AOTAI Dura ARC160 Manual de usuario
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 great features of your
new product. Meanwhile, please remember safety rules and operate as
instructed.
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:
Dura ARC200
Dura ARC200II
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.
Dura ARC160
Dura ARC160II
Dura ARC250
1
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” indicates a possible hazardous situation which, if not avoided, may result
in slight or moderate injury.
“Note!” indicates a situation which implies a risk of impaired welding result and
damage to the equipment.
“Important!”indicates practical tips and other useful special-message. It is no signal
word for a harmful or dangerous situation.
Utilisation for intended purpose only.
defined by the “Intended purpose”.
Utilisation for any other purpose, or in any other manner, shall be deemed to be “not
in accordance with the intended purpose”. The manufacturer shall not be liable for
any damage resulting from such improper use.
The machine may only be used for jobs as
Safety signs.
be kept in legible condition, not removed, not be covered, pasted or painted cover.
All the safety instructions and danger warnings on the machine must
Safety inspection.
regular intervals.
The manufacturer 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 housing and all metal parts
touching the welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts of the welding circuit, electrodes and wires with your
bare skin or wet clothing.
The operator must wear dry hole-free insulating welding gloves and body protection
while performs the welding.
Insulate yourself from work and ground using dry insulating protection which is large
enough to prevent you full area of physical contact with the work or ground.
Connect the primary input cable according to rules. Disconnect input power or stop
machine before installing or maintenance.
If welding must be performed under electrically hazardous conditions as follow: in
damp locations or wearing wet clothing; on metal structures such as floors, gratings,
or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or in
Touching live electrical parts can cause fatal shocks or
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occasion when there is a high risk of unavoidable or accidental contact with the work
piece or ground. Must use additional safety precautions: semiautomatic DC constant
voltage (wire) welder, DC manual (Stick) welder and AC welder with reduced open-
load voltage.
Maintain the electrode holder, ground clamp, welding cable and welding machine in
good, safe operating condition. Replace damaged part immediately.
Electric and magnetic fields (EMF) may be dangerous.
interference is found to be occurring, the operator is obliged to examine any possible
electromagnetic problems that may occur on equipment as follow:
- Minas, signal and data-transmission leads
- IT and telecoms equipment
- Measurement and calibration devices
- Wearers of pacemakers
Measures for minimizing or preventing EMC problems:
- Mains supply
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.
Do 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 when welding or watching.
Use protective screens or barriers to 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.
Visible and invisible rays can burn eyes and skin.
Fumes and gases can be dangerous.
breathing these fumes and gases can be hazardous to your health.
When welding, keep your head out of the fume. If inside, ventilate the area at the arc
to keep fumes and gases away from the breathing zone. If ventilation is not good,
wear an approved air-supplied respirator.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied
respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury
or death. Always use enough ventilation, especially in confined areas, to insure
breathing air is safe.
Welding may produce fumes and gases,
3
Welding and cutting sparks can cause fire or explosion.
sure the electrode circuit is not touching the work or ground. Accidental contact can
cause sparks, explosion, overheating, or fire. Make sure the area is safe before doing
any welding.
Welding and cutting on closed containers, such as tanks, drums, or containers, can
cause them to blow up. Make sure proper steps have been taken.
When pressure gas is used at the work site, special precautions are required to
prevent hazardous situations.
Connect work cable to the work as close to the welding zone as practical to prevent
welding current from passing too long and creating fire hazards or overheat.
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap. Wear ear plugs when welding out of position or in
confined places. Always wear safety glasses with side shields when in a welding
area.
Be attention that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas and start a fire. Remove fire
hazardous from the welding area, if not possible, cover them thoroughly. Do not weld
where flying sparks can strike flammable material and where the atmosphere may
contain flammable dust, gas, or liquid vapors (such as gasoline).
Protect yourself and others from flying sparks and hot 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
Cylinder can explode if damaged.
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.
Always install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling over or tipping.
Keep a safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.
No touching cylinder by welding electrode, electrode holder or any other electrically
“hot” parts. Do not drape welding cables or welding torches over a gas cylinder.
Use only correct compressed gas cylinders, regulators, hoses, and fittings designed
for the process used; maintain them and associated parts in good condition.
Use only compressed gas cylinders containing the correct shielding gas for the
properly operating regulators designed for the gas and pressure used. All hoses,
Pressure gas cylinders contain gas under high
4
fittings, etc. should be suitable for the application and maintained in good condition.
Open the cylinder valve slowly and keep your head and face away from the cylinder
valve outlet.
Valve protection caps should be kept in place over valve expect when the cylinder is
in use or connected for use.
Hot parts can burn.
Ensure equipment is cooled down before perform any work.
If touching hot parts is needed, use proper tools and/or wear heavy, insulated
welding gloves and clothing to prevent burns.
Do not touch hot parts with bare hand or skin.
Flying metal or dirt can injure eyes.
grinding can cause sparks and flying metal. It can hurt your eyes.
Remember wear appropriate safety glasses with side shields when in welding zone,
even under your welding helmet.
When welding, chipping, wire brushing, and
Noise can damage hearing.
hearing.
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, or guards when servicing and maintenance is
finished and before reconnecting input power.
Stay away from moving parts such as fans.
Overuse can cause overheating.
reduce duty cycle before starting to weld again.
Allow cooling period.
Do not block or filter airflow to unit.
Use machine follow duty cycle. Reduce current or
Safety markings.
Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974).
Equipment with CCC markings meets the requirements of implementations rules for
China compulsory certification.
Equipment with CE-markings fulfils the basic requirements of the
5
Contents
1-GENERAL REMARKS
1-1 Power source features
1-2 Functional principle
1-3 Output characteristics
1-4 Duty cycle
1-5 Applications
2-BEFORE COMMISSIONING
2-1 Utilization for intended purpose only
2-2 Machines set-up regulations
2-3
2-4
3-DURA ARC160/160II/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
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6
6
6
7
7
8
8
8
8
8
9
9
9
9
10
11
11
16
16
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21
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26
1-GENERAL REMARKS
1-1 Power source features
SMAWDura ARC160/160II/200/250/200II welding machine is suitable for DC , simple TIG
process, which can weld carbon steel, stainless steel, copper, titanium, etc. Because of the
ideal static characteristic and dynamic characteristics, machines highlights are as follows:
- Single phase 230V power supply, portable design
- Leading IGBT tube technology
- Rapid adjustment adapting to changes in the load, stable arc length, excellent
constant-current characteristics
- Low spatter
- Easily arc ignition, anti-stick features
- High penetration power, pretty weld formation
- Reliable and durable with patented technology
1-2 Functional principle
The schematic diagram is as shown in Fig. 1-2-1:
AC 230V
50/60Hz 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 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
condition changes (such as power grid voltage fluctuation, fast distance welding with long
welding cable). Easy to arc start, stable arc length, pretty weld formation and capability of
continuous adjusting the welding current.
1-3 Output characteristics
The output characteristic is droop characteristic, which is suitable for Stick process.
6
1-4 Duty cycle
Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If
unit overheats, thermostat(s) close, output stops, and cooling fan runs. Wait twenty minutes
for unit to cool. Reduce amperage or duty cycle before welding.
NOTE! Exceeding duty cycle can damage unit and void warranty.
Fig. 1-4-1: Duty Cycle (at 40 C)
1-5 Applications
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
I min I max
Fig. 1-3-1: Output Characteristics
7
1 0 20 30 40 5 0 6 0 7 0 8 0 9 0 1 0 0
WELD AMPERES
0
% DUTY C YCLE
2 0 0
250
300
3 5
1 0 0
160
1 1 2
118
1 2 4
D u r a A R C 2 0 0 / 2 0 0Ⅱ
D u r a A R C 2 5 0
D u r a A R C 1 6 0 / 1 6 0Ⅱ
2 - BEFORE COMMISSIONING
Warning! Operating the equipment incorrectly can cause serious injury and damage.
Do not use the machine until you have read "Safety rules".
2-1 Utilization for intended purpose only
The power source may only be used for SMAW and Simple TIG welding. Utilization for
any other purpose, or in any other manner, shall be deemed to be "not in accordance
with the intended purpose". The manufacturer shall not be liable for any damage
resulting from such improper use.
Please perform the inspection and maintenance work in accordance with all the
instructions given in this manual.
2-2 Machines set-up regulations
The power source is tested to "Degree of protection IP23S", However, direct wetting
should be avoided.
Warning! A machine that topples over or falls from its stand can easily kill someone.
Place machine on an even, firm floor in such a way that it stands firmly.
The venting duct is 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 the respective rating
plates.
- The mains cables and plugs must be mounted in accordance with the relevant technical
standard.
- The power supply socket come with power source is designed to use strictly according to
the marked voltage class.
Note! Inadequately dimensioned electrical installations can lead to protection failed
or partially failed. The mains plug and socket, and its fuse protection, must be
dimensioned in accordance with local power supply.
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2-4 Welding cables instruction
- The cross section area of welding cable must meet the requirements of welding machine
output current value.
- When the extension cable is being used, please appropriately increase the cross-sectional
area of the cable.
3–DURA ARC160/160II/200/ 250200II/
3-1 System components
Welding cable
Ground cable
Power source
3-2 Basic equipments for welding
- Power source
- Ground cable
- Electrode holder
- Electrode
9
Fig. 3-1-1: System components
3-3 Control panel
Note! Your 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 completely
understood this operating manual.
Este manual sirve para los siguientes modelos
4
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