1.catalog Tandem 1250+tractor-Aotai

A 0 TA l
150°7+ - 300°7+ efficiency improvement

Steel Fabrication • Wind Tower • Bridge • Pressure Vessel
TANDEM SAW SYSTEM
DIGITAL SUBMERGED ARC WELDING MACHINE
TANDEM SAW system is the welding equipment with high efficiency, high quality and low
cost. It takes advantage of anterior wire's DC arc to provide deep penetration and high
welding speed. Meanwhile, it also takes advantage of posterior wire's AC arc to improve the
appearance, formation and surface finish of the welding seam. It is the best choice for
welding medium and thick plates.
Effectively reduce the number of welding layers and passes, as well

as inter-layer cleaning and other auxiliary time. The total efficiency
can reach 3 times of single wire welding;
The best choice for thick plate welding, which can realize welding
medium plate less than 25 mm without back chipping and grooving.
Reduce the welding costs more than 60%.
Under the condition of same welding heat input, twin-wire SAW

enjoys higher deposition rate and welding speed. ASAW 1250 II
The DC arc of anterior wire ensures penetration, and the AC arc of
posterior improves welding seam formation. The parameters of two
wires can be adjusted separately, which brings convenient
parameters presetting. It can meet more technical requirements.
It enjoys flexible configuration, which can be used to work with a

tractor, or form an automatic welding system.
Two full digital inverter power sources make it enjoy high efficiency
and energy saving.
ASAW 1000 ACDC
DC and AC power sources can work simultaneously or individually,
which meets different requirements of welding.
Tandem tractor
For more detailed

AOTAI ELECTRIC CO.,LTD
SMART STABLE POWERFUL information, visit
PUBLICATION 01 | ISSUE DATE 2/2022 www.aotaiwelding.com
© AOTAI GLOBAL, INC. ALL RIGHTS RESERVED.
WELDING POWER SOURCE AND ACCESSORIES
ASAW 1000 ACDC

High speed DSP control system realizes precise digital
control during welding, and improve welding seam formation.
Controllable AC square waveform output [AC frequency, duty

cycle, DC bias] can control the penetration and deposition
rate of welding seam.
Perfect parameters setting of arc starting and stopping solves

problems of low arc starting success rate and large crater of
arc stopping.
CC and CV modes
Synergic operation of twin-wire tandem system
Polarity can be swithed easily with no wiring change
DC and AC outputs, control at will

INPUT OUTPUT
Independent air duct design
cc
100% duty cycle 3 cv
Secondary inverter design, energy saving
Adopt square wave to precisely control commutating Continuous adjustment of ac parameters brings flexible
current, which enjoys quick commutation, high arc control of welding penetration and deposition rate,
ignition success rate and stable AC arc. which offers more options for twin-wire technology.
Sine wave commutation time
Square wave commutation time
Current
DC + Wire to positive pole 50% balance 25% balance

Deepest penetration Penetration decreases, tractor Penetration decreases, tractor
One speed increases speed increases, shallow
One cycle
cycle welding pass
1/50S
50Hz Sine wave 50Hz square wave
AC arc control AC parameters adjustment
For more detailed

information, visit
SMART STABLE POWERFUL
PUBLICATION 01 | ISSUE DATE 2/22
www.aotaiwelding.com
ASAW 1000 ACDC
Fill and cover:
balance 25%, bias -25%
Root:
balance 75%, bias +25%
Traditional DC SAW AC square wave SAW

Two sets of test workpiece adopt same technological parameters. Compared with traditional technology, AC
square wave SAW saves one welding pass through AC parameters adjustment.
As for the accumulated heat input, sample A is 84.82 kJ/mm and sample B is 77.22 kJ/mm. The latter
decreased by 8.96% compared with the former.
Through adjusting AC square wave parameters, more heat input is distributed to base metal during root
welding to get a deeper penetration; during fill and cover welding, more heat input is distributed to the wire to
get a higher deposition rate.
PRODUCT SPECIFICATIONS
ASAW 1000 ACDC
Primary power voltage /Frequency 3 phase, AC380V/400V±10%, 50Hz
Rated input power (KW) 55
Rated input current (A) 82/78
Welding current range (A) 50~1010
Welding voltage range (V) 22~44
Rated duty cycle (%) 100
Open circuit voltage (V) 90
Wire diameter (mm) Ф3.0 ~ Ф6.0
Dimensions (mm3) 1040×500×720
Weight (Kg) 165
Protection/Insulation class IP21S / H
Input: AC Sine Wave
AC Wave form
Output: AC Square Wave
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ASAW1250II
High speed CPLD and MCU twin-core control system realizes
precise digital control during welding, and improve welding
seam formation.
DC high current output brings extremly deep welding

penetration.
CC and CV modes, the welding wire with diameter of 1.6 -

6.0 mm can be applied.
100% duty cycle
The parallel connected double inverters design brings great

energy saving.
Trouble self-diagnosis system, error code display
INPUT OUTPUT
3 cc
cv
ASAW1250II
Primary power voltage /Frequency 3 phase, AC 380V/400V ± 10%, 50Hz
Rated input power (KW) 75.7
Rated input current (A) 115/109.3
Welding current range (A) 50~1250
Welding voltage range (V) 20~50
Rated duty cycle (%) 100
Open circuit voltage (V) SAW: 92
Efficiency (%) ≥89
Wire diameter (mm) Ф1.6 ~ Ф6.0
Dimensions (mm3) 785×360×848
Weight (Kg) 100
Protection/Insulation class IP21S / H
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TANDEM TRACTOR
MCU control system realizes digital precise control during welding.
Independent control of anterior and posterior welding wire meets needs of

all technologies.
Accessible to save 10 sets of welding parameters respectively

Twin welding heads tractor can be connected to AC and DC power
sources.
Equipping the function of short-circuit test between wire and workpiece

when it is standby to ensure tractor travelling stably.
4WD + encoder wire feeder motor realize digital motor control to provide a
more precise and stable wire feeding speed.
4 rollers (twin-gear) drive offers a more stable wire feeding drive.
Twin thick wires design, 3.0 - 5.0 mm wire can be adopted.
Cross carriage provides a convinient welding seam location.
Tandem tractor
Rated input voltage of traveling mechanism DC110V
Rated input voltage of wire feeder motor DC110V
Welding speed range 20～150cm/min
Wire feeding speed range 25～250cm/min
Wirefeeding motor speed 6000 RPM
Suitable Wire Diameter Ф3.0～Ф5.0mm
Lifting height of crossbeam 100mm (-50mm -> +50mm)
MAX distance of two heads 600mm
Rotation angle of cross beam around column ±90°
Head rotation angle ±45°
Deflection angle of welding gun ±45°
Flux capacity 6L×2
Wire coil capacity 25Kg×2
Boundary dimension (L × w × h) 1100×900×770mm
weight 75Kg(Without welding wire)
For more detailed

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AUTOMATION SYSTEM CONFIGURATION

MCU digital control system realizes digital precise
control of welding.
Independent control of anterior and posterior welding

wires meets demands of all technologies.
When it stands by, the short-circuit test function between

wire and workpiece ensures tractor travelling stably.
4WD + encoder wire feeding motor realize digital motor

control to provide more precise and stable wire feeding
speed.
4 rollers (twin-gear) drive, more stable drive.
Twin thick wires design, 3.0 - 5.0 mm wire can be

adopted.
It can be started and stopped synchronously with

automation equipment through linkage control.
Main welding head technical parameters:

Wire feeding speed range 25～250cm/min
Suitable wire diameter Ф3.0～Ф5.0mm
Wire feeding motor speed 6000 RPM
Power voltage 110VDC
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RECOMENDED CONFIGURATION
TRACTOR SYSTEM CONFIGURATION

Configuration 1 - cost-effective
AC power source ASAW1000ACDC

DC power source ASAW1250II
Tandem tractor(MZK-IVs control box
TANDEM1250&TRACTOR recommended configuration

Item Model Qty Remarks
Power source ASAW1000ACDC 1
Power source ASAW1250II 1
Tractor MZCs 1 For tractor
Wedling cable 70mm2*15m 2 ASAW1000ACDC
Ground cable 70mm2*2m 2 ASAW1000ACDC
Welding cable 95mm2*15m 2 ASAW1250II
Ground cable 95mm2*2m 2 ASAW1250II
Control cable 16m 2
Configuration 2 - highly flexible
AC power source ASAW1000ACDC*2

Tandem tractor(MZK-IVs control box）
TANDEM1000&TRACTOR recommended configuration

Tractor MZCs 1 For tractor
Wedling cable 70mm2*15m 4
Ground cable 70mm2*2m 4
Control cable 16m 2
For more detailed

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RECOMENDED CONFIGURATION
AUTOMATION SYSTEM CONFIGURATION

Confoguration 1 - cost-effective
AC power source ASAW1000ACDC

DC power source ASAW1250II
Twin thick wires twin welding heads
Control box | [MZK-IVsz]
TANDEM 1250 & automation system recommended configuration

Power source ASAW1250II 1
Machine head Twin wire twin arc 1
Control box MZK-IVSz 1 For automation system
Wedling cable 70mm2*15m 2 ASAW1000ACDC
Ground cable 70mm2*2m 2 ASAW1000ACDC
Wedling cable 95mm2*15m 2 ASAW1250II
Ground cable 95mm2*2m 2 ASAW1250II
Control cable 16m 2
Wire spool 2
Wire reel shaft 2
Confoguration 2 -- highly flexible
AC power source ASAW1000ACDC*2

Twin thick wires twin welding heads
Control box | [MZK-IVsz]
TANDEM1000 & automation system recommended configuration

Machine head Twin wire twin arc 1
Control box MZK-IVSz 1
Wedling cable 70mm2*15m 4 For automation system
Ground cable 70mm2*2m 4
Control cable 16m 2
Wire spool 2
Wire reel shaft 2
INDUSTRIAL APPLICATION
WIND POWER INDUSTRY - WIND POWER TOWER
Welding time
Under the condition of same
6.69 welding energy input, the welding
efficiency of twin-wire is improved
2.32 nearly 2 times.
Welding process
Welding speed
Thickness (mm) Power source Wire Diameter (mm) Current (A) Voltage (V) (cm/min)
DC 750 30
30 Ф4.0 80
AC 650 32
For more detailed

information, visit
STEEL FABRICATION INDUSTRY - H-BEAM

Full penetration technology without grooving and back gouging
Web:25mm
Technical
demands
Groove processing time comparison

(workpiece length: 9m)
0.8
0.6
Time/h
0.4
New technology saves this procedure
0.2
0
Traditional multi-layer New technology
multi-pass welding
Groove processing time comparison

(workpiece length: 9m)
1.5
Time/h
1.0
New technology saves this procedure
0.5
0
Traditional multi-layer New technology
multi-pass welding
Welding quality: Welding advantages:

Welding seam 100%UT test; Save groove processing and back gouging
meets quality qualified requirements of procedures.
GB11345; Seam quality meets the Save more than 60% of time.
requirements of first-level seam. Reduce more than 60% of cost.
Welding process
Welding speed
DC 950~1000 33~34
20 Ф4.0 55~60
AC 600~650 37~38
For more detailed

information, visit
STEEL FABRICATION INDUSTRY - GANTRY WELDING + TRACTOR TYPE
Application effect: Compared with GMAW that needs groove filling

and back gouging, it enjoys more than 2 times higher manufacturing
efficiency and less than 40% lower welding cost of GMAW.
Welding process
Thickness (mm) Power source Wire Diameter (mm) Current (A) Voltage (V) Welding speed
(cm/min)
DC 850~900 33~34
18 Ф4.0 55~60
AC 600~650 37~38
For more detailed

information, visit
HEAVY MACHINERY INDUSTRY - PRESS DRUM OF ROAD ROLLER
Welding process
Welding speed
DC 850 31
30 Ф5.0 45~55
AC 750 34
HEAVY-DUTY VEHICLE INDUSTRY - WHEEL/HUB
Welding process
Thickness (mm) Power source Wire Diameter (mm) Current (A) Voltage (V) Welding speed
(cm/min)
DC 750 31
25 Ф3.2 40~50
AC 450 33
For more detailed

information, visit
SHIPBUILDING INDUSTRY - CORRUGATED BULKHEAD
The full penetration butt joint welding of 25mm plates without grooving
and back gouging.
Welding process
Welding speed
DC 950~1000 33~34
30 Ф4.0 50~55
AC 600~650 37~38
For more detailed

information, visit

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A 0 TA l

150°7+ - 300°7+ efficiency improvement

Effectively reduce the number of welding layers and passes, as well

Under the condition of same welding heat input, twin-wire SAW

It enjoys flexible configuration, which can be used to work with a

For more detailed

ASAW 1000 ACDC

Controllable AC square waveform output [AC frequency, duty

Perfect parameters setting of arc starting and stopping solves

Synergic operation of twin-wire tandem system

Polarity can be swithed easily with no wiring change

DC and AC outputs, control at will

Square wave commutation time

DC + Wire to positive pole 50% balance 25% balance

50Hz Sine wave 50Hz square wave

AC arc control AC parameters adjustment

For more detailed

Traditional DC SAW AC square wave SAW

For more detailed

DC high current output brings extremly deep welding

CC and CV modes, the welding wire with diameter of 1.6 -

100% duty cycle

The parallel connected double inverters design brings great

Trouble self-diagnosis system, error code display

For more detailed

Independent control of anterior and posterior welding wire meets needs of

Accessible to save 10 sets of welding parameters respectively

Equipping the function of short-circuit test between wire and workpiece

4 rollers (twin-gear) drive offers a more stable wire feeding drive.

Twin thick wires design, 3.0 - 5.0 mm wire can be adopted.

Cross carriage provides a convinient welding seam location.

For more detailed

AUTOMATION SYSTEM CONFIGURATION

Independent control of anterior and posterior welding

When it stands by, the short-circuit test function between

4WD + encoder wire feeding motor realize digital motor

4 rollers (twin-gear) drive, more stable drive.

Twin thick wires design, 3.0 - 5.0 mm wire can be

It can be started and stopped synchronously with

Main welding head technical parameters:

For more detailed

TRACTOR SYSTEM CONFIGURATION

AC power source ASAW1000ACDC

TANDEM1250&TRACTOR recommended configuration

AC power source ASAW1000ACDC*2

TANDEM1000&TRACTOR recommended configuration

For more detailed

AUTOMATION SYSTEM CONFIGURATION

AC power source ASAW1000ACDC

TANDEM 1250 & automation system recommended configuration

Confoguration 2 -- highly flexible

AC power source ASAW1000ACDC*2

TANDEM1000 & automation system recommended configuration

WIND POWER INDUSTRY - WIND POWER TOWER

For more detailed

STEEL FABRICATION INDUSTRY - H-BEAM

Groove processing time comparison

Groove processing time comparison

Welding quality: Welding advantages: