AOTAI ARC315 Instruction Manual
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AOTAI ARC315 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 many great features of your new product. Meanwhile, please
remember well safety rules and operate as instruction.
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:
ARC315/400/500/630
ARC1000/1250
ARC400II
ARC400-3T
TIG315/400/500/630
TIG1000/1250
TIG400II
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.
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Summary of Contents for AOTAI ARC315

  • 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: ARC315/400/500/630 ARC1000/1250 ARC400II ARC400-3T...

  • 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 If electromagnetic interference still occurs, despite the fact that the mains connection in accordance with the regulations, take additional measures - Welding cables Keep these as short as possible. Connect the work cable to the work piece as close as possible to the area being welded. Lay them well away from other cables.
  • Page 4 Cylinder can explode if damaged. Pressure 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. Cylinders should be located away from areas where they may be struck or subjected to physical damage. Use proper equipment, procedures, and sufficient number of persons to lift and move cylinders.

  • Page 5: Table Of Contents

    2- VERSIONS BRIEFS 3-BEFORE COMMISSIONING 3-1 Utilization for intended purpose only 3-2 Machines installation rules 3-3 Power source connection 3-4 Welding cables instruction 4-ARC315/400/500/630 4-1 System components 4-2 Basic equipments for welding 4-3 Interface 4-4 Connections 4-5 Installation and operation...
  • Page 6 8-TIG315/400/500/630 8-1 System components 8-2 Basic equipments for welding 8-3 Interface 8-4 Connections 8-5 Installation and operation 8-6 Technical data 8-7 Main components list 9-TIG1000/1250 9-1 System components 9-2 Basic equipments for welding 9-3 Interface 9-4 Connections 9-5 Installation and operation 9-5 Technical data 9-6 Main components list 10-TIG400II...

  • Page 7: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features This series machines include ARC and TIG types, with different specifications of rated current: 315A, 400A, 500A, 630A, 1000A, 1250A etc., which are high-efficient and energy-saving DC Arc welding machine. Enjoy reasonable static characteristic and sound dynamic characteristic and HF arc starting function (this HF arc starting function is for TIG series only).

  • Page 8: Duty Cycle

    1-4 Duty cycle Duty cycle is percentage of 10 minutes that a machine can weld at rated load without overheating. If overheats, thermostat(s) will open, output stops, and cooling fan runs. Wait for fifteen minutes for the machine to cool down. Reduce amperage or duty cycle before welding.

  • Page 9: 2-Versions Briefs

    Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding. ARC315/400/500/630 The power sources have logical arranged control panel for convenient operation, which can perform SMAW and Gouging (≥ 500A). Welding cable can be extended to 50m.

  • Page 10: 3-Before Commissioning

    3-BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood the “Safety rules”. 3-1 Utilization for intended purpose only The power source may only be used for SMAW (ARC and TIG series) and TIG (only TIG series) welding. Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in accordance with the intended purpose”.
  • Page 11 Correct When the excess cables are only be used by rolling up, coil the cables to two windings in reverse direction and overlap them. The number of turns for A is same as the number for B. Handle the welding cable and ground cable according to above-mentioned method.

  • Page 12: 4-Arc315/400/500/630

    4-ARC315/400/500/630 4-1 System components This series of machines can be equipped with many different accessories. Please refer to Fig. 4-1-1. Welding c a ble Ground c a ble Gouging t o rch(Optional) Wireless remote contro l l er (Op t ional)

  • Page 13: Interface

    4-3 Interface Notes! You may find that your machine has certain functions or some parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. Howerever, these controls function in exactly the same way. Front panel REMOTE DEFAULT P H ASE...
  • Page 14 9.“Arc force current” regulation knob It is used to adjust arc force current on panel control mode. When welding, short circuit between wire and work piece may occur because of operation or droplet transfer. In order to avoid short circuit or wire stick, when arc voltage is low, increase current to shorten the droplet transfer time. 10.Positive output terminal (+) Connect with electrode holder via welding cable in SMAW.

  • Page 15: Connections

    4-4 Connections Remote control socket Socket pin Description REMOTE DEFAULT P H ASE PROTECTION PANEL Null START C U RRENT ARC F O RCE WELDING C U RRENT A R C 4 0 0 Inverter DCAr c We lding Ma chine -9V power supply Remote welding current given signal Power GND...

  • Page 16: Installation And Operation

    4-5 Installation and operation Warning! Electric shock is very dangerous. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the machine when - the mains switch is in the “OFF”...
  • Page 17 Model Power supply 3 phase, AC380V/400V/415V/440V ±10%, 50/60Hz Power network Min. power (KVA) Generator Fuse Input protection (A) Circuit breaker Input cable Cable size (mm²) Output cable Protective GND wire Table 4-5-2: Input power supply cable installation- single voltage AC380V/400V/415V/440V Multi voltage Model Power supply...
  • Page 18 315A/400A welding machine L1 L2 L3 500A/630A welding machine L1 L2 L3 Yellow-Green protective GND wire is used for grounding! Not zero wire! Please connect according to picture or other correct way. Please disconnect mains power when connecting! If main case is grounded, this cable needs no grounding. Fig.

  • Page 19: Technical Data

    Welding electrode diameter (mm²) Weight (Kg) Dimension (mm³) 576×297×557 636×322×582 686×322×584 Insulation class Main transformer/output reactor Table 4-6-1: ARC315/400/500/630 technical data-single voltage Multi voltage Model 3 phase, AC220V/440V ±10% , 60Hz Primary power voltage /Frequency Rated output capacity (KW) 27.7 10.3...

  • Page 20: Main Components List

    Model Weight (Kg) 576×297×557 Dimension (mm³) 686×322×584 Main transformer/output reactor Insulation class Table 4-6-2: ARC315/400/500/630 technical data- multi voltage 4-7 Main components list ARC315/400/500/630 Fig. 4-7-1: Inner structure Item Stock No. 262005-00231 380V/50HZ Front plate 262005-00795 220/380/440V/60HZ 740002-00048, 740002-00046 380V/50HZ...
  • Page 21 Diode protection board 220455-00004 220/380/440V/60HZ 220281-00008 380V/50HZ Current exchange inductor 220281-00005 220/380/440V/60HZ 264011-00121 380V/50HZ Output diode radiator 264011-00144 220/380/440V/60HZ Table 4-7-1: Components list for ARC315 Item Stock No. 262005-00231 380V/50HZ, 415V/50Hz Front plate 262005-00020 CE model 262005-00795 220/380/440V/60HZ 740002-00048 380V/50HZ, 415V/50Hz...
  • Page 22 Item Stock No. 262011-00120 380V/50HZ , 415V/50Hz Rear plate 262011-00011 CE model 262011-00490 220/380/440V/60HZ 745011-00021 380V/50HZ, 415V/50Hz, CE model Circuit breaker 745011-00022 220/380/440V/60HZ 773002-00003 380V/50HZ 773002-00003 415V/50Hz Junction box 773002-00009 CE model 773002-00011 220/380/440V/60HZ 746001-00011 380V/50HZ 746001-00014 415V/50Hz 746001-00034 CE model 746001-00018 220/380/440V/60HZ 263065-00100 380V/50HZ, 415V/50Hz 263065-00007 CE model...
  • Page 23 Item Stock No. 735005-00002 380V/50HZ,415V/50Hz,CE model,220/380/440V/60HZ Three phase rectifier module 720021-00017 380V/50HZ 720021-00021 415V/50Hz Varistor 720021-00001 CE model 720021-00001 220/380/440V/60HZ 220005-00022 380V/50HZ,415V/50Hz, CE model IGBT protection board 220005-00107 220/380/440V/60HZ 264005-00028 380V/50HZ,415V/50Hz, CE model IGBT radiator 264005-00141 220/380/440V/60HZ Temperature relay 745008-00006 380V/50HZ,415V/50Hz, CE model, 220/380/440V/60HZ 735006-00029 380V/50HZ,415V/50Hz, CE model Output diode module 735006-00019 220/380/440V/60HZ...
  • Page 24 Item Stock No. 210580-00197 380V/50HZ, 415V/50Hz Main control board 210580-00611 220/380/440V/60HZ 210310-00032 380V/50HZ ,415V/50Hz Drive board 210310-00088 220/380/440V/60HZ 763001-00043 380V/50HZ 763001-00060 415V/50Hz Power transformer 763001-00174 220/380/440V/60HZ 763001-00195 220/380/440V/60HZ 220629-00015 380V/50HZ ,415V/50Hz Main transformer 220629-00158 220/380/440V/60HZ 220521-00004 380V/50HZ ,415V/50Hz Resonant inductor 220521-00040 220/380/440V/60HZ ,415V/50Hz 722001-00074 380V/50HZ...
  • Page 25 Item Stock No. 740002-00052 380V/50HZ,415V/50Hz 740002-00053 380V/50HZ ,415V/50Hz Output quick socket 740002-00027 CE model 740002-00031 220/380/440V/60HZ 740002-00032 220/380/440V/60HZ 262011-00135 380V/50HZ ,415V/50Hz 262011-00287 CE model Rear plate 262011-00641 220/380/440V/60HZ 745011-00026 380V/50HZ ,415V/50Hz 745011-00026 CE model Circuit breaker 745011-00026 220/380/440V/60HZ 740016-00009 380V/50HZ ,415V/50Hz 773002-00012 CE model...
  • Page 26 Item Stock No. 220521-00029 380V/50HZ,415V/50Hz,CE model Resonant inductor 220521-00055 220/380/440V/60HZ 722001-00075 380V/50HZ,415V/50Hz,CE model Polypropylene capacitor 722001-00075 220/380/440V/60HZ 220149-00007 380V/50HZ,415V/50Hz,CE model Current transformer 220149-00084 220/380/440V/60HZ 722001-00014 380V/50HZ,415V/50Hz,CE model Polypropylene capacitor 220/380/440V/60HZ 735007-00073 380V/50HZ,415V/50Hz,CE model IGBT module 735007-00073 220/380/440V/60HZ 735005-00003 380V/50HZ,415V/50Hz,CE model Three phase rectifier module 735005-00003 220/380/440V/60HZ 720021-00017 380V/50HZ,CE model...

  • Page 27: 5-Arc1000/1250

    Please refer to “ARC315/400/500/630” the relevant “4-1 System components” in details. 5-2 Basic equipments for welding Please refer to “ARC315/400/500/630” the relevant “4-2 Basic equipments for welding” in details. 5-3 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual.
  • Page 28 6.SMAW/Gouging switch It is used to switch between SMAW and Gouging mode. 7.Arc length “L/S/M” switch In SMAW mode: Long: output cable length is more than 25m, less than 40m; Short: output cable length is less than 10m; Middle: output cable length is more than 10m, less than 25m; It is on “Long”...

  • Page 29: Connections

    1. Circuit breaker The function of circuit breaker is to protect welding machine and operator by automatic trip to turn-off power supply when overload or short circuit happens to the power source. Normally, the switch flipped to upward means power-on. To start or stop the welding machine is done by the mains switch in the distribution box. Please do not take this circuit breaker as the power switch.
  • Page 30 SMAW OVER-H E A T FAULT GOU GI NG ARC LE NGTH DEFAU LT PHASE AR C F O RCE CURREN T ARC ST A RT I N G C U RRE NT WEL DING C U RRENT ARC1000 Inverter D C arc We lding Ma chine Fig.
  • Page 31 L1 L2 L3 Yellow-Green protective GND wire is used for grounding! Not zero wire! Please connect according to picture or other correct way. Please disconnect mains power when connecting! If main case is grounded, this cable needs no grounding. Fig. 5-5-2: Connection between input power supply cable and switch box Operating guide Warning! Operating the welding machine incorrectly can cause serious injury and damage.

  • Page 32: Technical Data

    9.Adjust arc length “L/S/M” switch on “L” position; 10.Open the gas valve of the compressed air, and regulate the needed shielding gas flow and pressure; 11.Choose proper carbon rod according to current; 12.Open gas valve on gouging torch, make gas flow towards to work piece; 13.Start Gouging.
  • Page 33 Fig. 5-7-1: Inner structure Item Stock No. Front plate 262005-00205 380V 50HZ,380V 60HZ, 415V 50HZ 740002-00052 380V 50HZ,380V 60HZ, 415V 50HZ Assembly type cable socket 740002-00053 380V 50HZ ,380V 60HZ, 415V 50HZ Rear panel 262011-00113 380V 50HZ ,380V 60HZ, 415V 50HZ Circuit breaker 745011-00001 380V 50HZ ,380V 60HZ, 415V 50HZ...
  • Page 34 Item Stock No. Resonant inductor 220521-00002 380V 50HZ ,380V 60HZ, 415V 50HZ Resonant capacitor 722001-00074 380V 50HZ ,380V 60HZ, 415V 50HZ Capacitor filter inductor 220155-00001 380V 50HZ ,380V 60HZ, 415V 50HZ Polypropylene capacitor 722001-00062 380V 50HZ ,380V 60HZ, 415V 50HZ Current sensor 753001-00020 380V 50HZ ,380V 60HZ, 415V 50HZ...
  • Page 35 Item Stock No. 220629-00011 380V 50HZ Main transformer 264011-00020 380V 50HZ Output diode radiator 735006-00029 380V 50HZ Output diode module 220455-00002 380V 50HZ Diode protection board 745008-00006 380V 50HZ Temperature relay 220281-00008 380V 50HZ Current exchange inductor 264005-00039 380V 50HZ IGBT radiator 264005-00036 380V 50HZ IGBT module...

  • Page 36: 6-Arc400Ii

    6-ARC400II 6-1 System components This series of machines can be equipped with many different accessories. Please refer to Fig. 6-1-1. Welding c a ble Ground c a ble WE LDIN G CURRENT ARC FORCE Wireless r e mote c o ntroller ( Optional) WIRELESS REMOTE CONTRO LLER Wire re m ote co n troller (Option a l) WEL DIN G C UR RENT...
  • Page 37 Front panel REMOTE PROTECTION PANEL ARC L E NGTH ARC FO RCE START C U RRENT WELDING CU RRENT ARC400 Ⅱ Inverter DC ar c We lding M a chine Fig. 6-3-1: Front panel 1.“Amp/Volt” displayer When display mode switch indicates to “Amp”: LCD displays preset current value, min.

  • Page 38: Connections

    GND wire, or make sure the protective GND wire (mixed-colored) of the input power cable is grounded firmly. 6-4 Connections Please refer to “ARC315/400/500/630” the relevant “4-4 Connections” in details. 6-5 Installation and operation Warning! Electric shock is very dangerous. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage.
  • Page 39 REMOTE PROT ECTION PANEL A/ V ARC LE NGTH ARC FO RCE STA RT CU RRENT W E L DING C URR E NT ARC400Ⅱ Inverter D C A r c W e lding Mac h ine Fig. 6-5-1: Installation Input power supply cable installation Please note the size of fuse and circuit breaker in the table below are for reference only.
  • Page 40 Multi voltage 400II Model 3 phase, AC220V/380V/440V, 60Hz Power supply Min. power capacity (KVA) Power network Fuse Input protection (A) Circuit breaker Input cable Output cable Min. cable size (mm ) Protective GND wire Table 6-5-3: Input power supply cable installation- multi voltage Note! Welding machine must be taken special design if it is powered by generator, please contact with manufacturer if you have such needs.

  • Page 41: Technical Data

    Operating guide Warning! Operating the welding machine incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood all the following guides: -“safety rules” -“before commissioning” Warning! Electric shock is very dangerous. As soon as the power source is switch on, the welding electrode is power on.

  • Page 42: Main Components List

    Multi voltage Model 400II 3 phase, AC220/440V, 60Hz Primary power voltage/Frequency 14.4 Rated output capacity (KW) Rated input current (A) 220V input, 320A/32.8V 60% 440V input, 400A/36V 60% Rated duty cycle 11±3 Max. open circuit voltage (V) 20~400 Range of output current (A) Arc-force current (A) 15~200 Arc-starting current (A)
  • Page 43 Item Stock No. 262005-00229 380V/50HZ Front plate 262005-00765 220V60HZ 740002-00048 380V/50HZ Output quick socket 740002-00046 380V/50HZ 740002-00026 220V60HZ 262011-00117 380V/50HZ Rear panel 262011-00495 220 60HZ 745011-00021 380V/50HZ Circuit breaker 745011-00022 220 60HZ 773002-00003 380V/50HZ Water-proof clamp connector 773002-00011 220 60HZ 746001-00011 380V/50HZ 746001-00010 220 60HZ 263065-00097 380V/50HZ...
  • Page 44 Item Stock No. 735006-00029 380V/50HZ Output diode module 735006-00018 220 60HZ Diode protection board 220455-00002 380V/50HZ ,220V60HZ 220281-00008 380V/50HZ Current exchange inductor 220281-00008 220 60HZ 264011-00121 380V/50HZ Output diode radiator 264011-00121 220 60HZ Table 6 7-1: Components list for ARC400II Note: This table is for reference only, and the detail of actual product shall prevail.

  • Page 45: 7-Arc400-3T

    7-ARC400-3T 7-1 System components This series of machines can be equipped with many different accessories. Please refer to Fig. 7-1-1. Welding c a ble Welding c a ble Welding c a ble Ground c a ble FAN C O N TROL Power s o urce De fault p h ase FAN IN D ICATOR...
  • Page 46 Front panel FAN CO NTROL Default p h ase FAN I N DICATOR Ⅱ Ⅲ Protection Protection Protection A/ V A/ V A/ V WELDING CURR E NT START CURR E NT WELDING CU RRENT START C U RRENT WELDING C U RRENT START CUR R ENT ARC400-3T Inverter DCAr c We lding Ma c hine...

  • Page 47: Connections

    Rear panel 3/N/PE～380V 50 H z Ⅲ Ⅱ Ⅰ MODEL A R C 4 0 0 (3T) 3～ STANDARD: GB 1 5579.1-2004 20A/21V ～ 400A/36V 100% 400A 310A =79V 36 V 32.4V =380V 1max =28A 1eff =22A INSULATION DEGREE : 3～50Hz PROTECTION DEGRE E: IP21S...

  • Page 48: Installation And Operation

    Compression type Fig. 7-4-1: Output socket 7-5 Installation and operation Warning! Electric shock is very dangerous. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the machine when - the mains switch is in the “OFF”...
  • Page 49 Model ARC400-3T Power supply 3 phase, 380V/400V/415V/440V±10%, 50/60Hz Min. power capacity (KVA) Fuse Input protection (A) Circuit breaker Input cable 3X10 ＋ Min. cable size (mm ) Output cable － Protective GND wire Table 7-5-2: Input power supply cable installation- single voltage 380V/400V/415V/440V The connection between input power supply cable and switch box (Fig.

  • Page 50: Technical Data

    Operating guide Warning! Operating the welding machine incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood all the following guides: -“safety rules” -“before commissioning” Warning! Electric shock is very dangerous. As soon as the power source is switch on, the welding electrode is power on.

  • Page 51: Main Components List

    7-7 Main components list ARC400-3T Fig. 7-7-1: Inner structure Item Stock No. Front plate 262005-00228 380V/50Hz 740004-00052 380V/50Hz Assembly type cable socket 740004-00057 380V/50Hz Rear panel 262011-00124 380V/50Hz Circuit breaker 745011-00021 380V/50Hz Juction box 740016-00009 380V/50Hz 746001-00017 380V/50Hz Power transformer 763001-00041 380V/50Hz Main control board 210580-00138 380V/50Hz...
  • Page 52 Item Stock No. 722001-00070 380V/50Hz Polypropylene capacitor 264005-00046 380V/50Hz Right IGBT radiator 264011-00047 380V/50Hz Right output diode rediator 264005-00048 380V/50Hz Left IGBT radiator 735007-00089 380V/50Hz IGBT module 220005-00040 380V/50Hz IGBT protection board 722001-00067 380V/50Hz Polypropylene capacitor 720021-00017 380V/50Hz Varistor 735005-00002 380V/50Hz Three phase rectifier module 264011-00048 380V/50Hz Left output diode rediator (former)

  • Page 53: 8-Tig315/400/500/630

    8-TIG315/400/500/630 8-1 System components This series of machines can be equipped with many different accessories. Please refer to Fig. 8-1-1: TIG to rch Welding c a ble Ground c a ble Gouging torch (Optional) Wireless remote controller (Optional) WEL DIN G CURRENT AR C FORC E WIRE LES S RE MOTE CO NTRO LLER Wire rmote controller (Optional)

  • Page 54: Interface

    8-3 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. However, these controls function in exactly the same way. Front panel 4-STEP REMOTE...
  • Page 55 Fig. 8-3-2: Press torch trigger Fig. 8-3-3: Hold torch trigger Fig. 8-3-4: Release torch trigger 2-step operation mode (Fig. 8-3-5): a. Press and hold torch trigger to start welding. Open solenoid valve, shielding gas will flow out to expel air from torch hose (pre-gas time depends on the hose length).
  • Page 56 PRE-GAS UP-SLOPE CURRENT DOWN-SLOPE POST-GAS Fig. 8-3-6: 4-step operation mode 7. “Remote control/ Panel control” switch It is used to connect to the wire remote controller with remote control cable, then user can adjust welding current, arc force current on “Remote control” mode. It is convenient to realize welding control in extended distance. 8.

  • Page 57: Connections

    Rear panel 3/N/PE～380V 50Hz MODEL T IG 5 0 0 3～ STANDARD: GB15579.1-2004 20A/20.8V ～500A/40V 60% 00% Ur=20V 500A 387A =84V 35.5V 20A/10.8V ～500A/30V X 0% 100% 500A 387A =84V 25.5V =440V =33A =25A 1max 1e ff 3～60Hz PROTECTION DG E REE: IP23 I NSULATION D E GREE: MADE IN Fig.

  • Page 58: Installation And Operation

    Remote control socket Socket pin Description REMOTE DEFAULT P H ASE PROTECTION PANEL Torch trigger (TIG mode) START C U RRENT ARC F O RCE WELDING C U RRENT A R C 4 0 0 Inverter DCAr c We lding Ma chine -9V power supply Remote welding current given signal Power GND...
  • Page 59 Workpiece Fig. 8-5-1: Installation Input power supply cable requirement Please refer to “ARC315/400/500/630” the relevant “4-5 Installation and operation” in details. Operating guide Warning! Operating the welding machine incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood all the following guides: -“safety rules”...

  • Page 60: Technical Data

    11.Choose proper carbon rod according to current; 12.Open gas valve on gouging torch, make gas flow towards to work piece; 13.Start Gouging. 8-6 Technical data Please refer to “ARC315/400/500/630” the relevant “4-6 Technical data” in details. 8-7 Main components list TIG315/400/500/630 27 28...
  • Page 61 Item Stock No. 262005-00220 380V/50HZ, 415V 50HZ Front plate 262005-00806 220/380/440V/60HZ 262005-00951 CE model 740002-00048 380V/50HZ,415V 50HZ ,415V 50HZ 740002-00046 380V/50HZ Output quick socket 740002-00026 220/380/440V/60HZ 740002-00026 CE model 262011-00120 380V/50HZ ,415V 50HZ 262011-00525 220/380/440V/60HZ Rear panel 262011-00653 CE model 745011-00021 380V/50HZ ,415V 50HZ Circuit breaker...
  • Page 62 Item Stock No. 220629-00023 380V/50HZ ,415V 50HZ,CE model Main transformer 220629-00148 220/380/440V/60HZ 220521-00007 380V/50HZ ,415V 50HZ,CE model Resonant inductor 220521-00040 220/380/440V/60HZ 722001-00073 380V/50HZ ,415V 50HZ,CE model Resonant capacitor 722001-00074 220/380/440V/60HZ Isolating transformer 220047-00006 380V/50HZ ,415V 50HZ,CE model,220/380/440V/60HZ 220149-00016 380V/50HZ, 415V 50HZ,CE model Current transformer 220149-00098 220/380/440V/60HZ 264005-00028 380V/50HZ...
  • Page 63 Item Stock No. 763004-00041 380V/50HZ ,415V/50HZ Output reactor 740016-00017 380V/50HZ ,415V/50HZ Copper-Al wiring terminal 720041-00010 380V/50HZ ,415V/50HZ Shunt 220431-00008 380V/50HZ ,415V/50HZ Voltage boosting transformer 220263-00005 380V/50HZ ,415V/50HZ HF box 263071-00126 380V/50HZ ,415V/50HZ Middle board 210580-00382 380V/50HZ ,415V/50HZ Main control board 210310-00032 380V/50HZ ,415V/50HZ Drive board...
  • Page 64 Item Stock No. 220431-00006 380V/50HZ ,415V/50HZ Voltage boosting transformer 220263-00005 380V/50HZ ,415V/50HZ HF box 263071-00130 380V/50HZ ,415V/50HZ Middle board 210580-00213 380V/50HZ ,415V/50HZ Main control board 210310-00032 380V/50HZ ,415V/50HZ Drive board 763001-00043 380V/50HZ ,415V/50HZ Power transformer 763001-00060 415V/50HZ 220629-00016 380V/50HZ ,415V/50HZ Main transformer 220521-00029 380V/50HZ ,415V/50HZ...

  • Page 65: 9-Tig1000/1250

    9-TIG1000/1250 9-1 System components Please refer to “TIG315/400/500/630” the relevant “8-1 System components” in details. 9-2 Basic equipments for welding Please refer to “TIG315/400/500/630” the relevant “8-2 System components” in details. 9-3 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual.
  • Page 66 6.“Amp/Volt” displayer mode selection switch 7.SMAW / TIG / Gouging switch Transfer among SMAW / TIG / Gouging. 8.4-step/ 2-step switch (used in TIG welding) Press this button to switch between 2-step and 4-step operation mode, the indicator will lights up accordingly. For torch operation mode, please refer to “TIG315/400/500/630”...

  • Page 67: Connections

    1. Circuit beaker The function of circuit breaker is to protect welding machine and operator by automatic trip to turn-off power supply when overload or short circuit happens to the power source. Normally, the switch flipped to upward means power-on. To start or stop the welding machine is done by the mains switch in the distribution box.
  • Page 68 4-S TEP OVER - HEAT GOU GIN G FAULT SMAW 2-STEP ARC LE N GTH DEFAUL T PHASE ARC FO RCECURRENT ARC ST AR T ING CURRE NT WE LDING CURRE N T TIG1000 Inverter MM A /TIG Arc W e lding M a chine Workpiece Fig.

  • Page 69: Technical Data

    12.Adjust down slope time according to welding current value; 13.Open gas valve of shielding gas regulator, press torch trigger, adjust flow rate, release torch trigger; 14.Press torch trigger, HF arc starting; 15.Welding: 2 step - press and hold torch trigger; 4step - release torch trigger after arc is established; 16.Stop arc: 2 step - release torch trigger, current down slopes until arc stops;...
  • Page 70 Item Stock No. 740002-00052 380V/50HZ ,415V 50HZ Assembly type cable socket 740002-00053 380V/50HZ ,415V 50HZ 745011-00001 380V/50HZ ,415V 50HZ Circuit breaker 740016-00009 380V/50HZ Juction box ,415V 50HZ 746001-00017 380V/50HZ ,415V 50HZ 746001-00019 415V 50HZ Solenoid valve 752001-00014 380V/50HZ ,415V 50HZ 763001-00041 380V/50HZ ,415V 50HZ Power transformer...
  • Page 71 Item Stock No. 740002-00052 380V/50HZ ,415V 50HZ Assembly type cable socket 740002-00053 380V/50HZ ,415V 50HZ 745011-00001 380V/50HZ ,415V 50HZ Circuit breaker 740016-00009 380V/50HZ ,415V 50HZ Juction box 746001-00017 380V/50HZ ,415V 50HZ 746001-00019 415V 50HZ Solenoid valve 752001-00014 380V/50HZ ,415V 50HZ 763001-00041 380V/50HZ ,415V 50HZ Power transformer...

  • Page 72: 10-Tig400Ii

    10-TIG400II 10-1 System components This series of machines can be equipped with many different accessories. Please refer to Fig. 10-1-1: TIG to rch Welding c a ble Ground cabl e WE LD IN G C U RRENT AR C FORCE Wireless r e mote c o ntroller (O p tional) WI REL ESS RE M OTE CONTRO L LE R Wire remote c o ntroller (O p tional)

  • Page 73: Interface

    10-3 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. However, these controls function in exactly the same way. Front panel 4-STEP PROTECTION...
  • Page 74 It is used to adjust arc force current under SMAW. When welding, short circuit between wire and work piece may occur because of operation or droplet transfer. In order to avoid short circuit or wire stick, when arc voltage is low, increase current to shorten the droplet transfer time.

  • Page 75: Connections

    3. Nameplate 4. Cooling fan Cool down the heat components in the welding machine. 5. Gas inlet Connect to Argon gas regulator with gas hose. 10-4 Connections Please refer to “TIG315/400/500/630” the relevant “8-4 Connections” in details. 10-5 Installation and operation Warning! Electric shock is very dangerous.

  • Page 76: Technical Data

    6.Adjust “L/S/M” switch on control panel according to welding cable length; 7.Adjust arc start current, arc force current, welding current according to electrode diameter, welding position; 8.Welding SMAW welding with cellulose electrode: E6010/E6011 and acid electrode: E6013 1.Connect electrode holder with output terminal (-), connect work piece with output terminal (+); 2.Place switch on “ON”...
  • Page 77 — Fig. 10-7-1: Inner structure Item Stock No. 262005-00212 380V/50HZ Front plate 740002-00048 380V/50HZ Output quick socket 740002-00046 380V/50HZ 262011-00117 380V/50HZ Rear panel 745011-00021 380V/50HZ Circuit breaker 773002-00029 380V/50HZ Water-proof clamp connector 746001-00011 380V/50HZ 752001-00014 380V/50HZ Solenoid valve 263065-00097 380V/50HZ Base plate 722001-00070 380V/50HZ Polypropylene capacitor...
  • Page 78 Item Stock No. Three phase rectifier module 735005-00002 380V/50HZ Varistor 720021-00021 380V/50HZ IGBT protection board 220005-00022 380V/50HZ IGBT radiator 264005-00028 380V/50HZ Temperature relay 745008-00006 380V/50HZ Input filter inductor 220479-00011 380V/50HZ Output diode module 735006-00029 380V/50HZ Diode protection board 220455-00002 380V/50HZ Current exchange inductor 220281-00008 380V/50HZ Output diode radiator...

  • Page 79: 11-Remote Controller

    11-REMOTE CONTROLLER 11-1 Wire remote controller (support hot-plug) Note! Match all ARC series (except ARC400-3T, ARC1000/1250), also match all TIG series (except TIG1000/1250). The analog wire remote controller can be used for current regulation of this series power sources. Fig. 11-1-1: Remote controller 1.

  • Page 80: Wireless Remote Controller

    11-2 Wireless remote controller Note! Match all ARC series (except ARC400-3T, ARC1000/1250), also TIG series (except TIG1000/1250) when on non-HF arc strike mode! The wireless remote controller adopts MCU controller to modulate given signal. Signal is transferred to welding machine by welding cable, then modulated and turned into given signal. It needs no external wire comparing with wire remote controller, and easy to use.
  • Page 81 Parameter adjustment range Model WY-315 WY-500 WY-400 WY-630 Item Welding current (A) 20-315 20-500 20-400 20-630 Arc force current (A) 0-160 0-200 0-250 0-250 Table 11-2-1: Parameter adjustment range Operating guide 1.Set the control mode at “Remote control”; 2.Attach the remote controller to the work piece, and ensure good contact; 3.Connect the clamp with electrode holder to supply power to remote controller;...

  • Page 82: 12-Trouble Shooting

    12-TROUBLE SHOOTING Warning! An electric shock can be fatal. Before opening the machine: -Switch it off and unplug it from the mains -Unplug machine from the mains -Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching it back on again -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.

  • Page 83: 13-Care And Maintenance

    13-CARE AND MAINTENANCE Before open the machine Warning! An electric shock can be fatal. Before opening the machine: - Switch it off and unplug it from the mains - Unplug machine from the mains - Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching it back on again - Check to make sure the electrically charged components (e.g.capacitors) have been discharged - Bolts in machine case also work for ground connection.

  • Page 84: 14-Basic Welding Technique

    14-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. 14-1 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 85 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. Similar to Oxygen Acetylene torch welding, TIG welding normally requires two hands and in most instances requires the welder to manually feed a filler wire into the weld pool with one hand while manipulating the welding torch in the other.

  • Page 86: Smaw (Stick) Welding Technique

    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. Tungsten has the highest melting point of any metal, 3,410 degrees Celsius. Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements.
  • Page 87 Core wire Flux coating Gas shield from flux melt Power source Arc with core wire melt Flux residue forms slag cover Weld metal Fig. 14-2-1: Stick arc Core wire Molten pool Protective gas Flux coating Slag Base metal Fig. 14-2-2: ARC ignition Fig.

  • Page 88: Cac-A Technique

    Average Thickness of Material Maximum Recommended Electrode Diameter 1.0 - 2.0mm 2.5mm 2.0 - 5.0mm 3.2mm 5.0 - 8.0mm 4.0mm 8.0 - > mm 5.0mm Table 11-3-1: Electrode size The size of the electrode generally depends on the thickness of the section being welded, and the thicker the section the larger the electrode required.
  • Page 89 Gouging direction α Fig. 14-3-1: CAC-A process 1- Carbon rod 2- Gouging torch chuck 3- Compressed air 4- Work piece 5- Arc L- Carbon rod extension length α-Angle between carbon rod and work piece Welding parameter for CAC-A and effects 12 Power source polarity CAC-A usually choose DC reversed polarity (work piece connect to negative electrode).
  • Page 90 Suitable current/A Carbon rod standard /mm Sectional form shape 3×12×355 200 300 4×8×355 180 270 4×12×355 200 400 5×10×355 300 400 Square 5×12×355 350 450 5×15×355 400 500 5×18×355 450 550 5×20×355 500 600 Table 14-3-1: Carbon rod standard and suitable current •...

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