CT312

CT416

INSTRUCTION
MANUAL
PLEASE READ AND KEEP FOR FUTURE
REFERANCE

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 1. General Description.
CT416 is our newly developed multi-function machine. It can be used as Argon Welder, DC
stick welder and air plasma cutting machine. It adopts MOSFET to change frequency of 50/60 Hz
to high frequency AC of 100KHz, then through step down, rectification, pulse adjusting
technology to change it into DC up to the requirements for welding and cutting. Featuring: light,
small, with little power expenditure (improves efficiency more than 30%), with multi-functions.
2. Technical Parameter
Type CT312 CT416
Input Voltage AC220V±10%, 50/60Hz AC220V±10%, 50/60Hz

Input Power Capacity 3.5KVA 4.8KVA

No-load Loss 35W 40W
Duty Cycle 60% 40%
COSφ
0.93 0.93

Efficiency 85% 85%

Insulation Class F F
Cover Protection Class IP21 IP21
Weight 8Kg 11Kg
Dimension 371*155*287mm 423*173*273mm
----------------------- TIG MMA CUT TIG MMA CUT
Input Current 10.2A 15.6A 14.3A 23.5A 28A 29A
Rated Output Current 125A 110A 30A 160A 150A 40A
Current Range 15-120 15-110 10-30 10-160 10-150 10-40
No-load Voltage 58V 58V 220V 64V 64V 260V
Working Voltage 15V 23V 92V 16.4V 26V 96V
Nozzle’s Inside Diameter φ1.0mm φ1.2mm
--------- ------ ---------- ------

Air Pressure --------- ------ 0.4Mpa --------- ------- 0.4Mpa

Gas Flow 2-5L/min ------ 80L/min 2-5L/min ------ 80L/min
Cutting Thickness ---------- ------ 1-8mm ---------- ------ 1-12mm
Way to strike arc H/F Vibration Touch H/F Vibration H/F Vibration Touch H/F Vibration
3. Make Up
3.1 Connection of Input Wire (See Figure I)
3.1.1 Make sure that the power wire on back of welder is connected with AC power 220V.
3.1.2 Connect ground with wire of no smaller than 6mm2 : use a cable to do earth connection from
the grounding screw at back of welder to the ground.
3.2 Connection Of Output Wire (See Figure I)
For TIG
3.2.1 Connect gas supply: tightly butt connect the Argon gas tube with the copper nozzle at the
back of this machine. Gas supply passage should include gas bottle, Argon pressure reducer
and gas tube. The connection part of tube should use hoop to tighten it, in case of gas
leakage and entry of other gas.
3.2.2 Install Argon torch properly according to Figure I, connect the gas-electric integrated

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 connect joint and tele-control on the faceplate properly, and turn clockwise to tight it.

3.2.3 Connect joint should connect with the “+” socket on faceplate. The earth clamp on other
terminal should clamp workpiece.

Figure I Figure 2
3.3 For MMA
3.3.1 Insert earth wire joint into the relative socket on front faceplate, turn it tight.
3.3.2 Insert electrode holder joint into the relative socket on front faceplate, turn it tight..
ATTENTION: The above mentioned is the positive connection for welding of acid electrode. If
for welding of basic electrode or stainless steel electrode should connect conversely.
3.4 For Plasma Cut
3.4.1 Butt connect the tube of compressed air with the copper nozzle on back of this machine. Use
hoop or other thing to tighten it. (The air source should supply suitable pressure, sufficient
flow and need to de dry.)
3.4.2 The other copper nut of cutting torch should connect with the gas-electric integrated joint
and turn clockwise to tighten it. The tele-control pin on cutting torch should connect relative
connect socket and turn tight the connect screw.
3.4.3 Insert the fast connector on earth clamp to the red fast connect socket on machine’s front
faceplate, turn tight.
ATTENTION: when use Argon welding and cutting, should change gas source at first.
4. Operation

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4.1 Use Argon Welding Function
4.1.1 Turn the power button on front faceplate to “ON”. The power indicating light is on, the fan
inside will turn.
4.1.2 Turn shift switch to TIG welding place.
4.1.3 Open the Argon gas switch, adjust gas flowmeter to rated standard.
4.1.4 Press the switch on welding torch, the solenoid valve starts, you’ll hear the sound of high
frequency fire. Meanwhile, there is Argon gas flowing out from torch nozzle. Attention: you
need to press the switch for seconds before first welding, till all the air in gas passage is
ventilated. Then when stop welding, there are still some gas flowing out, especially
designed to protect welding spot before cooling. So should keep the torch at the welding
spot for seconds after the arc is out, then move away the torch.
4.1.5 Choose suitable welding current according to the thickness and technical requirements.
4.1.6 Keep 1-4mm space between wolfram and welding workpiece. Press the control switch on
torch to generate high-frequency electricity discharge between wolfram and workpiece.
After striking arc, the high frequency sparkle inside machine will disappear, then can start
working.
4.2 Use STICK Function
4.2.1 Turn the shift switch to “STICK”.
4.2.2 Switch on power, the power indicating light is on, fan inside starts to turn.
4.2.3 Set relative welding current and choose suitable electrode according to the thickness of
workpiece, then can do welding.
4.3 Use CUT Function
4.3.1 Turn the shift switch to “CUT”.
4.3.2 Switch on power, the power indicating light is on, fan inside machine starts to turn.
4.3.3 Open the air control valve or switch, adjust pressure and gas flow to rated standard.
4.3.4 Press the switch on torch, the solenoid valve starts, you’ll hear the sound of high frequency
fire, meanwhile there is gas flowing out from torch nozzle.
4.3.5 Set relative cutting current according to thickness of workpiece.
4.3.6 Use spray nozzle of cutting torch to touch the cutting workpiece. Press the button on torch to
strike arc. The high frequency arc strike disappears, then can start cutting. After striking arc,
should keep 1mm space between nozzle and workpiece to protect spray nozzle.
5. Attention Points
5.1 Using Condition
5.1.1 Use in dry place, air humidity ≤80%.
5.1.2 Temperature between -10~+40℃.
5.1.3 Avoid using in place with too much dust or erosive air.
5.2 Security Summary
5.2.1 Make sure of fine atmospheric conditions.
It’s small, compact, and with high output current, natural ventilation can’t satisfy the heat
emission of components, so an axial fan is installed inside to cool machine.
ATTENTION: the two sides and shutter for ventilation of this machine shouldn’t be blocked or
covered. Keep 0.3 meters between machine and its surrounding things. Should
assure the atmospheric condition is improved gradually. These are important for
welder’s proper work and working life.

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5.2.2 Never Over load
Users should strictly accord with maximum current of each duty cycle condition to control
welding current, never over load, in case of shortening working life, even burn down.
5.2.3 Avoid over voltage
As for power voltage, should accord with the Form of Main technical parameters, in this case,
can assure welding current between applicable value. If power voltage exceeds the regulated
value, it will damage the components. Users should pay especially attention to this.
5.2.4 There is a earth connection screw at the back of the machine, choose a cable of 10mm2 as
earth wire before work, in case of the generated static electricity or electricity leakage and
causing breakdown.
6. Maintenance
6.1 Use the dry clean compressed air to clear off dust periodically, should clear off dust once a
month if using in the place with much smoke and pollution.
6.2 Decrease the pressure of compressed air to necessity, in case that it may damage little
components inside machine.
6.3 Check the connection inside machine, especially for the plugs and sockets. Tighten the loose
connections. If there is oxidation, should use sand paper to clear off oxidation film and
reconnect it.
6.4 Avoid water entry. If being wetted, should dry it. Use ohmmeter to measure the insulation
condition between connections, and between connection and machine.
6.5 Should place it in the original package in dry place, if won’t use it for long.
7. Repair
ATTENTION: For the following operations, operator need enough professional
knowledge on electronics and general security knowledge. The operator should
received the qualification affirmative.
8. Fix Breakdown
1. Power indicating light 1. Power switch is broken.
and fan don’t work, no 2. Confirm whether input wire is connected with live wire.
output to do welding. 3. Confirm whether input wire is broken somewhere.
1. Maybe the input is connected with 380V, and causes the over
voltage protection start. Connect to 220V, change the Fuse resistor
R30 on power plate, and restart machine.
2. Power indicating light
2. Assistant transformer is broken down.
is on, the fan can’t turn, or
3. Fuse resistor R30 is broken down.
stop turning after second
4. Under voltage protection starts.
turning. No output to do
5. Guiding wire between power plates are loose off, should tighten it.
welding.
6. The 24V Relay in main return circuit on power plate isn’t closed,
or is broken down. Examine 24V power and Relay, if relay is broken
down, can replace it with another one of same type.
3. Fan can turn, abnormal 1. Use multimeter to measure positive & negative voltage between
indicating light isn’t on, power plate and Pin CN7 on MOS plate, should be about DC308V.
but there is no “sha-sha” 1) Broken circuit or poor contact of the pin wires of silicon.
sounds of high frequency 2) One or two of the four ELCCs on power plate (about
discharging electricity, 470UF/450V) leaks electricity, should change it.
scrape wolfram can’t 2. Assistant power can’t supply power normally, should be DC24V.

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strike arc. 3. The pin wires in machine are poorly contacted.
4. Something is wrong with control circuit.
4. Abnormal indicating 1. Torch cable is broken.
light isn’t on, with 2. Earth wire is broken or isn’t connected with welding workpiece.
“sha-sha” sound, no 3. Connection between positive output terminal or Gas-Electric
welding & cutting output. Output of torch and inner part of machine is loose off.
1. Connection between primary winding of arc strike transformer and
power plate is poorly contacted, should tighten.
5. Abnormal indicating
2. Electricity discharge nozzle is oxidized or is too far, should clear
light isn’t on, no
off the oxidation film, or adjust the nozzle distance between 1mm.
“sha-sha” sounds, scrape
3. STICK, TIG, CUT switch is broken, replace it.
wolfram can strike arc.
4. One or two components on high frequency arc strike circuit is
broken, should find out and replace it
1. May due to over current protection, should power off machine, and
restart machine to work normally.
2. May due to over voltage protection, should power off machine and
restart after 2-3 minutes to work normally.
3. May due the breakdown at the inverter circuit, please pull off the
power plug on main transformer of MOS plate ( near to Fan Pin
CN9) restart machine:
1) If the abnormal indicating light is still on, should power off
machine, and pull off the power plug on high frequency arc strike
power source (near to Fan Pin CN8), restart machine:
6. Abnormal indicating
a) If abnormal indicating light is still on, shows one or two field
light is on, no output to do
effect tubes on MOS plate is broken, find out and replace it with the
welding.
same type one.
b. If the abnormal indicating light isn’t on, shows the voltage step-up
transformer in high frequency arc strike circuit is broken, replace it.
2) If abnormal indicating light isn’t on.
a. Maybe the transformer on middle plate is broken, use bridge to
measure the main transformer’s primary inductance and Q value.
K-0.9-1.6Mh, Q>35, if inductance and Q value is small, replace it.
b. Maybe some secondary silicon controlled rectification tubes of
transformer are broken down, replace it with the same type ones
4. Maybe feedback circuit is broken down.
7. Output current is not 1.1K POT is broken, replace it.
stable or can not be 2. The connections are poorly contacted, especially the pins, should
controlled, when welding. examine them.
8. Much splash when do
1. Polarity is wrong when connecting, exchange the earth wire and
STICK welding, hard to
earth clamp wire.
burn basic electrode.
1. Input voltage is low. 2. Poorly contacted or cable is too long.
9. Welding and Cutting 3. Pressure is over high or over low. 4. Spray nozzle isn’t fit with
abilities are poor, with
electrode. 5. Wave-filter capacitor 47μ/450V loses efficiency.
broken arc.
6. Be wetted or poor. 7. Rated current is too low.

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9. Install and Operate of Pressure Reduce Valve
1. Connect tightly the copper nozzle with IN and OUTPUT terminals and seal up.
2. Install the top of meter and seal up.
3. Fix the connect rack on the pressure reduce valve installed part like See the following picture.
4. Turn off rubber screw and fix the valve to the connecting rack like showed in the picture.
5. Aerate air, lift the pressure adjust knob, (Graduation on top of meter is Kg value) Adjust
pressure to regulated (increase towards “+”, decrease towards “-”), then press the adjust knob.
6. The graduation on top of meter is as following showed.
7. Should drain water if water is accumulated too much in air filter bottle.

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