WZM-400 Pulse TIG Welder

USER MANUAL

Before use WZM-400, please carefully read this manual.

This manual includes its operation &maintenance.

Please keep it well after reading.

Shandong Aotai Electric Co., Ltd.

Jinan, China
2017.09
 Power Source WZM-400

Thank you for choosing AOTAI WZM-400！

We provide you with reliable welding equipment, comprehensive after-sale service and high

efficient technical support. We are proud of your choice and hope that you will be proud to

choose us!

Manual’s Purpose
This manual helps you understand this orbital welding system’s basic structure, complete its

debugging, realize automatic welding and improve production efficiency.

In order to ensure safety, please carefully read and fully understand this manual. Operation has to

be done by professional workers.

Technical Support & After-Sale Service

Warranty scope of this product is any failure under operating requirement in the warranty period from

the date of factory delivery. Other faults out of warranty scope have to be paid for service.

Below cases are out of warranty scope.

A: Accidents caused by operations that do not comply with operation requirement.

B: Damage caused by natural disasters and others.

C: Disassemble, modify and repair without permission.

You can contact us for technical support and after-sale service as below.

◆ Tel：0531-88879130 Fax：0531-88876665

◆ Add：282 Bole Ave, High-tech Development Zone, Jinan, Shandong 250101, P.R. China

More info for AOTAI products.

Please check our website www.aotaiwelding.com for more info of our company and products.

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 Power Source WZM-400

Contents
1. SAFETY CAUTION..................................................................................................................................................................2

2. ELECTROMAGNETIC COMPATIBILITY......................................................................................................................... 4

2.1 SUMMARY.............................................................................................................................................................................. 4
2.2 ENVIRONMENTAL ASSESSMENT RECOMMENDATIONS...........................................................................................................4
2.3 METHODS OF REDUCING RADIATION.................................................................................................................................... 4

3. WELDING MACHINE INSTALLATION............................................................................................................................. 6

3.1 INSTALLATION ENVIRONMENT............................................................................................................................................... 6

3.2 SUPPLY VOLTAGE QUALITY................................................................................................................................................... 6
3.3 MAINS INPUT..........................................................................................................................................................................6
3.4 EQUIPMENT INSTALLATION................................................................................................................................................... 6

4. MODEL NAMING & DESCRIPTION................................................................................................................................... 7

5. INTRODUCTION OF WELDING MACHINE..................................................................................................................... 8

5.1 WELDING SOURCE..................................................................................................................................................................8

5.2 CONTROL PANEL FUNCTION.................................................................................................................................................10
5.3 DIGITAL REMOTE CONTROLLER........................................................................................................................................... 19
5.4 BRIEF INTRODUCTION OF THE PRINCIPLE.............................................................................................................................20
5.5 EQUIPMENT LIST..................................................................................................................................................................21

6. OPERATION GUIDE............................................................................................................................................................. 22

6.1 OPERATION.......................................................................................................................................................................... 22
6.2 FINE TUNING OF PARAMETERS DURING WELDING................................................................................................................24

7. MAINTENANCE.....................................................................................................................................................................25

7.1 COMMON FAILURE ANALYSIS AND EXCLUSION................................................................................................................... 25

7.2 MATTERS NEEDING ATTENTION........................................................................................................................................... 27
7.3 CLEANING AND MAINTENANCE............................................................................................................................................27

8. TECHNICAL DATA...............................................................................................................................................................29

8.1 TECHNICAL PARAMETERS.................................................................................................................................................... 29

8.2 MAIN CIRCUIT SCHEMATIC DIAGRAM.................................................................................................................................. 30
8.3 WZM-400 MAIN PARTS LIST............................................................................................................................................... 31

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1. Safety Caution
For your safety, health and proper use of this product, please read the following safety precautions

carefully before using.

Basic requirements for safe operation

◆Please strictly use the manual for installing and debugging !
◆Electrical connection must be performed after the power switch is off!
◆Operation process should be carried out according to relevant safety operation procedure!
◆Irrelevant personnel please do not enter welding site! Be sure to wear right clothes and
protective gears!
◆Construction of input power supply, selection of the site, usage, storage and configuration
of high pressure gas, storage of welded work piece, and waste disposal should be done
according to relevant standards！
◆In order to ensure safety, please carefully read and fully understand this manual. Operation
has to be done by professional workers！
◆The equipment shall not be used for work other than welding！
◆Please do not use cable with insufficient capacity or damaged insulation sheath！
◆Regular maintenance is very necessary. Damaged parts have to be repaired before use
again！
◆Turn off all input power if not use！

Warning: Shock hazard

◆Please do not touch the electrified parts. During welding, temperature of electrode, nozzle,
welding torch and workpiece is very high. Please do not touch them directly with your skin
or wet cloth.
◆Use dry insulation to insulate you from workpiece and ground. Size of insulation material
should be big enough.
◆In safe operation mode, check whether electrode, ground clamp, welding cable and welder
are in good condition, replace if damaged.
◆Workpiece and welded metal need to be grounded well.
◆Electrodes cannot be thrown into water for cooling.

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Warning: Welding arc, spatter and welding slag are harmful to health

◆When welding, please wear good protective glasses. Arc can cause inflammation of eyes, splash
and welding slag can burn eyes.
◆Please wear protective clothing made of flame retardant material so as to avoid arc, splash and
welding slag burn, or scald skin.
◆Use incombustible screen to protect people around from arc rays.

Warning: Smoke is harmful to health

◆Smoke during welding is harmful to health. Please try to avoid breathing in these smoke.
◆Inhalation of protective gas for welding is harmful to human health. So, welding site must be well
ventilated.
Warning: Fire risk
◆Combustible materials cannot be put at welding site. Spatter and hot welding seam can cause fire.
◆Welding cable and base metal must be well connected. Otherwise heating might cause fire.
◆Fire extinguisher should be prepared.

Warning: Cylinder will explode if damaged.

◆Only good compressed gas cylinder can be used. Its regulating valve, gas tubes, filter should be
well and suitable.
◆Cylinders must stand upright and should be fixed well.
Gas cylinder installation

◆Sufficient space is necessary so as to avoid collision.

◆Maintain safe distance from welding site or other heat source and fire source.
◆Do not touch gas cylinders with electrodes, electrode clips or other charged parts.
◆When opening valve, head and face should not face to valve outlet.
◆Please do not remove protective cap and handle of gas valve unless the cylinder s in use or ready
to use.

Warning: Noise over 70 db will permanent damage to hearing

◆Please wear appropriate earmuffs.
◆Ensure that the noise does not cause inconvenience to other people passing through the working
area.
Warning: Electromagnetic interference must be reduced to a level that no longer constitutes
interference
◆Reduce factors that cause interference.
◆Regular maintenance for welding machine is very necessary.
◆Wires should be as short as possible and should be close to or near the ground.
◆Protecting surrounding wires and equipment can reduce impact of radiation.

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2. Electromagnetic Compatibility

2.1 Summary
Welding will cause electromagnetic interference, which can be minimized by suitable installation and

correct usage.

The product described in this manual is A class device, which is applicable to all situations except

residential areas powered by a public low voltage power system.

Warning: A class device is not suitable for using at residential areas because of radiation.

2.2 Environmental Assessment Recommendations

Before installing arc welding equipment, user should evaluate the potential electromagnetic disturbance in

the surrounding environment.Below factors need to consider.

1) Check whether there are power supply cable, control cable, signal and telephone wires around arc

welding equipment;

2) Check whether there is broadcasting or television transmission and receiving equipment;

3) Check whether there is computer or other control equipment;

4) Check whether there is high safety grade equipment, such as industrial protective equipment;

5) Need to consider health of the workers around, such as those who use hearing AIDS or heart

pacemakers;

6) Check whether there are equipment for calibration or testing;

7) Need to pay attention to other surrounding equipment’s immunity to interference. Users should ensure

that other equipment is compatible, which might need extra protective measures.

8) Time of welding or others.

Environment scope consideration depends on building structure and other possible activities. The scope

may exceed boundary of the building itself.

2.3 Methods of Reducing Radiation

1) Public Power Supply System

Arc welding equipment shall be connected to public power supply system as recommended by the

manufacturer. If interference occurs, additional precautions should be taken, such as add filters in utility

system. For fixed installation of arc welding equipment, shielding of power supply cable should be

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considered, which can be realized by metal tube or other equivalent method. Shielding needs to keep

electrical continuity. Shielding layer also needs to be connected to the welding machine case to ensure

good electrical contact between them.

2) Maintenance of Arc Welding Equipment

Welding equipment should be maintained according to manufacturer's recommended method. All inlet,

auxiliary doors and cover plates should be closed and properly tightened when welding equipment is

running.Arc welding equipment shall not be modified in any form, unless there is a corresponding change

and adjustment on the instruction manual, especially.In particular, spark gap between arc starting and arc

keeping devices should be adjusted and maintained according to manufacturer's suggestion.

3) Welding Cable

Welding cables should be as short as possible and close to each other, as well as close to the ground.

4) Equipotential Overlap

Be sure to pay attention to overlap of all metal objects surrounding.Overlap of metal objects and

workpieces can increase risk of work.Operator may be electrocuted when touching metal objects and

electrodes at the same time. Operators should be insulated from all these metal objects.

5) Workpiece Grounding

Owing to electrical safety or workpiece position &size, workpiece might not be grounded, such as ship

body or building steel frame.Workpiece grounding can reduce irradiation sometime, but not always.

Therefore, it is necessary to prevent increasing of electric shock for users or damage of other electrical

equipment. When necessary, workpiece should be directly grounded, but not allowed in some countries

and can only be realized by suitable capacitance as specified .

6) Shielding

Suitable shielding of surrounding equipment and other cables can reduce electromagnetic

interference.Special applications may need shielding of the entire welding area.

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3. Welding machine installation

3.1 Installation environment

1) Welding machine should be put indoor with no direct sunlight &rain, low humidity, less dust, and

ambient air temperature - 10 ℃ ~ + 40 ℃. Cooling liquid in the tank must be antifreezing

2) Ground slope should be no more than 15 °.

3) There should be no wind in welding position.

4) Distance between welding machine and walls needs to be above 20cm, and more than 10cm

between welding machines.

3.2 Supply voltage quality

1) Waveform should be standard sine wave, effective value is 380V ±10%, and frequency is 60Hz.

2) Imbalance of the three-phase voltage is less than 5%.

3.3 Mains input

Welding machine model WZM-400

Input power 3phase, AC380V

Minimum capacity of power grid 28KVA

Fuse 50A
Input protection
Breaker 63A

Input side 2.5mm2

Cable Output side 50mm2

Ground cable 2.5mm2

Table 3-1 Power Input

Note: capacity of fuse and circuit breaker in the above table is only for reference.

3.4 Equipment Installation

Welding machine input power is 3 phase 380V/60Hz AC.Users shall have corresponding power

distribution cabinet and shall have auto air switch in it. Ground cable connection must be reliable.

1) Connect ground cable.

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2) Connection of welder and machine head.

● Connect machine head’s aviation plugs to welding machine front panel’s 5 pin & 24 pin aviation

sockets.

● Connect head’s welding cable to welder front panel’s quick socket “-” .

● Connect head’s yellow and black PU tubes to welder front panel’s copper gas outlets “1” & “2”. ；

● Connect machine head's red and blue PU tubes with welder front panel's red and blue quick sockets

respectively.

3) Connect flow meter gas outlet and welder gas inlet with rubber tube.

4) Connect quick socket "+" to workpiece through welding cable (with ground clamp).

5) Switch on air switch of TIG welding machine.

6) Connect 3 phase input cable to disconnecting link, switch on.

4. Model Naming & Description

WZM-XXX

Rated welding current

Pulse
Auto welding
TIG welding

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5. Introduction of welding machine

WZM-400 is mainly composed of WZM-400 power source (including control panel, water cooling
system, trolley), digital remote controller and welding cables. Its control function mainly includes
providing DC/pulse current output, control head's front &back, rotation, wire feeding motions, control
gas & arc length(optional), etc. This welding machine can weld carbon steel, stainless steel, etc. It can
realize fully automatic all positional tube/plate welding.

5.1 Welding source

Front panel：

A1

A2 A11
A10
A9
A3 A8
A7
A4
A5
A6

Fig. 5-1 Front panel

Rear panel：

A12
A20

A13
A14
A19
A15
A16 A18

A17

Fig. 5-2 Rear panel

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Welding Equipment Introduction

Code Name Function

Modify welding parameters, real-time monitoring of

A1 10 inch touch screen human interface
welding

A2 Exhaust window Remove internal gas, cooling power source

A3 Compressed air outlet Connect pneumatic components of machine head

A4 Water tank inlet

A5 Plastic water tank Put cooling fluid

A6 Water outlet Connect water inlet tube of torch

A7 Backwater connector Connect backwater tube of torch

A8 Protection gas outlet Provide protection gas for torch

A9 Power source negative pole Connect torch negative pole

A10 Head control interface Control torch's motions

A11 Digital remote control interface Connect power source and digital remote controller

A12 Mains switch

A13 Compressed air inlet Connect power source and gas cylinder

A14 Protection gas inlet Connect power source and gas cylinder

Place the cylinder, convenient moving of welding power

A15 Trolley
source

A16 Exhaust window Remove internal gas, cooling power source

A17 Water tank drain interface Plastic water tank drainage

A18 Power source positive pole Connect workpiece

A19 Exhaust window Remove internal gas, cooling power source

A20 Power supply cable interface Supply power for whole system

Table 5-1 Welding Equipment Introduction

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5.2 Control panel function

● Control panel main interface

Fig 5-3 Control panel main interface

This system control panel adopts 10 inch touch screen display. As above figure, it mainly includes user
log in, welding parameter setting, system setting, welding monitoring.
User log in：need to enter password for changing welding specs.
Welding parameter setting:include advanced and normal parameter setting interfaces, convenient for
operation.
System setting:setting parameters of rotation speed increment, wire feeding speed increment, current
increment and voltage increment, as well as manual rotation speed, manual wire feeding speed and
welding torch jog speed, etc.
Welding monitoring: real-time monitoring of whole welding process. Relevant welding parameters,
operation stage, current position, welding mode and alarm information can be viewed in real time.
Operation: Directly click on corresponding functional control to show corresponding functional
interface, as shown in below.
● User login function interface

Fig. 5-4 User login interface

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Only after log in this interface, can users change welding parameters and other relevant data, otherwise

can't do anything. This prevents wrong operation on equipment by users themselves or others.

Click on behind “Password”, interface fig. 5-5 will display. Directly click on numbers to

enter password, click on for log in. Factory setting password is 123. Users can click on

for changing. As shown in fig.5-6, enter new password, click on .

Fig. 5-5 Password input interface

Fig. 5-6 Password modification interface

After log in, users can complete setting and changing of relevant parameters. Then, they can directly

click on ，then click to exit from this interface.

Note: in Fig. 5-6 number input interface, is to empty all input digits, is to exit from digit
input interface.

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● Welding parameter setting function interface

This interface has two parameter setting functional modes for different users. They can switch with

and on top right corner of the interface.

Default interface is for normal user as shown in fig.5-7. Click green arrow on the left, users can check

or change other welding parameters, as shown in Fig. 5-8.

Fig. 5-7 Welding parameter changing interface1

Fig. 5-8 Welding parameter changing interface 2

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Related function keys

Item Function Remark

Specification Program specification range：0~59

Name Specification name setting by users

Mounting mode of machine head: Operating frame or

Installation
balancer

Subsection Subsection range：1~16

Can select different interface types displayed by

Sequence diagram/list
welding parameters

Pulse/DC Can select type of welding current

Whether welding torch returns to arc starting position

Return OFF/ON
after welding

Tracking OFF/ON Whether arc length automatic tracking function is on

Whether function of tungsten electrode touching

Touch OFF/ON
workpiece is On

Save Save modified parameters

Delete Delete current specs

New New welding specifications

Main menu Display control panel main interface

Table 5-2 Function Introduction of Keys on Welding Parameter Setting Interface

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1.Selection of welding specifications

All systems have prestored suitable welding specs for user’s workpiece. They can select suitable specs

on below interface and can return to main interface by clicking .

Fig. 5-9 Welding specification selection interface

2.New or modified welding specifications

1) Select on the interface, fig 5-9 will display. Select and name new specs as shown in Fig.

5-9&5-10. As shown in Fig. 5-11, select working mode corresponding to welding head. As
shown in Fig. 5-12, enter new subsection quantity.

Fig. 5-10 Welding specification naming interface

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Fig. 5-11 Welding specs installation mode selection interface

Fig. 5-12 Welding specs subsection selection interface

2) Select corresponding control below each welding parameter and enter corresponding parameters to

complete setting of parameters.

3) Click parameter control at the bottom line of welding parameter interface to select required welding

mode and function state.

4)After all welding parameter settings are completed, select "Save", the new set of welding

specifications can be saved.

For welding specs modification, after selecting the specs that need to modify, do as the above.

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For operating users with certain welding skills, we have image intuitive setting interface, as shown in

Fig. 5-13.

T22
T11 T12
T23 N21
T21
I21 I23 I22
T24 I24
V31

V41

T41 V42 T42

N41
N51 H52
H51 U51

Fig. 5-13Welding Parameter Setting Sequence Diagram Interface

Label Annotation

Function
Label Annotation Parameter range Remark
module

T11 Pre-gas time 0.01~30 S

Gas feeding
T12 Post-gas time 0.01~30 S

T21 Premelting time 0.01~30 S

T22 Peak time 0.01~1 S

T23 Base time 0.01~1 S

T24 Down slope time 1~60 S

I21 Premelting current 5~400 A

Current
I22 Peak current 5~400 A

I23 Base current 5~400 A

I24 Extinguish current 5~400 A

Starting point of
N21 1~9999°
down-slope

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Rotation V31 Rotational speed 0.35~6.0r/min

T41 Delay wire feeding time 0~30 S

T42 Wire retracting time 0.01~5 S

Wire
V41 Peak wire feeding speed 0~1800mm/min
feeding
V42 Base wire feeding speed 0~1800mm/min

N41 End of wire feeding 1~9999°

N51 Delay tracking time 0~30 S

Lifting height after

H51 0.1~9.9 mm
touching work piece
Arc voltage
Torch lifting height after
H52 0.1~19 mm
welding

U51 Arc voltage 0.1~30 V

Table 5-3 Label Annotation

● System Setting Functional Interface

Fig. 5-14 System Setting Functional Interface

Increments of rotation speed, wire feeding speed, current, voltage are adjusted by digital remote

controller during welding.

Inching speeds of rotation, wire feeding, and torch are motion speeds of all parts when manually

controlled.

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On this interface, users can change system parameters according to needs and can save the changing. If

they want to use the previous parameters, they can select . If they want to use

factory parameters, they can select .

● Welding monitoring function interface

Fig. 5-15 Welding monitoring function interface

As shown in the above interface, during welding, control panel will real-timely display welding current

&voltage, wire feeding speed, rotation speed, running status, welding position and welding mode, etc.

This makes it convenient for users to know welding status in time and better control whole welding

process.

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5.3 Digital remote controller

Digital Remote Controller Label and Function Description
Label Function Description
Emergency stop button
Press the button and welding will stop immediately.

Welding start button

Simulate welding button

Press this button, no current and wire feeding, but others are same with
real welding.
Current slope-down button
During welding, press this button, current will start to decrease as
presetted and finally stop.
Function button
Press this button to select welding specs.
Before welding Welding process
Release function
Press Function button
button Upper button is for increasing arc length,
Upper button is for Upper button is for increasing ΔU51 per time of pressing.
increasing program no. torch moving forward. Lower button is for decreasing arc
Lower button is for Lower button is for length, decreasing ΔU51 per time of
decreasing program no. torch moving back. pressing.
Upper button is for increasing current,
increasing setted ΔI on power source per
Upper button is for gas test. time of pressing.
Lower button is for water test. Lower button is for decreasing current,
decreasing setted ΔI on power source per
time of pressing.
Left button is for decreasing welding
speed, decreasing ΔV31 per time of
Left button is for reverse rotation. pressing.
Right button is for positive rotation. Right button is for increasing welding
speed, increasing ΔV31 per time of
pressing.
Left button is for decreasing wire
feeding speed, decreasing ΔV41 per time
Left button is for retracting wire. of pressing.
Right button is for feeding wire. Right button is for increasing wire
feeding speed, increasing ΔV41 per time
of pressing.

Table 5-4 Digital remote control function description

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5.4 Brief introduction of the principle

Brief introduction of the principle is as shown in below.

3 phase rectifier HF inverter HF transformer Rectifier filter

Control circuit

Fig.5-10 Welding Machine Principle

This welding machine adopts IGBT HF inverter technology. After rectified, PF 3 phase 380V power

will be given to IGBT inverter and changed to HF AC, then pass HF transformer, HF rectifier filter,

and then output. This process greatly improves welding machine’s dynamic response capability,

reduce size and weight of transformer and electric reactor, as well as increase whole machine’s

efficiency.

Design of control circuit ensures good welding performance despite of external condition changes,

such as power grid voltage fluctuation, and different output cable length, etc. Easy arc starting, stable

arc, good welding seam, and continuous adjustment of welding current are its good features.

Welding machine output feature is as shown in below.

Fig. 5-11 TIG Output Feature

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5.5 Equipment List

All products must pass strict quality inspection and are well packed before delivery from factory.

While, for some unexpected reasons during transportation, there might be damage or loss. Therefore,

please carefully check the goods after receiving.

No. Name Unit Qty Remark

1 WZM-400 power source pc 1

2 Digital remote controller pc 1

3 welding cable m 5

4 User manual set 1

5 QC card pc 1

6 Warranty Card pc 1

7 Protective tube pc 1

8 Stainless steel clamp pc 1

9 Grounding clamp pc 1

10 packing list pc 1

Table 5-5 Equipment List

Remark：Due to continuous improvement of technology, appearance, color and parameters of the equipment

may change.

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6. Operation guide

6.1 Operation
1) Starting up

Switch on the power source, it will be in standby, check whether rotating, wire feeding, arc length and

other function keys on the digital remote controller are normal

Note: Check whether there is enough coolant in water tank before starting up and ensure that it is not

less than 3/4 of water tank volume. Otherwise, it will damage water pump or welding torch.

Coolant in the tank must use antifreezing fluid.

Antifreezing fluid function：1.Antifreezing; 2.Anti-corrosion; 3.Anti-boil; 4.Antifouling. Main index is

its freezing point, which should be lower than local lowest temperature.

Recommended manufacturer：Changcheng

Model:FD-1, Antifreezing temperature: -25℃, suitable for:lowest temperature >-15℃

Model:FD-2b,Antifreezing temperature: -35℃, suitable for:lowest temperature> -25℃

Model:FD-2a, Antifreezing temperature: -45℃, suitable for:lowest temperature> -35℃

Specs: 4L/6L/10L/200L.

2) Call welding specs

User can log on system interface for selecting, setting up or modifying welding specs. Please refer to

above Control Interface Function Description for detailed operation.

User can also do this with digital remote controller without logging on system interface. Please refer to

above Digital Remote Controller Function Description for detailed operation.

3) Adjust position of welding torch

For this operation, users must be familiar with the torch. Before welding start, they mainly use remote

controller’s torch control keys & to realize precise positioning of tungsten electrode.
Please refer to above Digital Remote Controller Function Description for detailed operation.

4)Setting of wire feeding position

On remote controller, with key to control wire feeding, key for wire retracting.

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5) Start Welding

1. Before welding starts, check whether selected welding specs on digital remote controller LCD are

correct. If not, directly change it on digital remote controller.

2. In order to check whether this program is suitable for the work piece, press key on digital
remote controller for welding simulation.

3. Press key to start welding.

6)Shutdown

This equipment can be directly shut down any time. There are mainly 3 methods as below and users

can choose accordingly.

1. Shut down step by step

During welding, press current slope-down button on digital remote controller, current starts to

decrease according to presetted program and finally arc stops. Wire feeding and automatic arc length

control functions stop when slope-down begins. After arc stops, rotation will stop and there will be a

period of post-gas time to protect welding torch and tungsten electrode. This method is recommended

in normal use case.

2. Emergency shut down

When emergency or system crash, users can directly press emergency shut down key on digital
remote controller.

3. Shut down because of power cut

Users can put the mains switch on rear panel of welding machine to OFF, then the whole machine will

be power off.

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 Power Source WZM-400

6.2 Fine tuning of parameters during welding

Following parameters can be modified on digital remote control during welding.

◆ Welding current

◆ Rotation speed

◆ Wire feeding speed

◆ Arc voltage

Increment size can be set during programming. When welding, every time you press button “I+” or

“I-”, current will change according to the set increment. This can improve welding quality. As is

known to all, metal composition of different tubes are not the same. The operator can select suitable

welding parameter values according to different tubes.

Below buttons can be used for parameter modification.

Button Function

Upper button is for increasing arc length, increasing ΔU51 per time of pressing.

Lower button is for decreasing arc length, decreasing ΔU51 per time of pressing.

Upper button is for increasing current, increasing setted ΔI on power source per time of
pressing.

Lower button is for decreasing current, decreasing setted ΔI on power source per time
of pressing.

Left button is for decreasing welding speed, decreasing ΔV31 per time of pressing.

Right button is for increasing welding speed, increasing ΔV31 per time of pressing.

Left button is for decreasing wire feeding speed, decreasing ΔV41 per time of pressing.

Right button is for increasing wire feeding speed, increasing ΔV41 per time of pressing.

Table 6-1 Button function description

During each welding cycle, parameter modification on digital remote controller only affect parameters

in this cycle. After the cycle is completed, welding parameter value will restore to program set value.

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 Power Source WZM-400

7. Maintenance
7.1 Common failure analysis and exclusion
During welding, system monitors different points. Once failure occurs, it will automatically stop
depending on the situation.
Fault Reason Remedy
1.Confirm that the equipment is in normal use range.
Touch screen 2.Place the power source properly and keep its
1.Exceed power source welding capacity.
or digital suitable distance to the surrounding objects. Check
2.Air cooling cycle is not good.
remote whether there is blocking in air duct. If yes, clear
3. Power supply is not correct.
controller it.Check whether the ambient temperature of the
4.Cooling fan problem.
display equipment is too high.
5.Main control board problem.
"overheating" 3.Correct wire connection.
4.Check, repair or replace.
1.Tungsten electrode touches work piece.
1.Adjust workpiece or tungsten electrode position.
2.Tungsten electrode touches welding wire.
2.Adjust wire feeding angle, position or tungsten
3.Arc starting looping touches torch
Tungsten electrode position.
electrode.
electrode 3. Remove.
4.Wire feeding tube is not insulated from
short circuit 4.Check and repair.
welding torch.
5.Replace.
5.CPU mainboard problem.
6.Check and repair.
6.Voltage sampling circuit problem.
1.Check whether wire feeder motor cable is
1.Wire feeder motor cable is open circuit. correctly connected.
Wire feeder 2.Wire feeder motor cable is short circuit. 2.Check wire feeder motor cable is short circuit.
does not work 3.Wire feeder motor is blocked. 3.Check whether wire spool is twined, whether there
4.Wire feeder motor is damaged. are things in wire guiding tubes or wire guiding tips.
4.Check and repair.
1.Check whether rotary motor cable is correctly
1.Rotary motor cable is open circuit.
Rotary connected.
2.Rotary motor cable is short circuit.
motor does 2.Check whether rotary motor cable is short circuit.
3.Infinite rotating part fails.
not work 3.Check and repair.
4.Rotary motor is damaged.
4.Check and repair.
1.There is no or not enough coolant in water
Touch screen
tank. 1.Check, add coolant.
or digital
2. Cooling circulating water pipe is blocked. 2.Check, clear, or replace.
remote
3.Water quick connector is not well 3. Reconnect correctly.
controller
connected. 4.Check, repair, or replace.
display "Lack
4.Water cooling pump problem. 5.Check, debug or repair.
of Water"
5.Problem of water detection element.

Table 7-1 Common failure analysis

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 Power Source WZM-400

Water cooler fault & reason is as below.

Fault Reason Remedy

Wire connector is drop off
Ensure connector is good or replace the wire.
or wire is broken.
Motor or start-up capacitor
Replace motor or start-up capacitor
is burned.
Power cut, open machine case, turn fan leaves with
hand. If can turn, start up the machine, after
Motor cannot run
confirming water cooler can output water, then can
There is fouling in water use. If cannot turn, use a wrench to loosen the pump's
pump. 4 fixed bolts (see figure 7.1), then turn fan leaves until
they are not stuck, then tighten pump mounting
bolts.Start up the machine again, after confirming
water cooler can output water, then can use.

water Pump leakage Replace sealing ring

Drain cover is leaking Replace the sealant pad or replace the drain cover.
Water leakage
Water pipe is leaking Replace the clamp or connect the pipe

Radiator leakage Replace radiator

Open the air releasing cover on rear panel, release air

until see antifreezing fluid is flowing out.
Motor runs, but If there is no water output with above operation,
There is air in the pump.
no water output please put quick plugs into water outlet and backwater
port, feed air with air compressor into the two plugs,
then start up and check whether there is water output.

Table 7-2 Common Fault Analysis

Pump's fixed bolts

Fig. 7.1 Water Pump

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 Power Source WZM-400

7.2 Matters needing attention

1) Only professional personnel can check the machine. If the problem cannot be solved, please contact
us or our distributors.
Note: Highest voltage in the machine is up to 600V. In order to ensure safety, please do not open the
case at will and do safety protection against electric shock when repair.
2) During working, welding machine’s below phenomenon are normal.
◆ Welder does not work when input voltage is too low.
◆ When long time used at high temperature or high current, welding machine’s temperature
relay will automatically stop it. In this case, please run the machine in open-load for several minutes
and it will return to normal.
◆ When long time used at high temperature or long-time load running, air switch on rear panel
might automatically be off and cut power supply. In this case, switch off the power supply from
distribution box and shut down the machine for 5 minutes and then start up. For machine start up,
firstly switch on the welding machine's air switch, then switch on the power switch in distribution box.
After startup, run the machine at no-load for several minutes , then use.
3) Replace with original accessories.
4) Only professional personnel can repair the machine.
7.3 Cleaning and maintenance
In normal use, this machine only needs little maintenance.While, in order to avoid problems during
usage, it needs to pay attention to some matters, such as regular cleaning and checking. Of course, as
described below, this also depends on environment pollution level and welding machine usage time.
Cleaning, checking and maintenance must be done by professional personnel. If do not
obey below requirement and fault happens, please do not operate the machine until fault is
solved.
● Cleaning
Cut the power supply before cleaning.
◆ After power cut, wait for 2 minutes until the capacitor is fully discharged and then proceed to next
step.
◆ If dust is too much, use dry compressed air to clean.
◆ Electronic components of electrodes and circuit boards need to be cleaned with vacuum cleaner
instead of compressed air.

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 Power Source WZM-400

● Maintenance
◆ Water cooling system
1)Check whether anti-freezing liquid is enough before using water-cooler.
2)Replace anti-freezing liquid every 12 months. Method of emptying anti-freezing liquid: Firstly,
empty anti-freezing liquid through water outlet. Then put quick plugs into water outlet and backwater port,
feed air with air compressor into the two plugs, push anti-freezing liquid into water tank from pump and radiator, and

then empty anti-freezing liquid in water tank through water outlet.

3)Radiator should be clean up dust once every six months. If welding or cutting torches are too hot, reason might be

that dust on radiator is too much and reduce cooling ability of water cooler. It should be cleaned with dry

compressed air.
4) Filter should be cleaned once every 2 months.
Note: Our company is not liable for free warranty due to the damage caused by improper use, as
mentioned in below.
1 Radiator damage, water pump leaking, and motor damage caused by unreasonable use of
anti-freezing liquid.
2 When no or not enough anti-freezing, start up water cooler and cause pump or torch damaged.
3 Environment with acid, alkali, salt composition cause corrosion, leaking and damage to water
cooler.
◆ Airway seal
Regularly check sealing of all airway joints and tubes
◆ Fusing protection device
In order to protect equipment and operator, there is fusing protection device for WZM-400 TIG machine
at power transformer 380V input port.

◆ Short-circuit protection
During welding, improper setting or other reasons might cause tungsten electrode stick to work piece,
and welding machine will stop immediately so as to protect welding torch and power source. When
tungsten electrode sticks to work piece, it needs to carefully separate them and check whether tungsten
electrode is damaged. If damaged, replace it before using.
◆ Check whether there is fastener loosening in the machine. If yes, tighten it. Regular checking is
very necessary for connection of quick plugs or terminals, at least once every month.

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 Power Source WZM-400

8. Technical data
8.1 Technical parameters

Technical parameters

Item Technical parameters

Model Name WZM-400
Type Inverter
Application All position TIG tube/plate welding
Welding current 5~400A
Duty cycle（40℃） 400A 60% / 315A 100%
No-load voltage 70V
Input Voltage/Frequency 380V±10% 60Hz
Power 13.5KVA
Torch cooling Built-in circulating water cooling
Display 10 inch touch screen digital display
DC/pulse current
Rotational motion
Wire feeding
Control function
Gas control
Arc length control (optional)
Horizontal pendulum control (optional)
Stored program 60
Section 16
Pump head 35m
Water tank volume 6L
Protection/insulation level IP21S/H
Weight (no coolant) 99Kg
Dimension 1100×600×1250mm
Indoor temperature：-10℃~+40℃
Work environment
Humidity：≤ 95%

Table 8-1 Main technical parameters

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 Power Source WZM-400

8.2 Main circuit schematic diagram

Fig. 8-1Main circuit schematic diagram

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 Power Source WZM-400

8.3 WZM-400 Main parts list

No. Name Code Qty Remark

1 Air switch 745011-00021 1

2 Three-phase rectifier module 735005-00010 1

3 Polypropylene capacitor 722001-00070 1

4 IGBT module 735007-00046 2

5 Main transformer 220629-00246 1

6 Fast recovery diode module 735006-00029 2

7 Power transformer 763001-00229 1

8 Fuse tube 745007-00011 1

9 Fan 746001-00017 1

10 Temperature relay 745008-00006 1

11 Main control board 210580-00748 1

12 Drive board 210310-00020 1

13 Converter inductor 220281-00025 1

14 Current sensor 753001-00045 1

15 Output reactor 763004-00041 1

16 10 inch TFT LCD touch screen 755005-00040 1

man-machine interface

Table 8-2 Main parts list

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 Specifications and designs of this product are subject to change without prior notice.

Shandong Aotai Electric Co., Ltd.

Add: 282 Bole Ave, High-tech Development Zone, Jinan,
Shandong 250101, P.R. China
Tel：+86-531-88872807, 88879105
Fax：+86-531-88876665