AOTAI AMIG350P User manual

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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 many great features of your new product. Meanwhile,
please remember well safety rules and operate as instruction.
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 :
AMIG350P & AMIG500P
AMIG350PM & AMIG500PM
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.

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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.
Utilization for intended purpose only
•The machine may only be used for jobs as defined by the “Intended
purpose”.
•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.
Safety signs
•All the safety instructions and danger warnings on the machine must
be kept in legible condition, not removed, not be covered, pasted or
painted cover.
Safety inspection
•The owner/operator is obliged to perform safety inspection at regular
intervals.
•The manufacturer also recommends every 3-6 months for regular
maintenance of power sources.
Electric shock can kill
•Touching live electrical parts can cause fatal shocks or 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.

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•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 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
•If electromagnetic interference is found to be occurring, the operator is
obliged to examine any possible electromagnetic problems that may
occur on equipment as follow:
-mains, 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 term 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.
ARC rays can burn.
•Visible and invisible rays can burn eyes and skin.
•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

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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.
Fumes and gases can be dangerous
•Welding may produce fumes and gases, 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 and cutting sparks can cause fire or explosion.
•When not welding, make 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

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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.
Cylinder can explode if damaged.
•Pressure gas cylinders contain gas under high 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 and properly operating regulators designed for the gas and
pressure used. All hoses, 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
•Do not touch hot parts with bare hand or skin.
•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.
Flying metal or dirt can injure eyes
•When welding, chipping, wire brushing, and 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.
Noise can damage hearing
•Noise from some processes or equipment can damage hearing.
Remember wear approved ear protection to protect ears if noise level is

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high.
Moving parts can injure
•Stay away from moving parts such as fans.
•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.
Overuse can cause overheating
•Use machine follow duty cycle. Reduce current or reduce duty cycle
before starting to weld again.
•Allow cooling period.
Do not block or filter airflow to unit.
Safety markings
Equipment with CE-markings meets the basic requirements of the
Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant
product standards according to EN 60974).
Safety markings
Equipment with CCC markings meets the requirements of
implementations rules for China compulsory certification （e.g. relevant
product standards according to GB/T 15579）.
Safety markings
CSA marked equipment meets the requirements of the North American
market safety certification implementation rules (e.g. relevant product
standards according to CAN/CSA-E60974,ANSI/IEC 60974)

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Contents
1-GENERAL REMARKS............................................................................................ 9
1-1 Power source features................................................................................9
1-2 Functional principle..................................................................................... 9
1-3 Output characteristics...............................................................................10
1-4 Duty cycle................................................................................................... 10
1-5 Applications................................................................................................ 11
1-6 Warning label............................................................................................. 12
2-VERSIONS BRIEFS.............................................................................................. 12
3-BEFORE COMMISSIONING............................................................................... 13
3-1 Utilization for intended purpose only...................................................... 13
3-2 Machine installation rules.........................................................................13
3-3 Power source connection.........................................................................13
3-4 Welding cables instruction....................................................................... 14
4-AMIG 350/500 P/PM............................................................................................. 16
4-1 System components................................................................................. 16
4-2 Basic equipments for welding................................................................. 16
4-3 Control panel..............................................................................................17
4-4 Sub-menu................................................................................................... 23
4-5 JOB mode-CALL& STORE function.......................................................29
4-6 Interface...................................................................................................... 31
4-7 Installation.................................................................................................. 32
4-8 welding process installation.....................................................................37
4-9 Technical data........................................................................................... 38
4-10 Dimension................................................................................................ 40
4-11 Disassembly and reassembly............................................................... 41
5-WF-P WIREFEEDER............................................................................................ 45
5-1 Features......................................................................................................45
5-2 Interface...................................................................................................... 46
5-3 Control panel..............................................................................................48

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5-4 Structure..................................................................................................... 50
5-5 Installation and operation.........................................................................52
5-6 Technical data........................................................................................... 52
5-7 Dimension...................................................................................................53
5-8 Disassembly and reassembly................................................................. 54
6-TROUBLE SHOOTING.........................................................................................58
7-CARE AND MAINTENANCE............................................................................... 61

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1-GENERAL REMARKS
This series of power sources apply IGBT soft switch inverter technology. Its internal
control system applies digital signal processor which ensures quick response to any
change during the welding process so as to achieve precise control of welding process
and ensure optimal welding results.
1-1 Power source features
This series of power sources are microprocessor controlled and apply MCU + DSP
control technology to improve the control precision. The strong ability of arc
self-adjustment ensures a highly stable welding current against grid fluctuation and arc
length change to get optimal results.
Highlights as follows:
- User friendly interface, synergic, easily control.
- Embedded welding expert database, automatic intelligent combination of parameters.
- To achieve beautiful ripple pattern of welding seam with the function of double pulse
MIG.
- Store 100 sets of user-defined parameters, save the operator’s time.
- Perfect functions of starting arc and reducing melting ball while stopping arc.
- Special 4-step mode is suitable for welding metal with good thermal conductivity, with
perfect welding quality when starting arc and stopping arc.
- Multiple protection functions
- Fully digital wire feeding control system to ensure stable and precise wire feeding
- Fan-on demand cooling system operates when needed to extend the service life of
fan.
- Advanced digital communication interfaces for robotic system and automation system
- Digital torch with quick and convenient adjustment.
1-2 Functional principle
This series of power sources adopt IGBT soft switch inverter technology to improve the
dynamic response rate and make the machines with small size and light weight. The

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control circuit's closed-loop control makes the power source enjoy strong ability against
power grid fluctuation and perfect welding performance. The schematic diagram is as
shown in Fig. 1-2-1:
Fig.1-2-1: Schematic diagram
1-3 Output characteristics
Fig.1-3-1: Output
characteristics
1-4 Duty cycle
Duty cycle is percentage of 10 minutes that a machine can weld at rated load without
overheating. If overheats, thermostat(s) will open, output stops. Wait for fifteen minutes
for the machine to cool down. Reduce amperage or duty cycle before welding.
Note! Exceeding duty cycle can damage the machine and greatly reduce its
lifespan.

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Fig.1-4-1: Duty cycle
1-5 Applications
This series of machines have many welding processes and can weld most of the metal
materials, including carbon steel, stainless steel, aluminum and Al-Mg alloy, copper and
alloy, etc.
Recommended areas of use as follows:
- Automobile and car manufacture industry
- Chemical structure and engineering
- Boiler pressure vessel manufacture
- Shipbuilding and offshore engineering
- Electric power construction
- Vehicle manufacturing
- Mechanical industry
- Other industries

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1-6 Warning label
The warning label is affixed on the top of machine.
Fig. 1-6-1: Warning label
2-VERSIONS BRIEFS
Professional welding of special materials requires special welding parameters. Different
models of the power sources are matched to different weldings.
●AMIG350P/PM
AMIG350P/PM apply the industrial standard design, have Double Pulse MIG, Pulse
MIG ,MIG,STICK,LIFT TIG and GOUGING welding processes, the output current is
350A .
●AMIG500P/PM
AMIG500P/PM apply the industrial standard design, have Double Pulse MIG, Pulse
MIG ,MIG,STICK,LIFT TIG and GOUGING welding processes, the output current is
500A.

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3-BEFORE COMMISSIONING
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 “safety rules”.
3-1 Utilization for intended purpose only
The power source may only be used for pulse MIG, MIG, STICK, LIFT TIG and
GOUGING(optional). Utilization for other purposes, 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.Operate, inspect and
maintain should follow all the instructions given in this manual.
3-2 Machine installation rules
According to test, protection degree of this power source is IP21S (optional IP23S).
However, the internal key components must be protected from direct soaking.
Warning! A machine that topples over or falls from its stand can cause
injury. Place equipment on an even, firm floor in such a way that it stands
firmly.
The venting duct is very important for safety protections. When choosing the machine
location, make sure it is possible for the cooling air to freely enter and exit through the
louvers on the front and back of machine. Any electro conductive metallic dust like
drillings must not be allowed to get sucked into the machine.
3-3 Power source connection
- The power source is designed to run on the voltage given on the nameplate.
- The mains cables and plugs must be mounted in accordance with the relevant technical
standards.

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- The power supply sockets that come with power source are designed to use strictly
according to the marked voltages.
Note!Inadequately dimensioned electrical installations can lead to serious
damage. The mains lead, and its fuse protection, must be dimensioned in
accordance with the local power supply. The technical data shown on the
nameplate shall apply.
3-4 Welding cables instruction
When welding, please pay attention to the followings:
a. The welding cables should be kept as short as possible;
b. If extended cable is used, please do as shown in Fig. 3-4-1.
Wrong
Coil the excess ground cable and welding
cable in same direction respectively.
Correct
Straighten the ground cable and welding
cable and make them close to each other.
Bundle the ground cable and welding cable
together, running the wires close to the
ground.

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Correct
When the excess cables are only be used by
rolling up, coil the cables to two windings in
reverse direction and overlap them.
The number of turns for A is same as the
number for B.
Handle the welding cable and ground cable
according to above-mentioned method.
Fig. 3-4-1: Welding cables instruction

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4-AMIG 350/500 P/PM
4-1 System components
AMIG350/500P/PM welding machine can be equipped with many different accessories
and can be used in different special sites with different configurations.
Fig. 4-1-1: System components
4-2 Basic equipment for welding
Only be equipped with the necessary accessories, can the power source
AMIG350/500P/PM operate well. The following is the needed accessories list.
MIG/P-MIG welding
-Power source
-Ground cable
-Welding torch
-gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas)
-Wire feeder
-Welding wire
TIG welding
-Power source
-Ground cable

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-TIG welding torch with air valve switch
-Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas)
-Welding wire
STICK welding
-Power source
-Ground cable
-Electrode holder
-Electrode
4-3 Control panel
The functions on the control panels are all arranged in a very logical way. The various
modes and parameters needed for welding are easy to select by pressing the
appropriate button; parameters are easy to be adjusted by rotating encoder. Synergic
adjustment makes the complicated operation much easier.
Note! Some described parameters in this manual may be slightly different
from the power source, some identification may be slightly different from
power source identification, but the manner of working is the same.
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 all content of this manual.

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Fig. 4-3-1: Control panel
(1) Adjustment knob
Adjust the parameters. When the light is on, this knob can be used to adjust parameters
of selected item.
Reset to factory setting:Press and hold adjustment knob (1) for about 5 seconds, it
comes back to factory setting.
Important! Values increase in clockwise direction while values decrease in
anti-clockwise rotation. To turn the knob left or right while pressing it will achieve quick
adjustment.
(2) Parameters selection button F2
Press this button,one parameter indicator light is on, the corresponding parameter is
chosen; keep pressing this button can switch among the following parameters:
- Arc length adjustment
- Welding voltage
- Job (Channel) No.
If both the indicators of parameter selection button and the adjustment knob (1) are on,
the indicated/ selected parameter can be altered with the adjustment knob (1).
(3) Parameters selection button F1
Press this button,one parameter indicator light is on and the corresponding parameter is
chosen; keep pressing this button can switch among the following parameters:
- “a” dimension
- Sheet thickness
- Welding current
- Welding speed
- Peak current/inductance
Important! On Panel control mode, press F1 to choose one of the above parameters,
and value of the parameter can be adjusted by the knob (1).
If Remote control mode, press F1 to choose one of the above parameters, and value of
the parameter can be adjusted by the current potentiometer knob on analog wire feeder.
(4) CALL button
Load stored set of parameters
(5) STORE button
- For accessing the sub-menu parameter set-up menu or (in job mode) for storing
parameter settings.
- During creating or correcting a job, store parameter settings.

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(6) Wire diameter button
For selecting wire diameter.
(7) Wire material selection button(s)
For selecting the filler metal and shielding gas type. OP is used for upgrade.
(8) MODE button(s)
For selecting the operating mode of the torch.
Operating mode of welding torch
Graphic symbol
Fig. 4-3-2 Press trigger Fig.4-3-3 Hold trigger Fig.4-3-4 Release trigger
P03……Pre-gas time
P05……Initial parameter: The base metal can be heated up rapidly, despite the fast
thermal dissipation at the start of welding.
P07……Down-slope time: The time from welding current to crater-filler current.
I………..Welding current: Uniform thermal input for the preheated base metals.
P06……Crater-filler parameter: Prevent burn-through caused by too much heat at the
welding ends.
P08……Spot welding time
P04……Post-gas time
P01……Burn back time
- 2-step mode