AOTAI ATIG315P User manual

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Dear Customer
Thank you for choosing our product! 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. Please also take special note of
the safety rules in the manual and follow exactly the instructions.
If you treat your product carefully, this definitely helps to prolong
its enduring quality and reliability. For more information, please
contact us or consult authorized distributor.
The products in the manual may be changed without prior notice.
The model you purchase is:
ATIG315/400/500P
ATIG315/400/500P-C
Please find corresponding models from the "Contents".
Important:
Please read carefully the safety rules given in the manual and
follow exactly the instructions to avoid potential hazard and 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 voided,
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.
•Insulate yourself from work and ground using dry insulating protection
which is large enough to prevent you full area of physical contact with

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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
watching.
•Use protective screens or barriers to protect other nearby personnel

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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
before perform welding.

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•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
high.

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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........................................................................................... 8
1-1 Power source features.................................................................................... 8
1-2 Functional principle..........................................................................................8
1-3 Output characteristics..................................................................................... 9
1-4 Duty cycle..........................................................................................................9
1-5 Applications.................................................................................................... 10
1-6 Warning label................................................................................................. 10
2-VERSIONS BRIEFS..............................................................................................10
3-BEFORE COMMISSIONING............................................................................... 11
3-1 Utilization for intended purpose only.......................................................... 11
3-2 Machine installation rules............................................................................. 11
3-3 Power source connection............................................................................. 11
3-4 Welding cables instruction........................................................................... 11
4-ATIG315/400/500 P/P-C.......................................................................................13
4-1 System components......................................................................................13
4-2 Basic equipments for welding...................................................................... 13
4-3 Control panel.................................................................................................. 14
4-4 Sub menu........................................................................................................17
4-5 Other function.................................................................................................19
4-6 Interface.......................................................................................................... 20
4-7 Installation.......................................................................................................22
4-8 Technical data................................................................................................26
4-9 Dimension....................................................................................................... 27
4-10 Disassembly and reassembly....................................................................28
5-REMOTE CONTROLLER.................................................................................... 31
5-1 Analog remote controller.............................................................................. 31
5-2 Digital remote controller................................................................................32
6-TROUBLE SHOOTING........................................................................................ 34
7-CARE AND MAINTENANCE.............................................................................. 36

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1-GENERAL REMARKS
1-1 Power source features
This series pulse TIG welding machine includes 315A, 400A and 500A types, can
perform DC TIG, Pulse TIG, and SMAW processes. This series welding machines enjoy
reasonable static characteristic and sound dynamic characteristic.
Features and benefits:
-MCU controlled technology
-Self-diagnostic function with error code display
-Precise pulse control, good welding performance
-Pre-gas, post-gas, up-slope time, down-slope time, adjustable parameters, easy to
control
-Pulse frequency, pulse ratio, pulse width can be adjusted to improve the welding
performance
-Soft switch technology, high efficiency, high power factor.
1-2 Functional principle
This series welding machines apply IGBT HF inverter technology. 3- phase input volt is
rectified, then transformed into HF AC by the inverter which includes IGBT, etc., reduced
by HF transformer, rectified and filtered by HF rectifier, then output. After this process,
the welding machine dynamic response ability has been greatly improved, size and
weight of transformer and reactor are reduced noticeably, and whole machine efficiency
has been improved.
The design of control circuit makes the welding machine enjoy strong ability against
power grid fluctuation and perfect welding performance. Welding machine has the
following features: easy arc-starting, stable arc, good welding seam formation and
capability of continuous welding current regulation. The schematic diagram is as shown
in Fig. 1-2-1:
Fig. 1-2-1: Schematic diagram

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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.
Fig. 1-4-1: Duty cycle