AOTAI Dura ARC160, Instruction Manual

Page 1: ...carefully this definitely helps to prolong its enduring quality and reliability things which are both essential prerequisites for getting outstanding results Production specification may change without advance notice The model you purchase is for Dura ARC200 Dura ARC200II Please find corresponding models from the Contents Important Please take special note of safety rules and operate as instructio...

Page 2: ...turer also recommends every 3 6 months for regular maintenance of power sources The owner operator is obliged to perform safety inspection at Electric shock can kill severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In MIG MAG welding the wire drive rollers wire feed housin...

Page 3: ...not place your body between your electrode and work cables Equipotential bonding Workpiece grounding earthing Shielding Shield the entire welding equipment and other equipment nearby If electromagnetic ARC rays can burn Wear an approved welding helmet or suitable clothing made from durable flame resistant material leather heavy cotton or wool to protect your eyes and skin from arc rays and sparks ...

Page 4: ...ot metal Remove any combustibles from operator before perform any welding Keep a fire extinguisher readily available Empty containers tanks drums or pipes which have combustibles before perform welding Remove stick electrode from electrode holder or cut off welding wire at contact tip when not in use Apply correct fuses or circuit breakers Do not oversize or bypass them When not welding make Cylin...

Page 5: ...aring Remember wear approved ear protection to protect ears if noise level is high Noise from some processes or equipment can damage Moving parts can injure Stay away from pinch points such as drive rolls Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for servicing and maintenance Reinstall doors panels covers o...

Page 6: ... 200 250 3 1 System components 3 2 Standard equipments for welding 3 3 Control panel 3 4 Interface 3 5 Rear panel 3 6 Installation and operation 3 7 Technical data 3 8 Main components 3 9 Disassembly and reassembly 4 TROUBLE SHOOTING 5 CARE AND MAINTENANCE 6 BASIC WELDING 6 1 TIG welding 6 2 welding Power source connection Welding cables instruction 200II TECHNIQUE technique SMAW STICK technique 1...

Page 7: ...60Hz 1 phase rectifier HF inverter HF transformer Rectifier filter Output Control circuit Fig 1 2 1 Schematic Diagram This series welding machine applies HF inverter technology 1 phase 230V 50 60Hz input volt is rectified by rectifier inverted into HF AC reduced by HF transformer rectified by HF rectifier then output DC power suitable for welding After this process the welder s dynamically respons...

Page 8: ...tions The ARC series can weld most of the metal materials absolutely including the welding of carbon steel stainless steel etc The recommend areas of use as follows Boiler and pressure vessel fabrication Chemical industry Power generation and process Shipbuilding Automotive manufacture Machinery manufacturing Pipeline industry Dura ARC160II 200II 0 15 20 59 U V I A U 20 0 04I Imin Imax Fig 1 3 1 O...

Page 9: ... a very important safety feature When choosing the machine location make sure it is possible for the cooling air to enter and exit unhindered through the louvers on the front and back of machine Any electroconductive metallic dust from e g grinding work must not be allowed to get sucked into the machine 2 3 Power source connection The power source is designed to run on the mains voltage given on t...

Page 10: ...ur machine has certain functions that are not in accordance with this operating manual or vice versa Also certain illustrations may be slightly different from the actual controls on your machine However these controls function in exactly the same way Warning Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described here until you have read and compl...

Page 11: ...nt regulation knob 3 Welding current regulation knob Used for adjusting current value Adjust welding current according to work piece thickness groove shapes welding position electrode diameter etc Welding current decides welding seam penetration and wire molten speed 4 Process selection switch Used for select the desired welding mode two modes are available DC Stick simple TIG 5 Striking current O...

Page 12: ...on this switch on the position ON then the front panel digital meter 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 50 60Hz power supply 3 Cooling fan Cool down the hot components inside welding machine Fig 3 5 1 Rear panel 3 5 Rear panel 2 3 1 11 3 6 Installation and operation Warning If the machine is plugg...

Page 13: ...ician Two machines should not be connected to the same one circuit breaker Check the input voltage circuit breaker input cable in accordance with Table 3 6 1 Specifications of mains input Fig 3 6 1 Connection between input cable distribution box Power socket and using region Table 3 6 2 Power socket selection A 2 plug flat type B 2 plug flat GND round hole type L N C 2 plug flat 8 type 12 E N L E ...

Page 14: ...n flat type K 3 pin round type M Switzerland type N Italy type O Denmark type P Israel type Power socket selection Table 3 6 3 Using region selection Country Type Country Type Asian Pacific region Hong Kong Vietnam Malaysia Indonesia Australia Japan I A B E G I E G C D A B Macau Thailand Singapore India New Zealand Korea E G A B I I K C D E G 13 ...

Page 15: ...K Using region selection Stick welding Stick welding with basic electrode E7016 E7018 Warning Operating the machine incorrectly can cause serious injury and damage Do not use the machine until you have read the following Safety rules Before putting the power source into service Warning If the machine is plugged into the mains supply and the mains switch is in ON position during preparation there i...

Page 16: ...nticlockwise to blow off any dust and dirt 3 Check the tightness of pressure regulator 4 Screw the pressure regulator onto the gas cylinder and tighten it 5 Place the shielding gas cylinder on the solid level surface or use cylinder bracket to prevent from toppling over The connection and operation for gas cooling TIG welding 1 Plug the ground cable into the output socket and fasten it 2 With the ...

Page 17: ...in A Protection class SMAW SMAW 7 31 8 35 9 4 43 5 20 59 20 200 20 250 50 70 IP23S Insulation class COSφ Efficiency Cooling style Dimension W D H mm Weight Kg F 0 98 80 Forced air cooling 389 155 299 7 3 Technical data 3 8 Main components No Tab Item Stock No Quantity Remark 16 Table 3 8 1 Main components 59 80 160 II 250 250 200 II 160 II 200 II 1 1 2 2 745002 00019 745011 00068 735004 00005 7350...

Page 18: ... 00041 8 250 160 II 200 II 10 BB1 745009 00012 1 ALL Temperature relay 11 PG1 755001 00028 1 ALL 12 FA1 Fuse 745007 00045 1 ALL 13 FA2 FA3 Fuse 720022 00049 2 ALL 14 BE401 753001 00074 1 ALL 15 GQ1 Fan 746002 00025 1 ALL Digital display meter Current transformer 210580 00620 1 00 210580 00649 1 250 1 160II 200II 210310 00094 1 160 200 210310 00103 1 250 1 160II 200II 160 2 16 A1 Main board 17 A2 D...

Page 19: ...011 00639 745002 00019 779002 00502 746002 00025 GB_CROSS_COUNTERSUNK_SCREWS M4X12 Cross Recess Pan Head Screw M4 10 Black three combinations Cross Recess Pan Head Screw M5 16 Black three combinations 1 8 14 1 1 1 1 4 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 16 17 10 11 12 13 14 15 16 210340 00637 263065 00397 740002 00080 720031 00105 720031 00128 715002 00014 Radiator Components Bottom Board ...

Page 20: ...ion Quantity 1 2 3 4 5 6 7 8 9 10 11 12 763001 00207 775001 00037 775001 00038 779002 00009 779002 00281 779007 00017 779007 00006 210310 00094 210580 00620 763002 00022 779002 00082 779007 00008 Power Transformer Power Transformer Fixed Plate 1 Power Transformer Fixed Plate 2 GB_CROSS_COUNTERSUNK_SCREWS M4X12 Flat Washer Ф4 Spring Washer Ф4 Drive Board Assembly Main Board Assembly Main Transforme...

Page 21: ...pper Plate Nut Temperature Relay Transistor Housing Output Diode IGBT Tube Rectifier Bridge 5 1 1 1 16 8 8 8 Key components 21 22 23 24 25 26 27 766007 01433 779002 00009 776025 00019 264005 00170 264005 00171 264005 00172 264011 00172 Positive Output Copper Plate Radiator Support IGBT Radiator 1 IGBT Radiator 2 IGBT Radiator 3 Diode Radiator GB_CROSS_COUNTERSUNK_SCREWS M4X12 1 8 3 1 1 1 2 20 ...

Page 22: ...cables are not connected firmly 2 Main control board is damaged 1 Check and fasten the connection 2 Check and replace 3 Circuit breaker on the switchboard trips while in welding 1 The following devices may be damaged IGBT output diode input rectifier bridge etc 1 Check and replace 4 Welding current is not stable or not adjustable 1 Welding current adjustment potentiometer is damaged 2 Main control...

Page 23: ... points Conduct safe check at regular intervals see Safety rules According to actual situation but no less than twice a year dismantle machine side panels by professional maintenance personnel and clean machine inner part with clean compressed air of low pressure Avoid being too close to electronic components by the shower nozzle If a lot of dust has accumulated clean the cooling air ducts Mainten...

Page 24: ... sparks or spatter The intensity of the arc is proportional to the current that flows from the tungsten The welder regulates the welding current to adjust the power of the arc Typically thin material requires a less powerful arc with less heat to melt the material so less current amps is required thicker material requires a more powerful arc with more heat so more current amps are necessary to mel...

Page 25: ...o the weld pool to build up weld reinforcement and create a strong weld Once the arc is started the torch tungsten is held in place until a weld pool is created a circular movement of the tungsten will assist is creating a weld pool of the desired size Once the weld pool is established tilt the torch at about a 75 angle and move smoothly and evenly along the joint The filler metal is introduced to...

Page 26: ...en grinding and cutting While tungsten is a very hard material the surface of a diamond wheel is harder and this makes for smooth grinding Grinding without diamond wheels such as aluminum oxide wheels can lead to jagged edges imperfections or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects Always ensure to grind the tungsten in a longitudina...

Page 27: ...ode core itself acts as filler material the residue from the flux that forms a slag covering over the weld metal must be chipped away after welding SMAW Power Soure c Flux coating Gas shield from flux melt Core wire Arc with core wire melt Weld metal Flux residue forms slag cover Fig 6 2 1 Stick arc 26 Tungsten Diameter Constant Included Angle Degrees Current Range Amps 1 0mm 1 6mm 1 6mm 2 4mm 2 4...

Page 28: ...roviding fluxing elements and deoxidizers creating a protective slag coating over the weld as it cools establishing arc characteristics adding alloying elements Covered electrodes serve many purposes in addition to adding filler metal to the molten pool These additional functions are provided mainly by the covering on the electrode Electrode Selection As a general rule the selection of an electrod...

Page 29: ...tration produces spatter and gives a rough surface finish to the weld An excessively short arc will cause sticking of the electrode and result in poor quality welds General rule of thumb for down hand welding is to have an arc length no greater than the diameter of the core wire Electrode Angle The angle that the electrode makes with the work is important to ensure a smooth even transfer of metal ...

Page 30: ... depend on the method used include sawing punching shearing machining flame cutting and others In all cases edges should be clean and free of any contaminates The type of joint will be determined by the chosen application 29 ...

Page 31: ...MEMO ...

Page 32: ...service facility confirms the existence of a defect covered by this warranty the defect will be corrected by repair or replacement at AOTAI s expense At AOTAI s request the purchaser must return to AOTAI or it s authorized service facility any Goods claimed defective under the warranty FREIGHT COSTS The purchaser is responsible for shipment to and from the AOTAI or it s authorized service facility...