. Protection on LED Yellow color, which will light off if the machine operates properly; lights up if the power source overheats or some other fault, machine will stop working automatically, keep the machine power on and fan running until the overheat indicator lights off, then wait 20 minutes before start welding.

  • Page 12: Rear Panel

    6. Welding cable quick socket (+) For basic electrode: used for connecting the electrode holder. For cellulose electrode & acid electrode: used for connecting the work piece. (For Dura ARC160II/200II) In simple - TIG process: used for connecting the work piece. 7.Welding cable quick socket (-) For basic electrode: used for connecting the work piece.
  • Page 13 Table 3-6-1:Specifications of mains input Dura ARC200/200II Dura ARC250 Model Dura ARC160/160II ± 1- phase AC230V 15%, 50/60Hz Power supply Electricity grid min. capacity ( Input Fuse protection Circuit breaker Input cable ≥2.5 Cable size Output cable Protective GND wire ≥2.5...
  • Page 14 E: 2-plug round (4.0mm) type F: 2-plug round (4.0mm) type D: 3-plug flat 8 type G: 2-plug round + GND I: 3-pin flat type H: 2-plug round + bayonet type round hole type K: 3-pin round type N: Italy type M: Switzerland type O: Denmark type P: Israel type...
  • Page 15 Country Type Country Type Middle East region Saudi Arabia Iran A, B, I Dubai Europe region Italy Austria E, N E, F, G Hungary Poland F, G E, F, G Greece Belgium E, F, G E, F, G Netherlands E, F, G United Kingdom France E, F, G...
  • Page 16 3. Plug the welding cable into the output socket (+) and fasten it; 4. Connect with single phase 230V power supply, and put the circuit breaker in ON position; 5. Switch on the mains switch; 6. Turn “Welding Current” knob to adjust the welding current according to the size of electrode; 7.

  • Page 17: Technical Data

    3-7 Technical data Table 3-7-1: Technical data Model 160/160II 200/200II Control type IGBT inveter 1-phase AC230±15% Rated input voltage (V) 50/60 Input voltage frequency (Hz) Rated input power (KVA) Rated input current (A) 43.5 23.4 31.8 Rated duty cycle (%)(@40℃) Rated output open-load voltage (V) Ouput welding current (A) 20 ~ 160...

  • Page 18: Disassembly And Reassembly

    Item Stock No. Quantity Remark 720022-00013 160(II)/200(II) RD301~ Thermistor RD304 720021-00031 CE202~ Aluminum electrolytic 722004-00105 capacitor CE204 735003-00011 160/200 KF211~ IGBT tube KF242 735003-00013 160II/ 200II/ Power transformer 763001-00207 763002-00022 160/200/250 T251 Main transformer 160II/200II 730001-00027 160(II)/200(II) RB251~ Diode RB258 730001-00041 745009-00012 Temperature relay...
  • Page 19 18 19 14 15 Fig. 3-9-1: Disassembly and reassembly of unit Table 3-9-1: Key components Stock No. Description Quantity 262005-00943 Plastic Front Panel 779002-00009 GB_CROSS_COUNTERSUNK_SCREWS M4X12 Cross Recess Pan Head Screw 779002-00501 M4×10 Black (three combinations) 262047-00091 Main Case 766003-02141 Welding Machine Handle 262011-00639 Plastic Rear Panel...
  • Page 20 740008-00005 LED Base 755001-00028 Digital Displayer 262035-00296 Control Board Key components 3.9.2 Disassembly and reassembly of radiator 13 12 11 Fig. 3-9-2: Disassembly and reassembly of radiator Table 3-9-2:Key components Stock No. Description Quantity 763001-00207 Power Transformer 775001-00037 Power Transformer Fixed Plate 1 775001-00038 Power Transformer Fixed Plate 2 779002-00009...
  • Page 21 Stock No. Description Quantity 779007-00019 Flat Washer Ф6 766001-01708 Negative Output Copper Plate 779003-00022 745007-00012 Temperature Relay 776025-00018 Transistor Housing 730001-00027 Output Diode 735003-00011 IGBT Tube 735004-00005 Rectifier Bridge 766007-01433 Positive Output Copper Plate GB_CROSS_COUNTERSUNK_SCREWS M4X12 779002-00009 776025-00019 Radiator Support IGBT Radiator 1 264005-00170 264005-00171...

  • Page 22: 4-Trouble Shooting

    4 - TROUBLE SHOOTING Note! The following troubles and causes are uncertain. However, during the process SMAW and normal using conditions, that might happen. Table 4-1: Trouble shooting TROUBAL CAUSES REMEDY 1.Check power switch 1.Power switch is and the fan damaged 2.Check power supply .No electricity on the...

  • Page 23: 5-Care And Maintenance

    5 - CARE AND MAINTENANCE Before open the machine Warning! An electric shock can be fatal. Before doing any work on the machine: - Switch it off and unplug it from the mains - Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching it back on again - Discharge the capacity if necessary - Bolt in outer case also works for ground connection.

  • Page 24: 6-Basic Welding Technique

    6 - BASIC WELDING TECHNIQUE Note! This section being general welding technique guide is for reference only. Specific functions of your machine please refer to previous chapters. 6-1 TIG welding technique The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal).
  • Page 25 Gas flow Fig. 6-1-5: Tungsten off the work Fig. 6-1-6: Tungsten touches the work Fig. 6-1-7: Arc ignition Fig. 6-1-8: Established TIG Arc TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the workpiece.
  • Page 26 Gas shield Move the torch forward to the front of the molten pool Retract the filler wire Repeat the process Fig. 6-1-17: Retract the filler wire Fig. 6-1-18: Torch move Fig. 6-1-19: Repeat the process Tungsten Electrodes Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high-temperature resistance to carry the welding current to the arc.

  • Page 27: Smaw Stick ( ) Welding Technique

    Table 6-1-2: Tungsten diameter rating for angle and current Constant Included Angle - Degrees Tungsten Diameter Current Range Amps 1.0mm 05 - 30 1.6mm 08 - 50 1.6mm 10 - 70 2.4mm 12 - 90 2.4mm 15 - 150 3.2mm 20 - 200 3.2mm 25 - 250...
  • Page 28 The arc is initiated by momentarily touching the electrode to the base metal. - The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode. - The melted electrode metal is transferred across the arc into the molten pool and becomes the deposited weld metal.
  • Page 29 Welding Current (Amperage) Correct current selection for a particular job is an important factor in arc welding. With the current set too low, difficulty is experienced in striking and maintaining a stable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited.
  • Page 30 Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases edges should be clean and free of any contaminates. The type of joint will be determined by the chosen application.
  • Page 31 MEMO...
  • Page 32 WARRANTY REPAIR: If AOTAI or a it's authorized service facility confirms the existence of a defect covered by this warranty, the defect will be corrected by repair or replacement at AOTAI's expense. At AOTAI's request, the purchaser must return, to AOTAI or it's authorized service facility, any "Goods"...

This manual is also suitable for:

Dura arc160iiDura arc200iiDura arc200Dura arc250

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