lnverter DC Pulse TIG/NIMA

Welding Machine
AOTAI
ARC-1401L601180/200

TrG-P-160/180/200

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IsO 900il2(M)

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Designed afil Manufadurcd Under a
Quatity Prcgrem Cenif€d bY
China Quality Ceriification Center
to ISO 9q)12000 Requit€ments.
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Operating Manual
Aou.r ELECTRIC Co., LTD
National Leading Manufacturer in Inverter Welding & Cutting Equipments
877 Shunya Ave, High-Tech Developm ent Zone Shandong, 250lOL P.R.China
Tel. 0086-531- 81921006 Fax. 0086-531'88876665
Email:sales@aotaiwelding.com Web: www.aotaiwelding.com
 ARC /TIG-P series

Thank you for your business!

We are glad to have you as our customer and will strive to provide you with
the professional service and reliability in the industry. To find further help
informatiorr and immediate service, please
TEL 0086-531-81921006
FAX 0086-531-88876665
Send Email: service@aotaiwelding.com
Visit website: www.aotaiwelding.com

This Operating Manual has been designed to assist you on the proper use and
operation of Aotai welding machine. Your satisfaction with this product and
its safe operation is our major 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.

Record the following information for Warranty purpose

Where Purchased:

Purchase Date:

Equipment Serial Number:

l"-
 ARC /TIG-P series

Index

I 1. Safety Precautions........ .(1)

,

i
i
F

I
2. PrinCiple &Technical data. (7)
F

3. FeaturesApplications (14)

4. Installation Guide (16)

5. Operating Instruction .... '(19)

o Pyt one: ARC Series Operating instruction """""""""'(19

o , Part two: TIG-P Series Operating instruction "'(21)

6. Repaii & Maintenance. .(24)

Appendix A: EMC Suggestion for installation and use of welder ........(27)

':
Appendix B: Eeedback Form " " ""(29)

This operating manual can be fit for ARC (include ARC140/16011801200) and
TIG-p (include TIG160P/180P/200P) series welding machines. The technical data

are measgred with power supply single 230Y, the data will be changed when you

use different voltage such as220Y and240Y-

 ARC/TIG-P series

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM

POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY PACEMAKER
WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPER,/ITING
BE SARE THAT ONLY QAALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES

For Engine Powered equipments

1.a. Turn the engine offbefore troubleshooting and maintenance work unless the maintenance
work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the

engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine until fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts

when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required
maintenance. Remove guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
l.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler

by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
 ARC/TIG-P series

_il
affi ELECTRT. AND MAGNETIC FTELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields(EMF). Welding current creates EMF fields around welding cables and welding
machines.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should
consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not
known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
2.d.1. Route the electrode and work cables together-Secure them with tape when possible.
2.d,.2. Never coil electrode lead around your body.
2.d.3. Do not place your botly between your electrode and work cables. If the electrode
cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the work piece as close as possible to the area being
welded.
2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK can kill

3.a. The electrode and work (or ground) circuits are electrically "hof'when the welder is on. Do
not touch these "hot" parts with your bare skin or wet clothing. Wear dry hole-free gloves
to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under
electrically hazardous conditions (in damp locations or wearing wet clothingi on metal
structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or accidental contact with the work
piece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder

-2.
 ARC/TIG-P series
DC Manual (Stick) Welder
AC Welder with Reduced voltage control
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun arc also electricdlly "hot".
3.d. Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good,
safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically "hot" parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of
both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall

Tef^\RC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Head shield and filter lens
should conform to ANSI 287.I standard.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and
that of your helpers from the arc rays.
4.c. protect other nearby personnel with suitable, non-flammable screening and/or warn them
not to watch the arc nor expose themselves to the arc rays or to hot spatter or material.

FUMESAND GASES can be dangerous

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes

and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing (see
instructions\on container or MSDS) or on lead or cadmium and plated steel and other
materials or coatings which produce highly toxic fumes, keep exposure as low as possible
.3.
 ARC/TIG-P series

and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required.

Additional precautions are also required when welding on galvanized steel.

5.b. The operation of welding fume control equipment is affected by various factors including
proper use and positioning of the equipment, maintenance of the equipment and the
specific welding procedure and application involved. Worker exposure level should be
checked upon installation and periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and causs injury or death. Always use
enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer's instructions for this equipment and the

consumables to be used, including the material safety data sheet (MSDS) and follow your
employer's safety practices. MSDS forms are available from your welding distributor pr
from the manufacfurer.
5.f. Also see item 1.b.
\rr
\ Hin
[k *ELDTNGAND currING spARKs can cause fire or explosion.

6.a. Remove frehazardous from the welding area.If this is not possible, cover them to prevent

the welding sparks from starting a fire. Remember that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Avoid
welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used
to prevent hazardous situations. Refer to "safety in Welding & Cutting" (ANSI Standard
Z5g.l)and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a{trehazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken
to insure that such procedures will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have been "cleaned". For
information, purchase 'oRecommended Safe Practices for the Preparations for Welding and
.4.
 ARC/TIG-P series
Cutting of Containers and Piping That Have Hazardous Substances", AWS F4.l from the
American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating; cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. W6ar oil free protective garments such
as leather gloves, heavy shirt, high shoes and a cap over your hair. Wear ear'plugs when

welding out of position or in confined places. Always wear safety glasses with side shields
when in a welding area.
6.9. Connect the work cable to the work as close to the weldin g area as practical. Work cables
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cable
until they fail.
6.h. Also see item l.c.
6.i. Do not use a welding power source for pipe thawing.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used

and properly operating regulators designed for the gas and pressure used. A1l hoses,
fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position s"f*ely chained totan undercarriage or fixed
support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage, A safe

distance from arc welding or cutting operations and any other source of heat, sparks, or
flame.
7.d. Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a
cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
7.f. Valve protection caps should be always be in place and hand tight expect when the cylinder
is in use or connected for use.

.5.
 ARC/TIGJ series

FOR ELECTRICALLY powered equipment

8.a. Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
8.b. Install equipmenJ in accordance with the U.S. National Elecfrical Code, all local cedes and
the manufacfurer's recofirmendations.
8.c. Ground the equipment in accordance ri,ith the U.S. National Electrical Code and the
manufacturer's recommendations.

.6.
 ARC/TIG-P series

ARC /TIG-P series block diagram of principle:

AC230V+ l0% I 50l60Hz

Rectifier transformer

Figure 1: Block diagram of principle

This series welding machines applies HF MOSFET inverter technology. l- phase 230Y*.10%

input volt is rectified by rectifier, inverted into HF AC, reduced by HF transformer, rectified
and filtered by HF rectifier, then output DC power suitable for welding. After this process, the
welder's dynamically responsive speed has been greatly increased, so the welder size and
weight are reduced noticeably.

Power source enjoy sound anti-fluctuating ability and high-quality performance during external
context changes. Easy to arc start, stable arc length, pretty weld formation and capability of
continuous adjusting the welding current.

t0

lmax | (A)

Figure 2: TIG mode Volt-Ampere curve MMA mode Volt-Ampere curve

-7.
 ARC/TIG-P series

1. Main technical parameters

> ARC series:

Vlode ARC14O ARC160 ARC180 ARC2OO

rype MOSFET Inverter

Rated input voltage (V) Single phase AC230+ 1 0% 501 60HZ

Rated input frequency (Hz) s0/60

lated input power (KW) 4.4 5.3 6.1 7

Rated input current (A) t9 23 26.5 30.5

Rated output current (A) 140 160 180 2N

lated output voltage (V) 25.6 26.4 27.2 28

lated duty cycle (%) 35

Rated output open-load voltage (V) I 9 9 9

Range of output current (A) 10-140 10-160 r0-180 10-200

Range of output voltage (V) 20.4-25.6 20.4-26.4 20.4-27.2 20.4-28

VIMA arc-force current (A) 50 50 50 50

VIMA arc-starting current (A) 50 50 50 50

Protection class IP21

nsulation class F

Jos<p 0.98

Efficiency (%) 280

Weight (Kg) 9.5

)imension LxWxH (mm) 389x155x29

Table 1: ARC Series Parameter Specification

 ARCiTIG-P series

> TIG-P series welding machine

TIGI6OP TIGI8OP TIG2OOP
Description
Type MOSFET inverter

Rated input voltage AC230V+10% single Phase

Range of input voltage (V) 230xlU/o

Rated input frequencY (Hz) s0/60

4.5
Rated input power (KW) 3.3 3.9

18.1 20.9
Rated input current (A) 15.3

(A) 160 180 200

Rated output current
18
Rated output voltage (V) 16.4 17.2

TIG ff/o 6U/o Wo

Rated duty cycle ff/o
MMA 6ff/o

(V) 45 60 60
Rated output open-load'voltage
TIG 10-160 10-180 10-200
Range of output
current (A) MMA l0-160 10-160
TIG r0.4-164 10.4-17.2 10.4-18
Range of output
voltage (V) MMA I 20.4-26.4 20.4-26.4

MMA arc-force ctrrent (A) I 50 50

MMA arc-starting current (A) I 50 50

Pulse peak current (A) 10-160 I to-tgo 10-200

Pulse base current (A) l0

Down-slope time (S) 5

Pulse frequency QIz) 4

Pulse width 40%

Arc-starting style Higlr-firequency are-starting

Protection class of case Dzl

lnsulation class F

Power factor 0.73

Efficiency (%) >80

Cooling style Air-blast cooling

Dimension 1mm31 389x155x299

Weight (Kg) 9 9.5 9.5

Table 2: TIG-P Series Parameter Specification

Note: TIG160P only have TIG function.

.9.
 ARC/TIG-P series

2. Main circuit diagram

o
(,
o
E
o
Q
a
B -ra
*A -lr,'
-r?

,trddnc lorroJ E

Figure 3: ARC Series Main Circuit Diagram

 ARC/TIG-P series

tt) t, I Er:)
(rurqriu sraras g3)ro1rrdz1'3y1g

o
L G)

(J d

o c
H
o
(J tJr

s --li
d, I.
--ilr'
b
a --l:

60
c
!
d
an

o
ll c
----lt* a

uqcsu sraras IIf,)ralld fIlil

,(1ddng reaocl
l- E
 ARC/TIG-P series

3. Components List

O ARC16O /TIG16OP

No. Tab Item Model Remark

1 SA Power switch KCD2

2 v9. v10 1-phase rectifier module s2sv100

3 EV Fan DP200A2123XSL

4 C1 Polypropylene capacitor CBB22-630V-0.luF+20%

5 RVI Varistor 20D47tK

6 RTl. RT2 Thermistor MF72-0.7D25

7 C4 Eectrolytic Capacitor CD293 - 400V - 47 OUF *20%o

8 Vl-V8 MOSFET 25K2837

9 RV2 Varistor MYG3-I4K95

wsM-160.3.1-11
l0 T7-T2 Main Transformer (EER43x I 5 22:3,with magnetic
tue)
t1 vl1-V18 Diode ESAD92-02

t2 T4 Transformer BSH-6I I8D

t3 w Electromagnet valve zcQ-208-2

t4 K1 Relay G5LA-I4

t5 ST Thermal Switch BR-B2D 95C (open type)

16 Potentiometer wH30-2W-4.7K+5%

T7 APl Upper layer board components wsM-160.3.2.0

l4 AP6 Pulse drive board components wsM-160.3.4.0

Table 3:ARC160 /TIG160P Components List

.12.
 ARC/TIG.P sefles
I

O ARC18O /TIGl8O /ARC2OO /TIG2OOP

No. Tab Item Model Remark

1 SA Power switch KCD2

2 v13. V14 t -phase rectifier module s25V100

J EV Fan DP200A2123XSL
l
4 CI Polypropylene capacitor CBB22- 630V-0. 1 uF +20oh

I 20D47lK
5 RV1 Varistor

t
6 RTl. RT2 Thermistor MF72-0.7D25

7 C4 Eectrolytic Capacitor CD293 - 400V - 47 }uF +20Yo

8 vl-vl2 MOSFET 25K2837

9 RV2 Varistor MYG3-I4K95

wsM-180.3.1-4
10 TI-T3 Main Transformer (EER43x15 l7:3, with magnetic
rine)

il Yt5-Y26 Diode ESAD92-02

t2 T4 Transformer BSH-61I8D
t
tl
I 13 w Electromagnet valve zcQ-208-2
;1

t4 K1 Relay G5LA-14
I
l5 ST Thermal Switch BR-B2D 85 C (open ffie)
il
l6 Potentiometer wH30-2W-4.7K+5%
t

wsM-180
t7 API Upper layer board componentl
,l wsM-200

t4 AP6 Electromagnet valve wsM-160.3.4.0

l1
Table 4: ARC180 /TIG180 /ARC200 /TIG200P Components List

i1
.13
.i
L
 ARC/TIG-P series

) Features & Applications forARC series

ARC series include ARC140/16011801200. Unique patented technologies have been applied,
high reliability and durability. This series welding machines are suitable for welding mild steel,
alloy steel and have perfect welding performance.

Features and benefits:

I Unique patented technologies have been applied, high reliability and durability.
I Small size, light weight, more portable.
1 Quick response to the change of loads.
I Perfect welding performance, deep penetration.
O Automatic Arc force and hot start to perform perfect welding.
OVRD function to make the operation safer.

I Auto protection of over-load and restoration.

I Suitable for welding all kinds of acid and basic electrode.

Applications:
I Construction and installation
lMechanical maintenance
lRepair and mold manufacturing

I Chemical containers manufacture

lPipeline industry
lCans and tand-made crafts

I Offrce fumiture manufacturing

This series welding machine is strict in line with National standard IEC 60974-l and
rEC60971-10.

.14-
 ARC/TIG-P series

) Features & Applications for TIG-P series

TIG-P series welding machines includel60A, l80A and 2004 types, can Perform DC MMA,
DC TIG and DC Pulse TIG (TIGI60P does not have MMA function), suitable for used for mild
steel, stainless steel, Copper, and Titanium welding. This series welder enjoys reasonable static
characteristic and sound dynamic characteristic.

Features and benefits:

i Unique patented technologies have been applied, high reliability and durability.
I Small size, light weight, more portable.
i Quick response to the change of loads.
O Perfect welding performance, deep penetration.

a HF arc-starting, stable arc, less spatter and excellent seam.

I Automatic arc force and hot start to perform perfect welding.
aVRD function to make the operation safer, the noload voltage is around 9V and not affect
arc-starting.

I Auto protection of over-load and restoration.

i Suitable for welding all kinds of acid and basic electrode.

AppHcations:
O Construction and installation

J Mechanical maintenance
I Repair and mold manufacturing
I Chemical containers manufacture
O Pipeline industry
I Cans, and hand-made crafts

O Office furniture supplies

This series welding machine is strict in line with National standard IEC 60t974-l and
IEC60971-10.

15

t'
 ARC/TIG-P series

1. Pre-installation

1.1 Installation Environment

ARC /TIG-P series welding machines are designed for use in adverse
environments. Examples of environments with incrased edverse conditions are:

o 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;
o 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;
o In wet or damp hot locations where humidity or perspiration considerably reduces
the skin resistance of the human body and the insulaJion properties of accessories.
o Environments with adverse conditions do not include places where electrically
conductive parts, in the near vicinity of the operator, which can cause increased
hazard,, have been insulated.

o The gradient of ground must be no more than 10"

o Ensure no wind at the welding position, or use screen to block the wind.
o The distance between welder and wall must be more than 30cm, between welders
more than 10cm to ensure enough heat radiation.
o when using water-cooled torch, must be care of not being frozen.

1.2. Installation Location

Be sure to locate the welder according to the fo[owing guidelines:

o In areas, free from moisfure and dust.
a Ambient temperature between 0 degrees C to 40 degrees C.
o In areas, free from oil, steam and corrosive gases.
o In areas, not subjected to abnormal vibration or shock.
o In areas, not exposed to direct sunlight or rain.

.16.
 ARC/TIG-P series

1.3 Power Source Connections

Warnins
Thermal Arc advises that this equipment be electiically connected by a qualified
electrician.
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after
removal of input power.
DO NOT TOUCH live electrical parts.

o SHUT DOWN welding power source, disconnect input power employing

lockouVtagging procedures.
o Lockout/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.

1.4. Power Supply Requirements

o Input volt must be standard sine wave, effective value 230Y+10%, and frequency
50160H2.
a Unbalance degree of l- phase volt must be no more than 5o%.
'o Power supply:

Product type ARCl40 ARCl60 ARCl80 ARC2OO

Power Supply l- phase AC230Yrl0%o, 50l60Hz

Electricity Grid min.
5.5KVA 6.5KVA 9KVA 9.5KVA
caoacitv

Input volf Fuse 50A

Prurt,urru[ Circuit
60A
Breaker
lnput volt 2.5mm2 2.5mm2 4m# 4mm2

Cable size Output volt 16mm2 25mtrl

l

il Ground lead 2.51'ntr1

Table 5: ARC Series Power Supply Connection

. t7.
 ARC/TIG-P series

TIGI6OP TIG18OP

1- phase AC 230y+10o , 50/60H2

5.5KVA 6.5KVA 7.5KVA

Cable size

No'e :'0. .r:; [Jl;: ff:;T:;l'"'fl

":;;: i]1..... ",,,
2.Installation:
The input power supply of this series of welding
machine is 1- phase AC 230v*loyo,
50/60H2' The switchboard with circuit breaker is
needed. connect the ground cable
firmly.

3. Machine Assembling Guide:

a In MMA mode
(1) Connect the welding cable firmly.
(2) Turn on the power switch of the welding machine.
(3) Connect the input I phase power supply cable
with the switchboard, then switch
on.
O In TIG mode
(1) connect the ground cable to output terminal
(+), and connect TIG torch to output
terminal (_).
(2) connect gas hose of welding machine to gas
regulator.
(3) Turn on the power switch of the welding
machine.
(4) connect the input 1 phase power supply
cable with the switchboard, then switch
on.

Attention: cut offthe power supply before connecting

the welding cable. put the plug into the
socket, then turn it clockwise to ensure good connecfion
between the plug and sockel
.18.

fL
 ARC/TIG-P series

) Part one: ARC Series Operating Instruction

1. Front panel illustration

The front panel is shown as Figure 5:

Figure 5: Front panel

(1) Protection on LED

Light on yellow and stops welding automatically while in overheat, but will not light
up when normally welding.
(2) Power on LED
Indicate whether the machine is connected to power supply.

(3) Welding current adjustment knob

Used for adjusting current value.
(4) Welding cable quick socket (-)

Used for connecting the welding machine and workpiece.

(5) Welding cable quick socket (+)

Used for connecting the welding machine and electrode holder.

.19.
 ARC/TIG-P series

2. Rear panel illustration

The rear panel is shown as Figure 6:

Figure 6: Rear panel

(1) Power switch
Switch for 230V+10% single-phase AC power
Turn on this switch (on the position: "O*"), then the Power on LED lights up, and
the fan runs.
(2) Power supply cable

The mixed-colored wire must be firmly grounded; the rest wires connect to 1- phase
AC 230V+10% l50l60Hz power supply.

(3) Cooling Fan

Coql down the hot components inside welding machine

3. Wetding Parameters Guide

Workpiece thickness (mm) <1 2 3 4-5

Electrode diameter (mm) 1.5 2 3.2 3.2-4

Welding current (A) 20-40 40-60 90- 1 10 90- 150

Table 7: MMAWelding Parameters Guide

.20.
ts
) Part two: TIG-P Series Operating Instruction

1. Front panel illustration

Take TIGl60P i200P for example, the front panel is shown as Figure 7:

3 2

*$\ 4
/o o-<N
#,***,',n*"il*,1" ' EotB

Figure 7: TIGI60P Front panel TIG180P 1200P Front panel

(1) Protection on LED

Light on yellow and stops welding automatically while in overheat, but will not light
up when normally welding.
(2) Power on LED
Indicate whether the machine is connected to power supply.

(3) Welding current adjustment knob

Used for adjusting current value.
(4) "DC / Pulse" switch
Used for switching from DC TIG to DC Pulse TIG.. 66-" indicates DC TIG welding,
and "IJL'indicates DC Pulse TIG welding.
(5) "MMA / TIG" switch

Used for switching from DC MMA to DC TIG.. "-" indicates DC MMA welding,

un6*A-' indicates DC TIG welding.

Note: if you select MMA function, please refer to the part one of Operating
instruction.
-2t.
 ARC/TIG-P series

(6) Welding cable quick socket B

Connect TIG torch.

(7) TIG control socket E

Connect the control plug of TIG torch.
(8) Welding cable quick socket (-)
o In MMA mode, connect the workpiece.
o In MMA mode, connect TIG torch.
(9) Welding cable quick socket (+)
oIn TIG mode, connect the workpiece.
O In MMA mode, connect the electrode holder.

2. Rear panel illustration

The rear panel is shown as Figure g:

Figure 8: Rear panel

(1) Power switch
Switch for 230V+10%V single-phase AC power sqply.
' Turn on this switch (on the position: "ONP), then the power
on LED lights up, and
the fan runs.

@ Power supply cable

The mixed-colored wire must be firmly grounded; the rest wires connect
to l- phase
AC 230V+10% l50l60Hz power supply.

(3) Our,n,", €

.22.
 ARC/TIG-P series

Connect gas regulator with gas hose.

(4) Cooling Fan
Cool down the hot components inside welding machine
3. TIG welding procedure
TIGI60P series is high-frequency arc-starting,2-step mode, convenient to operate. The
procedure is as follows:

In DC Pulse TIG, the pulse frequency is 4Hz, and the peak current ratio is 40%o.

4. Welding Parameters Guide

o TlcWelding Parameters Guide

A o

*l I*
@

Tungsten
Sheet
electrode ly'ire diamete: Welding Gas flow rate Clearance Clearance
thickness
(mm)
diameter (mm) rurrent (A) (L/min) (mm) form
(mm)
0.4 1.0-1.6 0-1.0 5-30 4-5 1 o.@
1.0 1.0-1.6 0-1.6 10-30 5-7 1 o.@
1.5 1.0-1.6 0-1.6 50-70 6-9 I @
2.5 t.6-2.4 t.6-2.4 70-90 6-9 I @
3.0 t.6-2.4 1.6-2.4 90-120 7-t0 t-2 @.@
4.0 2.4 1.6-2.4 120-150 10-15 2-3 @.@
5.0 2.4-3.2 2.4-3.2 120-r80 10-15 2-3 @.@
6.0 2.4-3.2 2.4-3.2 150-200 10-15 3-4 @.@

Table 8: TIG Welding Parameters Guide

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L,
l.
l

t,
ARC/TIG-P series

IYARNING: Have a qualifted electrician do the maintenance and trouble shoating work
Turn the input power ffi using the dhconnect switch at the fuse box before wo*ing inside
the machine.

1. Cautions:
o Rivet equipment name tag on the specified area of the case, otherwise the inside parts
will possibly be damaged.
o Connect welding cable to terminals firmly, otherwise the terminals will be burn out
which will cause the instability of welding process.
o Avoid welding cable and control cable being broken, and prevent welding machine from
' being short circuit.
o Never let welding machine be bumped into or stacked up by heavy objects.
o Ensure good ventilation
o Under high temperature, if work with large current for long period, welder may shut
down automatically due to thermal protection acts .At this point, let the machine runs
under open-load for a few minutes, and it will be automatically recover.
o Under high temperature, if work with large current for long period, welder may shut
down automatically due to air switcher trips. Cut offthe power supply to the electricity
switchboard on frame, and wait for 5 minutes to turn on the air switcher on the power
source fist then connect the power supply to the electricity switchboard on frame. And
leave the machine runs under open-load condition for a while.
o After welding, cut offthe gas supply and the power supply.

2. General maintenance

o Remove dust from power resource with pressure air by qualified individuals every 3-6
months. Check if the jointers are loose.
o Check regularly if cables are worn out, knobs are loose, and components of panel are
damaged.
o Check regularly if cables are tightly connected to cable connecting terminals in case of
terminals being bumt out.
o Clean and replace Contact Tip and Tungsten Electrode in time.

.24.
 ARC/TIG-P series

3. Procedure for regular checking prior to maintenance

o Check if atl front panel switches are on the proper.positions.
o Check if the input volt has the phase missing, and range are between20T-253Y.
o Check if the input cable is connected correctly and firmly with the power source.
o Check if the ground lead is connected correctly and firmly.
o Check if the welding cables are connected correctly and firmly.
o Check if gas regulator is in good situation and gas flows out normally.

WARNING: Have a qualifted electrician do the tnaintenance and trouble shoofing work
Turn the input power olfi, ustng the disconnect switch at the fuse box before working inside
the machine. Don'l open up case uninstructed, the max volt inside machine is 400V Never
discharge high volnge tu welder case with welding torch! Shut down powq soutce before
changing orrepairing welding cable or torch

.25-

L
 ARC/TIG-P series

Irb TROUBAL CAUSES -WHATTO DO

l)Power switch is damaged

l)Check Power switch anc
Power on LED does not ligh' the fan
rp, fan does not ilfl, n( Z)No electricity
grid
on the
Z)Check pow€r srypty on the
I
)utput when machin( rlectricity
})Short circuit in the power
electricity grid
iwitches on.
supply cable
3)Check the comection ol
Dower suoolv cable
l)Tum off the machine, mc
[ )Over-current protection
lower on LED lights up, Z)Ground cable is not well
turn on again after I
minute.
2 rot Protection on LED, connected to the workpiece
ro output. ))Upper layer board ir
Z)Check the connection ol
ground cable
damaged
l)Reolace
l)The following devices ma1
1)Check and replace
be damaged: MOSFET Z)If MOSFET is damaged
lircuit breaker on the Output diode module, etc.
check is Resistor (10C2
a
J lwitchboard trips while ir 2)Pulse drive board ir
welding. damaged
3KO), and Voltage
3)Input rectifier bridge is
regulator tube (IN4148
3V) is damaged
damased
l)Welding Current adjustmenr
potentiometer on front
Welding current is
panel is damaged
4 Z)Main control board is lheck and replace
nstable.
damaged
3) Bad connection yithin the
weldins machine
l)Welding Current adjustmen
potentiometer on fron
Welding current is
5
rot adjustable.
panel is damaged lheck and replace
Z)Main control board il
damaeed

Table 9: Troubleshooting Table

.26.
 ARC/TIG-P senes

l. General
The user is responsible for installing and using the arc welding equipment according to the
manufacturer's instructions. If electromagnetic disturbances are detected, then it shall be the
ii
responsibility of the user of the arc welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial action may be as simple
as earthling the welding circuit, see note. In other cases it could involve constructing an
electromagnetic screen enclosing the welding power source and the word complete with
associated input filters. In all cases electromagnetic disturbances shall be reduced to the point,

where they are no longer troublesome.

NOTE: The welding circuit may not be earthedfor safety reasons. Changing the earthling
affangements should only be authorized. by a person who is competent to assess

whether the changes will increase the risk of iniury.

2. Assessment of area
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into account:
l) Other supply cables, control cables, signaling and telephone cables, above, below and
adjacent to the arc welding equipment;
2) Radio and television transmitters and receivers;
3) Computer and other control equipment;
4) Safety critical equipment, for example guarding of industrial equipment;
5) The health of the people around, for example the use of pacemakers and hearing aids;
6) Equipment used for calibration or measurement;
7) The immunity of other equipment in the environment is compatible. The user shall ensure
that other equipment being used in the environment is compatible. This may require
additional protection measures;
8) The time of day that welding or other activities ard to be carried out.
3. Methods of reducing emissions
1) Public supply system

Arc welding equipment should be connected to the public supply system according to the
manufacturer's recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the public supply system. Consideration should

.27.
 ARC/TIG-P series
be given to shielding the supply cable of permanently installed arc welding equipment, in
metallic conduit or equivalent. Shielding should be electrically continuous its length. The
shielding should be connected to the welding power source so that good electrical contact
is maintained between the conduit and the welding power source enclosure.
2) M4intenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to the

manufacturer's recommendations. All access and service doors and covers should be
closed and properly fastened when the arc welding equiprnent is in operation. The arc
welding equipment should not be modified in any way, except for those changes and
adjustments covered in the manufacturer's instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained according to the
manufacturer' s recommendations.
3) Welding cables
The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
4) Equipotent bonding
Bonding of all metallic components in the welding installation and adjacent to it should be
considered. However, metallic components bonded to the word piece will increase the risk

that the operator could receive an electric shock by touching these metallic components
and the electrode at the same time. The operator should be insulated from all such bonded
metallic components.
5) Earthling of the work piece
Where the work piece is nor bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example ships hull or building steelworlg a connection
bonding the work piece to earth may reduce emissions in some, but not all instances. Care
should be taken to prevent the earthling 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 a direct connection to tire 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 of the entire welding installation may be
considered for special applications.

-28.
 ARCITIG-P series

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.Contact information
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Tel: +86-53 l-8 I 921006,
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www.aotaiwelding.com
E-mail: sales@aotaiwelding. com

info@aotaiwelding. c om

29.

f
 TIG WELDING TORCH
ArgonArc Welding Gun
Description
1, Application
It is partial TIG welder, helps the TIG welder to weld.
The main characteristic is clamping the tungsten, conducting electricity and feeding the protective gas.
2. Attention
a. The working current should be not more than rated welding current
b. Strictly follow the welder's load sustained rate.
c. Steel cylinder outlet pressure between 0.1-0.3MPa
d. The water pressure for water cooled torch between 0.1-0.2MPa
3. The way to use
a. Choose the right tungsten electrode and collets; put the tungsten electrode on the tungsten electrode pointing machine to
get an appropriate point (cheek the attached form 1 andZ)
b. Choose thenozzle followthe formula:
Dn:(2.5-3.5)Dw
Dn:Nozzle lD
bw:Tungsten ID
c. Assembly the tungsten, collets, nozzle on the welding torch and start to weld in right welding current.

FORM 1

DC (A)
AC (A)
Electrodeo Electrode (+)
Tungsten ID ThoiiateG Thoriated- -.
(mm) Pure- Tungsten & Pure- Tungsten & Pure- Thoriated- Tungsten &
Tungsten Cerium- Tungsten Cerium- Tungsten Cerium- Tungsten
Tungsten Tungsten
0.5 2-20 2-20 2=-15 2-70
1.0 t0-75 l0-75 I 5-55 t5-70
1.6 40-130 60-150 t0^20 t0-20 45-90 60-r25
2.0 75-180 100-200 t5-25 t5-25 65*725 85-160
.. 1- 2.5 130-230 160-2s0 r7-30 .17^40 80-140 120-210
3.2 160-310 225-330 20-35 20-35 150-190 150-250
4.0 2754s0 3s0-480 30-50 30-50 180-260 240-350

FORM 2
Tungsten ID Tip ID TipAngle Steady Pulse
(mm) (mm) (") Cunent(A) Cunent(A)
1.0 0.125 12 2-15 2-25
1.0 0.25 20 s-30 5-60
1.6 0.5 25 8-s0 8-100
1.6 0.8 30 l0-70 10-140
2.4 0.8 35 t2-90 12-180
2.4 l.l 45 l5-1s0 1s-250
3.2 t.l 60 20-200 20-300
3.2 1.5 90 25-250 25-3s0