ASAW-630 /1000 /1250 –Ⅱ

Index

1. Safety Precautions……….……….…………………………………………...(1)

2. Principle & Technical data………………………………………………….....(7)

3. Features & Applications……………………………………………………...(15)

4. Installation Guide………………………………………………………….….(17)

5. Operating Instruction …………...…………………………………………....(20)

6. Repair & Maintenance………………………………………………………..(28)

Appendix A: EMC Suggestion for installation and use of welder………………...(31)

Appendix B: Feedback Form……………………………………………………...(33)

This operating manual can be fit for ASAW (include ASAW-630/1000/1250)

series welding machines. The technical data are measured with power supply 3

phase 415V, the data will be changed when you use different voltage such as

380V and 400V.

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 ASAW-630 /1000 /1250 –Ⅱ

Safety Precautions

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM

POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
BE SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES

For Engine Powered equipments

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance
work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the
engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine until fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to perform required
maintenance. Remove guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler
by pushing on the throttle control rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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 ASAW-630 /1000 /1250 –Ⅱ

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic
Fields (EMF). Welding current creates EMF fields around welding cables and welding
machines.
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should
consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not
known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
2.d.1. Route the electrode and work cables together-Secure them with tape when possible.
2.d.2. Never coil electrode lead around your body.
2.d.3. Do not place your body between your electrode and work cables. If the electrode
cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the work piece as close as possible to the area being
welded.
2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK can kill

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under
electrically hazardous conditions (in damp locations or wearing wet clothing; on metal

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 ASAW-630 /1000 /1250 –Ⅱ

structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or accidental contact with the work
piece or ground) use the following equipment:
Semiautomatic DC Constant Voltage (Wire) Welder
DC Manual (Stick) Welder
AC Welder with Reduced voltage control
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good,
safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of
both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Head shield and filter lens
should conform to ANSI Z87.I standard.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and
that of your helpers from the arc rays.
4.c. 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.

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 ASAW-630 /1000 /1250 –Ⅱ

FUMES AND GASES can be dangerous

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or cadmium and plated steel and other
materials or coatings which produce highly toxic fumes, keep exposure as low as possible
and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
5.b. The operation of welding fume control equipment is affected by various factors including
proper use and positioning of the equipment, maintenance of the equipment and the
specific welding procedure and application involved. Worker exposure level should be
checked upon installation and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use
enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used, including the material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from your welding distributor pr
from the manufacturer.
5.f. Also see item 1.b.

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 ASAW-630 /1000 /1250 –Ⅱ

WELDING AND CUTTING SPARKS can cause fire or explosion.

6.a. Remove fire hazardous from the welding area. If this is not possible, cover them to prevent
the welding sparks from starting a fire. Remember that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Avoid
welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used
to prevent hazardous situations. Refer to “Safety in Welding & Cutting” (ANSI Standard
Z59.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken
to insure that such procedures will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have been “cleaned”. For
information, purchase “Recommended Safe Practices for the Preparations for Welding and
Cutting of Containers and Piping That Have Hazardous Substances”, AWS F4.1 from the
American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such
as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places. Always wear safety glasses
with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cable
until they fail.
6.h. Also see item 1.c.

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 ASAW-630 /1000 /1250 –Ⅱ

6.i. Do not use a welding power source for pipe thawing.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process
used 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.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
7.c. Cylinders should be located:
. Away from areas where they may be struck or subjected to physical damage
. A safe distance from arc welding or cutting operations and any other source of heat,
sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a
cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder
valve.
7.f. Valve protection caps should be always be in place and hand tight expect when the cylinder
is in use or connected for use.

FOR ELECTRICALLY powered equipment

8.a. Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local cedes and
the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the
manufacturer’s recommendations.

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 ASAW-630 /1000 /1250 –Ⅱ

Principle & Technical data

ASAW-ⅡSeries Block diagram of principle shown as Figure 1:

Input Output

3 phase HF HF Rectifier &

Rectifier Inverter Transformer Filter

Control circuit

Figure1: Block diagram of principle

This series welding machines apply IGBT soft switch inverter technology. 3- phase input
volt are rectified by rectifier, inverted into HF AC, reduced by HF transformer, rectified and
filtered 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.
The design of Control Circuit carries out the all close-loop control. Ensure the welding
parameters instability, easy to start arc, arc instability, good weld forming when the external
conditions (e.g. power network voltage fluctuates, Output Cables in different lengths, etc.)
change. And achieve the function of continuous welding current adjustments.
ASAW-II Series Volt-Ampere Curve as shown in Figure 2 and Figure 3.

Figure 2: ASAW-Ⅱ Volt-Ampere Curve

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 ASAW-630 /1000 /1250 –Ⅱ

Figure 3: SMAW Volt-Ampere Curve

1. Volt-Ampere Curve illustration in SAW
ASAW-Ⅱ has flat characteristic and Droop characteristic:
Droop characteristic: 1) M-A-B-C is SAW Volt-Ampere static Curve.
2) N-B is load curve.
3) Welding current is in accordance with the distance between B
and ordinate axis. The regulation range is from welder 60A to
rated welding current.
Flat characteristic: 1) M-A is SAW Volt-Ampere Curve Static Curve.
2) N-A is load curve.
3) Welding Voltage is in accordance with the distance between A and
abscissa axis. The regulation range is from 20V to rated welding
voltage.
2. Volt-Ampere Curve illustration in SMAW
1) M-A-B-C is Volt-Ampere Curve static Curve in SMAW.
2) N-B is load curve.
3) Welding current is in accordance with the distance between B and ordinate axis. The
regulation range is from 60A to rated welding current.
4) Arc force current is in accordance with the distance between C and D in the
Volt-Ampere Curve. The regulation range is from 0 to 200A.

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 ASAW-630 /1000 /1250 –Ⅱ

3. Main technical data:

Model ASAW630Ⅱ ASAW1000Ⅱ ASAW1250Ⅱ

Input Power / Frequency 3 phase 415V-20% ~ 415V＋15% /50HZ

Rated output power (Kw) 27 44 55

Rated input current (A) 51 83 115

Rated duty cycle (%) 100

Range of welding current (A) 60-630 60-1000 60-1250

Range of welding voltage (V) 20-50

Output open- load voltage SAW 87 78 88

(V)
SMAW 8.4

Full-load efficiency (%) 89

Full-load power factor 0.88

Wire diameter (mm) 1.6-4 1.6-6 1.6-6

Weight (kg) 55 95 100

Dimension (mm3) 530×320×600 767×352×771 767×352×802

Main Transformer H
Insulation class
Transformer for
B
Output Reactor

Table 1: Parameter Specification

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 ASAW-630 /1000 /1250 –Ⅱ

2. Wiring Diagram
 ASAW630II

Figure 4: Wiring Diagram for ASAW630II

１０
 

Q1 IGBT 阻容吸收板A4A Q2
C4

N1A N3A
RA5
RB5
V+
G1A G3A
T2 R3
C1 1
TB1
QB1 C5 C1 7
E1A E3A C2 1
U 1 2 RA1 1
RE1
R1 C2 2
C7 C9
V 3 4

C1 2 RB6 A5机架电容板
W 5 6
RA6
N2A N4A 1 X1:3
G2A G4A R5
RA1
RA7 C1 8 1 X1:1
ASAW1000II /1250II

1 X1:2

E2A E4A
IFB RA3 1 X1:5
黄色 1 2
C1 C1 5
3 4 5 1 X1:4
GQ1 a b
1 X6:2
蓝色 6 7 8 9
1 X6:1
(1 ) KF1 (2 ) 3A
红色 FA1 10 11 12
(2 ) (1 ) Q3 IGBT 阻容吸收板A4B Q4
1 X6:4
黄色 13 14
RA8 X1

-
+
N1B N3B RB7
C2 G1B G3B
T3 R7
GQ2 C1 4

1 X 5 :2
1 X 5 :1
TB2
C1 9 1 X6:3
蓝色 E1B E3B
RA1 2 1 X10 :2
RE2
红色 RA2
1 X1:6
C8 C1 0 R2

C6
C1 5 RB8
RA9
N2B
GND
Vout

G4B N4B
T1 G2B R9
RA1 0 C2 0
3 X3:3 B1
1 11
C3 E4B
V-

１１
3 80 V 7V E2B
VC+
VC-

可恢复过载保护器
10 IFB RA4
3 X3:1 C1 6 T1:3 1 X2:3
2 (1 ) (2 )
a b 5A
c d
V C+
FB1
V C-
Vout
GND

9
FB1:1
21V 2X1:1

G1A
E1A
E2A
G2A
G3A
E3A
E4A
G4A
1 X10 :3
1 X 7 :1
1 X 7 :2
1 X 7 :3
1 X 7 :4

2 X2A:5
1 X8:5
3 2 X2A:3 X1 :7

2X3A:2

2X3A:1
8 2X1:2 A2A 1 X8:4 1 X10 :2
21V 2 X2A:4
1 X8:3 1 X10 :1
8 5V
7 1 X4:1 3 X2:6
2X1:3 1 X8:2
4
1 X8:1
1 X4:2 3 X2:5
6
1 X4:3 3 X2:4
50V
5 1 X4:4 3 X2:3
2X1:1
1 X4:5 3 X2:2
2 X2B:3
2X1:2 A2B 2 X2B:4 1 X4:6 3 X2:1

1 X3:9 3 X1:9

2X3B:1
2X3B:2

G1B
E1B
E2B
G2B
G3B
E3B
E4B
G4B
2X1:3
A1
1 X3:8 3 X1:8 A3
c d 1 X3:7 3 X1:7

1 X3:6 3 X1:6
1 X9:3
1 X3:5 3 X1:5
1 X9:1 1 X3:4 3 X1:4

1 X3:3 3 X1:3

1 X3:2 3 X1:2

1 X3:1 3 X1:1
温度保护 T1:1 0 3 X3:1

Figure 5: Wiring Diagram for ASAW1000II/1250II

T1:1 1 3 X3:3
1 X 2 :3

1 X 2 :1
1 X 2 :2
1 X 2 :4
1 X 6 :1
1 X 6 :2
1 X 6 :3
1 X 6 :4
1 X 1 :1
1 X 1 :2
1 X 1 :3
1 X 1 :4
1 X 1 :5
1 X 1 :6

1 X 5 :3
1 X 5 :4
1 X 5 :1
1 X 5 :2

BB1
BB3
1 X 1 0:2
FB1:2

1 X 1 0:1

BB2
1 X 5 :1
1 X 5 :2
X 1 :1
X 1 :2
X 1 :3
X 1 :4
X 1 :5
X 1 :6

X 1 :8
X 1 :9
X 1 :1 0
X 1 :1 1

R2 3

5 .1 /7 5 W
ASAW-630 /1000 /1250 –Ⅱ
 ASAW-630 /1000 /1250 –Ⅱ

3. Main Components List

 ASAW630Ⅱ

No. Tab Item Specification Quantity Memo

1 QB1 Circuit Breaker 745011-00026 1
2 TB1 3-phase Rectifier Module 735005-00003 1
3 RA1 Power Capacitor 220155-00004 1
4 RA3 Resonance Inductor 220521-00005 1
5 C5 Polypropylene capacitor 722001-00062 2
6 C7 Polypropylene capacitor 722001-00070 2

7 Q1～Q2 IGBT Module 735007-00042 2

8 RE1 Varistor 720021-00017 1
9 C15 Polypropylene capacitor 722001-00075 1
10 T2 Main Transformer 220629-00016 1
11 RB5～6 Fast Recovery Diode Module 735006-00019 4
12 T1 Transformer for ZKB/QDB 763001-00021 1
13 FA1 Fuse 745007-00015 1
14 GQ1 Fan 746001-00029 1
15 BB1 Thermal Switch 745008-00002 1
16 KF1 Solid-state Relay (SSR) 715004-00003 1
17 A1 Main Control Board 210580-00037 1
18 A2 Drive Board 210310-00007 1
19 A3 Display Board 220383-00005 1
20 A4 IGBT Protection Board 220005-00008 1
21 B1 Current Sensor 753001-00020 1

Table 2: Main Components List for ASAW630Ⅱ

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 ASAW-630 /1000 /1250 –Ⅱ

 ASAW1000Ⅱ

No. Tab Item Stock No. Quantity Memo

1 QB1 Circuit Breaker 745012-00011 1
2 TB1～2 3-phase rectifier Module 735005-00003 2
3 RA1～2 Power Inductor 220155-00001 2
4 RA3～4 Resonance Inductor 220521-00002 2
5 C5～6 Polypropylene capacitor 722001-00062 4
6 C7～8 Polypropylene capacitor 722001-00070 4
7 Q1～Q4 IGBT Module 735007-00037 4
8 RE1～2 Varistor 720021-00017 2
9 C15～16 Polypropylene Capacitor 722001-00074 2
10 T2～3 Main Transformer 220629-00009 2
11 RB5～8 Fast Recovery Diode Module 735006-00019 6
12 T1 Transformer for ZKB/QDB 763001-00021 1
13 RA11～12 Output Reactor 763004-00010 2
14 FA1 Fuse 745007-00015 1
15 GQ1～2 Fan 746001-00017 2
16 BB1～3 Thermal Switch 745008-00001 3
17 KF1 Solid-state Relay 715004-00003 1
18 A1 Main Control Board 210580-00037 1
19 A2 Drive Board 210310-00007 2
20 A3 Display Board 220383-00005 1
21 A4 IGBT Protection Board 220005-00007 2
22 B1 Current Sensor 753001-00003 1

Table 3: Main Components List for ASAW1000Ⅱ

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 ASAW-630 /1000 /1250 –Ⅱ

 ASAW1250Ⅱ

No. Tab Item Stock No. Quantity Memo

1 QB1 Circuit Breaker 745011-00012 1
3-phase Rectifier
2 TB1～2 735005-00003 2
Module
3 RA1～2 Power Inductor 220155-00001 2
4 RA3～4 Resonance Inductor 220521-00003 2
5 C5～6 Polypropylene Capacitor 722001-00062 4
6 C7～8 Polypropylene Capacitor 722001-00070 4
7 Q1～Q4 IGBT Module 735007-00042 4
8 RE1～2 Varistor 720021-00017 2
9 C15～16 Polypropylene Capacitor 722001-00075 2
10 T2～3 Main Transformer 220629-00011 2
Fast Recovery Diode
11 RB5～8 735006-00019 8
Module
Transformer for
12 T1 763001-00021 1
ZKB/QDB
13 RA11～12 Output Reactor 763004-00024 2
14 FA1 Fuse 745007-00015 1
15 GQ1～2 Fan 746001-00029 2
16 BB1～3 Thermal Switch 745008-00002 3
17 KF1 Solid-state Relay 715004-00003 1
18 A1 Main Control Board 210580-00037 1
19 A2 Drive Board 210310-00007 2
20 A3 Display Board 220383-00005 1
21 A4 IGBT Protection Board 220005-00008 2
22 B1 Current Sensor 753001-00003 1

Table 4: Main Components List for ASAW1250Ⅱ

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 ASAW-630 /1000 /1250 –Ⅱ

Features & Application

Aotai ASAW Series Digital Inverter DC Submerged Arc Welding Machine (ASAW630Ⅱ,
ASAW1000Ⅱ, ASAW1250Ⅱ) is new type of high-efficiency energy-saving equipment that
can be used for welding: carbon steel structure, stainless steel, heat resistant steel, and alloy
steel, etc. materials, and widely applied in Shipyard, Boiler Pressure Container manufacture,
Chemical Container manufacture, Bridge Construction, Crane industry and Metallurgy
industry and other industry fields.
This series machine has features of good static and dynamic characteristics, and well
furnished with control functions.
Features and benefits:
 Embedded expert program with 10 sets of complete welding parameter, for various
welding processor or material.
 Weakly influenced by input voltage fluctuation.
 Self-diagnostic function with error code display.
 Small, light, flexible adjustment and convenient operation.
 Flexible adaptability of welding parameters, reliable performance, low failure rate,
convenient for maintenance.
 Digital Communication between tractor and welder.
 It can perform big gradient SAW welding with gear parallels.
 Duty cycle is as high as 100%.
 Thermal protection and mechanical protection provide.
 Featured function of wire diameter selection.
 ASAW II has Drooping & flat characteristic, good for performing thin single wire
welding (Ф1.6, Ф2.0), thin double wire welding (Ф1.6, Ф2.0), and thick single wire
welding (beyond Ф3.0).

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 ASAW-630 /1000 /1250 –Ⅱ

Applications:
 Suitable for welding: mild steel, stainless steel, heat resistant steel, and alloy steel.
 Bridge Construction.
 Shipyards.
 Crane industry.
 Chemical container manufacture.
 Boiler Pressure Container manufacture.
 Metallurgy industry.
 Steel structure workshops.

Technical data: tractor

Rated input voltage (V) AC120

Rated input power (VA) 400

Drooping characteristic tractor: Ф3.0-Ф6.0
Wire diameter (mm)
Drooping & Flat characteristic tractor: Ф1.6-Ф6.0
Arc-starting method Scratch/retract

Range of welding speed (cm/min) 10-150

Drooping characteristic tractor: 0.3-3m / min
Range of wire feeding speed (m/min)
Drooping & Flat characteristic tractor: 0.3-6m / min
Contact tip up-down adjustment (mm) 100

Column horizontal adjustment (mm) 70

Rotary angle of cross beam ±90°

Beam retract adjustment (mm) 100

Welding head inclination ±45°

Dimension (mm3) 1020×480×740

Weight (kg) 54

Table 6: Technical data of tractor

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 ASAW-630 /1000 /1250 –Ⅱ

Installation Guide

1． Pre-installation

1.1 Installation Environment

The ASAW-Ⅱ series are designed for use in adverse environments. Examples of
environments with increased adverse conditions are
 In locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position
with physical contact with conductive parts;
 In locations which are fully or partially limited by conductive elements, and in
which there is a high risk of unavoidable or accidental contact by the operator;
 In wet or damp hot locations where humidity or perspiration considerably
reduces the skin resistance of the human body and the insulation properties of
accessories.
 Environments with adverse conditions do not include places where electrically
conductive parts, in the near vicinity of the operator, which can cause increased
hazard, have been insulated.

1.2. Installation Location

Be sure to locate the welder according to the following guidelines:
 In areas, free from moisture and dust.
 Ambient temperature between 0 degrees C to 40 degrees C.
 In areas, free from oil, steam and corrosive gases.
 In areas, not subjected to abnormal vibration or shock.
 In areas, not exposed to direct sunlight or rain.
 Place at a distance of 12" (304.79mm) or more from walls or similar
boundaries that could restrict natural airflow for cooling.
1.3 Power Source Connections
Warning _____
Thermal Arc advises that this equipment be electrically connected by a
qualified electrician.
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after
removal of input power.
DO NOT TOUCH live electrical parts. ____________

 SHUT DOWN welding power source, disconnect input power employing

lockout/tagging procedures.
 Lockout/tagging procedures consist of padlocking line disconnect switch in
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 ASAW-630 /1000 /1250 –Ⅱ

open position.
 Removing fuses from fuse box, or shutting off and red-tagging circuit breaker
or other disconnecting device.

1.4．Power Supplier Requirements

 Input volt must be standard sine wave, effective value 415V, frequency 50Hz.
 Unbalance degree of 3-phase volt must be no more than 5%.
 Power supply

Product type ASAW630Ⅱ ASAW1000Ⅱ ASAW1250Ⅱ

Power Supply 3-phase AC415V

Min. Electricity Grid 53KVA 83KVA 120KVA

capacity Generator 70KVA 110KVA 158KVA

Input volt Fuse 60A 90A 130A

protection Circuit Breaker 100A 120A 160A
Input volt 10mm2 16mm2 25mm2
Cable size Output volt 95mm2×1 70mm2×2 95mm2×2
Ground lead 10mm2 16mm2 16mm2

Table 7: Power supply connection

Note: The size of fuse and breaker in the table are for reference only.
1.4. Machine Assembling Guide:

1.4.1 Assembling diagram of ASAW Series Welding Machine as shown in Figure 5

Figure 5: External Wire diagram of ASAW-Ⅱ

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 ASAW-630 /1000 /1250 –Ⅱ

1.4.2 Users should equip the machines with Electrical Panel or Electrical switchboard,
connect the 3-phase 415V/50Hz AC to the Power Cable Junction Box of ASAW
welder via Circuit Breaker. And ensure to earth the ground bolt on the rear panel via
the wire set by the Table 4
1.4.3 Connect the Output Terminal (+) to the ASAW Tractor by the Output Terminal (+)
Cable
1.4.4 Connect the Output Terminal (-) to the welded work piece by the Output Terminal (-)
Cable.
1.4.5 Connect the ASAW welder with the Tractor control box by the Control Cable

Caution: Please refer to Appendix A for EMC suggestions for installation and use
of welder.

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 ASAW-630 /1000 /1250 –Ⅱ

Operating Instruction

1. Panel illustration and parts number reference

1. 1 Front panel illustration and parts number reference

Take ASAW1000Ⅱ for example, front panel is illustrated below. Shown in Figure 6

Figure 6: ASAW1000Ⅱ Front Panel

(1) Welding Current Meter: Show the preset current and welding current actual value.
Indicate the Error Code in failure. The detail shown as in Table 8:
No. Error Code Description
1 E001 Over-heat protection
circulating current fault (short circuit of output
2 E002
Diode)

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 ASAW-630 /1000 /1250 –Ⅱ

3 E003 Communication Fault

4 E004 Short Circuit of Wire feeder

5 E005 Wire feeder is out of control

6 E006 Short circuit of Travelling Motor

7 E007 Travelling Motor is out of control

8 E008 Short Circuit when switch SAW to SMAW

Table 8: Error Code Table

(2) Arc voltage/arc force current/ Arc Force Displayer
 During welding , indicate the welding voltage
 During SMAW Mode,
 open-load , indicate the open load voltage
 when adjust arc force knob, indicate the preset arc force current
 During SAW Mode
 Open-load, indicate the preset voltage value of welder
 When adjust arc force knob, indicate the preset arc force.
(3) Voltage/ Arc force / Arc strength indicate
(4) “Remote /Panel control” switches:

 Remote control mode, adjust welding current via SAW tractor control box.

 In the panel control mode, adjust welding current on the welder control
panel.
(5) Over-load protector: when the Armature current of weld feeding or travelling motor,
excitation current of weld feeder is too big, the over load protector works, and welder
stops working. switch on the over load protector after settle the fault, welder on.
(6) “SMAW / SAW” switches:

 Position （SMAW）, SMAW or Carbon Arc gouging Mode

 Position （SAW）, SAW Mode

(7) Welding Wire selection: select mode depends on the welding wire specification.
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 Position “ ”(vertical characteristic), select the wide wire, the selection

diameter could be the :φ3、φ4、φ5、φ6;

 Position “ ”(level characteristic),select the thin wire, the selection diameter

could be: φ1.6、φ2、φ2.4、φ3.
 When welding with single wire, the diameter selection indicator on.

(8) Droop/ Flat characteristic switches:

 Position “ ” Droop characteristic

 Position “ ” Flat characteristic

(9) Welding current adjustment knob: when in “Panel Control”, adjust the welding current,
the range is 60-Ie, e.g. the adjustment range of ASAW 1000II is 60-1000A.
(10) Arc force /Arc strength adjustment knob:
 During SMAW mode , adjust the arc force current when in SMAW, the range is
0-200A;
 During SAW, Flat characteristic, adjust the Arc strength, the range is 0-20, and this
adjustment can change the welding stability and the depth of molten pool
(11) Welder output (+):
 During SAW, connect welder (+) to the tractor with output cable (+)
 During SMAW, connect electrode holder
(12) Welder output (-): Connect welder (-) to the work piece by the output cable (-)
(13) Control Cable Socket: Connect welder and tractor control box, provide the power
supply of the tractor control box, armature voltage of the tractor and
wire feeder, excitation voltage of wire feeder, transmit the control
signal between SAW welder and control box, and provide feedback
signal for SAW Arc voltage

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 ASAW-630 /1000 /1250 –Ⅱ

1.2 Rear Panel

ASAW II Series Digital Inverter DC Submerged Arc Welding Machine Rear Panel (take
ASAW-1000II for example) as shown in Figure 7.

Figure 7: ASAW1000Ⅱ Machine Rear Panel

(1) Specification Plate: For showing the parameters of welder
(2) Input Cable Connecting Box: for connecting power supply AC 3-phase 415V.
(3) Fan: For cooling the internal radiating device.
(4) Ground Bolt: To ensure the personal safety and the normal use of welding machine, use
this bolt to grounding with the specified wire in Table 7.
(5) Air circuit Breaker: 3-phase power supply provides power via this Circuit Breaker. The
main effect is to automatically shut down the machine when welder is over load or
faults, so as to protect welder. In general, the breaker is up to the switch on position.

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 ASAW-630 /1000 /1250 –Ⅱ

Use power switch on the distribution panel (closet) to switch welder on/off. Do not
misuse this circuit breaker as power switch.
2. Procedures for regular operating .
2.1 SMAW or Carbon Arc gouging.
（1）Connect weld handle cable to the welder”+”
（2）Connect welder“-” to the weld work piece by the Output (-) cable.
（3）Connect the welder and control box with the control cable.
（4）Turn on the power supply

（5）Set the working mode to “ ”(SMAW)

（6）Select “ ”Remote control or “ ”（Panel Control） according to the

requirement.
（7）Preset arc force current.
（8）Preset welding current, then welding.

Note: (1). Position “ ”(SMAW), if the machine display error code “E008”, it means
there is short circuit between welder(+) and (-). Shut off the welder in time to
eliminate the fault.

(2）In SMAW, if misplace the position “ ”(saw), there will be no welding

current output
(3)When use SMAW, refer to the Welding Parameters in Table 9:
Workpiece thickness
＜1 2 3 4～5 6～12 ≥13
(mm)
Electrode diameter
1.5 2 3.2 3.2～4 4～5 5～6
(mm)
Welding current(A) 40 40～50 90～120 90～120 160～250 250～400

Table 9: Recommend SMAW Welding Parameters

2.2 For SAW use
（1）Refer to the Figure 1, completely wire the welding system , turn on the machines

（2）Select the work mode as “ ”(SAW)

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 ASAW-630 /1000 /1250 –Ⅱ

（3）Select “ ”(remote control)

（4）Select “ ” （Flat characteristic）or “ ” （Droop characteristic）according

to the requirement.
Note:

 Select “ ” （Flat characteristic）, when using the wire diameter less than
φ3.0;

 Select “ ”（Droop characteristic）when using the wire diameter larger than

φ3.0
（5）Select the wire diameter parameters according to the welding wire.
（6）When in SAW flat characteristic welding, adjust arc force knob to regulate it to the
proper value according to the welding requirement.
（7）Adjust welding parameters according to the work piece. Weld after setting the
welding current, voltage and the preset speed
Note: Switch off the welder before install/uninstall cable and Contact Tube.
3. SAW welding forming and parameters selection
Seam forming has a very close relation with welding parameters, the orderliness is as
follows:
 Increase the welding current, he penetration depth decreases，welding seam is
wider.
 Increase welding voltage ,the penetration depth decreases, Weld wider,
 Reduce the speed of tractor, increased penetration, wider weld;

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 ASAW-630 /1000 /1250 –Ⅱ

Welding Current Range in Different wire diameters

Wire diameter
2 3 4 5 6
(mm)
Current density
63～125 50～85 40～63 35～50 28～42
(A/mm2)

Welding current
200～400 350～600 500～800 700～1000 820～1200
(A)

Table 10: Welding Current Range in Different wire diameters

TROUBLE FEATURE CAUSES WHAT TO DO

(1) Welding speed odds
(2) Instable wire feeding
Seam odds
Seam width odds (3) Instable contact tube
points
(1)Welding speed is too
fast
(2)Welding current is too
Undercut large
(3)Arc voltage is too big
(4)Incorrect wire end
Excessive Flux backing
Convex
pressure
(1)Eliminate the circuit
faults
(2)Adjust the wire
feeding roller
(3)Replace the Contact
tube
(1)Reduce the welding
speed
(2)Reduce the welding
current
(3) Reduce the welding
voltage
(4) Adjust the welding
wire’s position
Improve the Flux backing

(1)Too long of wire (1)Reduce the length

extension
Metal spillage (2)Groove is too small
(3)Arc voltage is too low
(4)Incorrect wire end
(1) Welding Current is too
large
(2) Welding speed is too
Burn-thru and
slow
thick back weld
(3) Large groove gap
(4) Flux backing is loose
(2)Change the Groove
(3)Increase the Arc
voltage
(4)Adjust wire position
(1)Reduce the Welding
Current
(2)Increase the welding
speed
(3) Improve the assemble
quality
(4) Improve the fixture

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(1)Too low welding
current
(2)Welding speed is too
fast
(3)Arc voltage is too high
Poor fusion (4)Incorrect wire end
(5)Fluctuation of power
network voltage
(1)Cylindrical ditch (1)Base metal tarnished or
(2)distribute around not Clear
seam center (2)Wire does not
porosity (3)sporadic or swarm completely derusting
(3)Flux humid
(4)Flux composition or
bad performance
(1)Exist along the seam (1)Low melting point
vertical or horizontal sulfide excessive
Heat Crack grain boundaries segregation
(2)Forming a single (2)Before-or terminal at
double-sided welding Weld crystallization
at the beginning or the without adequate binding
end
(1) Slag is not clean when
multi-layer-welding
Slag
(2) Wire position is not
correct
Table 11: Seam defects, cause and troubleshooting in SAW
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(1)Increase the current
properly
(2)Slow down the
welding speed
(3)Reduce the Arc
Voltage
(4)Straighten wire and
adjusting welding
head position
(5)Avoid peak period of
power utility
(1) Enhance the clean-up
(2) Drying Flux
(3)Choose appropriate
Flux
(1) Choose low carbon,
low sulfur, high
manganese wire and
low silicon high
manganese Flux
(1) Clean the slag
(2) Adjust the wire
position
 ASAW-630 /1000 /1250 –Ⅱ

Repair & Maintenance

WARNING:

 Have a qualified electrician do the maintenance and trouble shooting work. Turn the
input power off, using the disconnect switch at the fuse box before working inside the
machine.

 Do not open up the shell frequently. The max volt inside machine is 600V. Please
take safety precautions to prevent from being electric shocked while in maintenance.
1.Easily misunderstood phenomena
Normal phenomena occurring in welding are as follows:
1.1 Welder does not work while in pretty low input volt.
1.2 Fan doesn’t work when standby; Fan works when welding.
1.3 When welder has worked for a long time in high temperature or in high welding current
context, the thermal-sensitive circuit breaker will trip to stop welder working, and protection
lamp will light up. Welder will automatically resume working after running up for several
minutes in open load (not necessarily shut down welder).
2. Caution
2.1 The machine should be placed in dry places with good ventilation, rather in high
temperature and wet places.
2.2 The input volt range is must between 340-420V, and no phase missing.
2.3 Check if the ground lead is connected correctly and firmly.
2.4 Check frequently all the cables and tighten terminals if they are loose. Otherwise
terminals will be burn out, causing welding process instability.
2.5 Power off as soon as the welding finishes.

3. Procedure for regular checking prior to maintenance

3.1 Check if the input volt has phase missing, and the range is between 340-420V.
3.2 Check if input primary power cable is connected correctly and firmly.
3.3 Check if the ground lead is connected correctly and firmly.
3.4 Check if the cables are connected correctly and firmly
3.5 Check if the indications and the selections of the panel is correct.
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 ASAW-630 /1000 /1250 –Ⅱ

3.6 Ordinary failures, probable causes and countermeasures refer to Table 12

№ TROUBLE CAUSES
(1)Power phase missing
(2)Fuse (3 A) broke
(3)Fan, power transformers,
Welding machine does solid state relays or the main
control board damage
1 not work
(4)Power off
Fan doesn’t work (5)Air switching Trip
(6)The following devices may
during welding,
be damaged: IGBT modules,
three-phase rectifier
modules, the output diode
modules and other devices
Welding Current not (1)Power phase missing
2 (2)Current sensor damage
stable
(3)Control board damage
(1)Inside cable break
Welding current can not
3 (2)Damage control board
be adjusted
(3)Damage control cables
4 Error Code E001 Over heat protection
WHAT TO DO
(1)Check power
(2)Check fan, power
transformers, relays and
solid state control board
is intact
(3) Check line connection
(4) Maintenance inspection
by the professionals ,
the damage of IGBT
will cause drive board
damage, both need be
examined and replaced
(1)Check power
(2)Check and replacement
Check and replace
Run in open-load for couple
of minutes

5 Error Code E002 Short-circuit on output diodes Check and replace

6 Error Code E003 Communication fault Check the control cable

7 Error Code E004 Short-circuit wire feeder Check and repair

8 Error Code E005 Wire feeder fault Check and repair

Short-circuit on travelling
9 Error Code E006 Check the control cable
motor
10 Error Code E007 Tractor motor fault Check and repair
Short-circuit when switch
11 Error Code E008 Check and repair
SAW to SMAW
12 Error Code E009 Current displayer fault Check and repair
Note: Except (4) and (11), must restart the machines after completing the trouble
shooting for continuing work

Table 12: Troubleshooting table

4. Periodical check and maintenance
 Rivet equipment name tag on the specified area of the case, otherwise the inside parts
will possibly be damaged.

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 ASAW-630 /1000 /1250 –Ⅱ

 Connect welding cable to terminals firmly, otherwise the terminals will be burn out
which will cause the instability of welding process.
 Avoid welding cable and control cable being broken, and prevent welding machine
from being short circuit.
 Never let welding machine be bumped into or stacked up by heavy objects.
 Ensure good ventilation
 Under high temperature, if work with large current for long period, welder may shut
down automatically due to thermal protection acts .At this point, let the machine runs
under open-load for a few minutes, and it will be automatically recover.
 Under high temperature, if work with large current for long period, welder may shut
down automatically due to air switcher trips. Cut off the power supply to the
electricity switchboard on frame, and wait for 5 minutes to turn on the air switcher on
the power source fist then connect the power supply to the electricity switchboard on
frame. And leave the machine runs under open-load condition for a while.
 After welding, cut off the Argon gas supply and the power supply.

5. General maintenance

 Remove dust from power resource with pressure air by qualified individuals every
3-6 months. Check if the jointers are loose.
 Check regularly if cables are worn out, knobs are loose, and components of panel are
damaged.
 Check regularly if cables are tightly connected to cable connecting terminals in case
of terminals being burnt out.
 Clean and replace Contact Tip and Tungsten Electrode in time.

WARNING: Have a qualified electrician do the maintenance and trouble shooting work.
Turn the input power off, using the disconnect switch at the fuse box before working
inside the machine. Don’t open up case uninstructed, the max volt inside machine is 600V,
Never discharge high voltage to welder case with welding torch! Shut down power source
before changing or repairing welding cable or torch

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 ASAW-630 /1000 /1250 –Ⅱ

Appendix A

1. General
The user is responsible for installing and using the arc welding equipment according to the
manufacturer’s instructions. If electromagnetic disturbances are detected, then it shall be
the responsibility of the user of the arc welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial action may be as
simple as earthling the welding circuit, see note. In other cases it could involve
constructing an electromagnetic screen enclosing the welding power source and the word
complete with associated input filters. In all cases electromagnetic disturbances shall be
reduced to the point, where they are no longer troublesome.
NOTE: The welding circuit may not be earthed for safety reasons. Changing the
earthling arrangements should only be authorized by a person who is
competent to assess whether the changes will increase the risk of injury.
2. Assessment of area
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into
account:
1) Other supply cables, control cables, signaling and telephone cables, above, below and
adjacent to the arc welding equipment;
2) Radio and television transmitters and receivers;
3) Computer and other control equipment;
4) Safety critical equipment, for example guarding of industrial equipment;
5) The health of the people around, for example the use of pacemakers and hearing aids;
6) Equipment used for calibration or measurement;
7) The immunity of other equipment in the environment is compatible. The user shall
ensure that other equipment being used in the environment is compatible. This may
require additional protection measures;
8) The time of day that welding or other activities are to be carried out.
3. Methods of reducing emissions
1) Public supply system
Arc welding equipment should be connected to the public supply system according to
the manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the public supply system. Consideration
should be given to shielding the supply cable of permanently installed arc welding
equipment, in metallic conduit or equivalent. Shielding should be electrically
continuous its length. The shielding should be connected to the welding power source
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 ASAW-630 /1000 /1250 –Ⅱ

so that good electrical contact is maintained between the conduit and the welding power
source enclosure.
2) Maintenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the arc welding equipment is in operation. The arc
welding equipment should not be modified in any way, except for those changes and
adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of
arc striking and stabilizing devices should be adjusted and maintained according to the
manufacturer’s recommendations.
3) Welding cables
The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
4) Equipotent bonding
Bonding of all metallic components in the welding installation and adjacent to it should
be considered. However, metallic components bonded to the word piece will increase
the risk that the operator could receive an electric shock by touching these metallic
components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.
5) Earthling of the work piece
Where the work piece is nor bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example ships hull or building steelwork, a
connection bonding the work piece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthling of the work piece increasing the
risk of injury to users, or damage to other electrical equipment. Where necessary, the
connection of the work piece to earth should be made by a direct connection to the work
piece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
6) Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding area
may alleviate problems of interference. Screening of the entire welding installation may
be considered for special applications.

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 ASAW-630 /1000 /1250 –Ⅱ

Appendix B

Feedback Form
Name of Company
Address
Contact person Title
Telephone No Fax No.
Email Address
Company’s filed of business
Comments:

Thank you for taking the time to share your feedback. Your comments and suggestions will
help us to serve you better.
Please send fax or e-mail your feedback, Aotai Electric will response you within 24 hours.

Contact information
Aotai Electric Co., Ltd.
Attend to Global Sales Department
Tel: +86-531-81921006,
Fax: +86-531-88876665
www.aotaiwelding.com
E-mail: sales@aotaiwelding.com
info@aotaiwelding.com

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