WARPP COMBO-401 i, COMBO-501 i Operator's Manual

COMBO-401 i /501 i

Inverter CO2/MIG/MAG Gas Shield

Welding Machines

OPERATOR’S MANUAL

(PLEASE READ CAREFELLY BEFORE OPERATION)

COMBO-401 i/501 i OPERATOR’S MANUAL

1

Safety Depends on You

Our arc welding and cutting equipment s are designed and built with safety in mind. However, your overall safety
can be increased by proper installation.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND
FOLLOWING THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

Special Attention (Very Important):

●

PLACE THE MACHINE ON A PROPER PLANE, SO THAT THE MACHINE DOES NOT SLIP.

●

PLEASE KEEP THE MACHINE AWAY FROM RAIN ( UNDER PROPER ROOFING ).

Purchase Date：

Serial Number：

Machine Type：

Purchase Place：

Cautions

Arc and arc rays may harm health.

COMBO-401 i/501 i OPERATOR’S MANUAL

2

Arc welding can be hazardous. All performing welding workers ought to have health qualification
that provided by authority organization. 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 all installation, operation, maintenance and repair procedures are performed only by qualified
individuals.

1

Electric shock can kill: The electrode and work (or ground) circuits are electrically “hot” when

the

welder

is

on.Donot

touch

these“hot”parts

with

your

bare

skinorwet

clothing,

Wear

dry,

hole-free

gloves

to

insulate

hands.

Users

needtofollow

the

below

itemstoavoid

electric

shocks:



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. Otherwise, use automatic or semiautomatic welding
machines, DC welding machines as possible as you can.



In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically“hot”.



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.



Ground the work or metal to be welded to a good electrical(earth) ground.



Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition.
Replace damaged insulation.



Never

dip

the

electrode

in

water

for

cooling.



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.



When

working

above

floor

level,

please

do

wear

safety

belttoavoid

falling

or

losing

balance

on

electric

shock.

2

Arc rays can burn: Use a shield with the proper filter and cover plates to protect your eyes

from

sparks

and

the

raysofthe

arc

when

welding

or

observing

open

arc

welding.

Head

shield

and

filter

lens

should

conform

to

nation

standards.



Use

suitable

clothing

made

from

durable

flame-resistant

material

to

protect

your

skin

and

that

of

your helpers from the arc rays.



Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor

expose

themselves

to

the

arc

raysorto

hot

spatter

or

metal.

3 Fumes and Gases can be dangerous: Welding may produce fumes and gases hazardous to

health.

Avoid

breathing

these

fumes

and

gases.

While

working

in

limited

room,

use

enough

ventilation

and/or

exhaust

to

keep

fumes

and

gases

away

from

the

breathing

zone,oruse

the

respirator.



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.



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.



Read

and

understand

the

manufacturer

’sinstructions

for

this

equipment

and

the

consumables

tobeused,

including

the material safety data sheet (MSDS) and follow your employer’s safety practices. Make sure they are asepsis

and

innocuity.

4

Spatter: Welding or cutting spatter can cause fire or explosion.



Remove

fire

hazards

from

the

welding

area.If

thisisnot

possible,

cover

themtoprevent

the

welding

sparks

from

starting

a

fire.

Remember

that

welding

sparks

and

hot

materials

from

welding

can

easilygothrough

small

cracks

and

openings

to

adjacent

areas.

Avoid

welding

near

hydraulic lines. Have a fire extinguisher readily available.



Where

compressed

gases

aretobe

usedinthe

field,

special

precautions

should

be

usedtoprevent

explosion.



When

not

welding,

make

certain

thatnoelectriferous

partistouching

the

work

pieceorthe

work

stage.

Accidental contact can create a fire hazard.



Do

not

weld

containers

or

lines,

which

are

not

proved

tobeinnocuity.



Do

not

heat,

cutorweld

tanks,

drums

or

containers

until

the

proper

steps

have

been

takentoinsure

that

such

procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though
they have been“cleaned”.



Spatter

might

cause

burn.

Wear

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes

andacap

over

your

hair

to prevent from burning by spatter. Wear the ear shield when performing sideways or face up welding. Always
wear safety glasses with side shields when being in a welding area.

 The welding cables should be as close to the welding area as possible, and the short, the better. Avoid welding

cables going through the building framework, lifting chains, AC or DC cables of other welding machines and

appliances.

The

welding

current

is

strong

enough

to

damage

them

while

having

short

circuit

with

them.

COMBO-401 i/501 i OPERATOR’S MANUAL

3

5 Cylinder may explode if damaged.



Make

sure

that

the

gasinthe

storage

cylinder

is

qualified

for

welding,

and

the

decompression

flowmeter,

the

adapter

and

the

pipe

are

allingood

condition.



Always keep cylinders in an upright position securely chained to an undercarriage or fixed

support.



Be

suretoput

the

cylinder

in

the

working

space

withnocrashorshake,

and

far

from

welding

area.



Never allow the electrode, electrode holder or any other electrically“hot”parts to touch a cylinder.



Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.



Valve

protection

caps

should

always

beinplace

and

hand

tight

except

when

the

cylinder

isinuseorconnected

for

use.

6

Power: (For electrically powered welding and cutting equipment) Turn off input power before

installation,

maintenance

and

repairtoavoid

accidents.



Huanyuan

welding

equipment

isΙclass

safeguard

equipment;

please

install

the

equipment

in

accordance

with

the

manufacturer

’srecommendations

by

specific

persons.



Ground the equipment perfectly in accordance with the manufacturer’s recommendations.

7

Power:(For engine driven welding and cutting equipment)



Workinventilated

placeoroutdoors.



Do

not

add

fuel

neartofireorduring

engine

starting

or

welding.

When

not

working,

add

fuel

after

engine

is

cooling

down;

otherwise,

the

evaporation

of

hot

fuel

would

resultindangers.

Do

not

splash

fuel

outofthe

fuel

tank,

anddonot

start

the

engine

until

complete

evaporation

of

the

outside

fuel.



Make

sure

that

all

the

safeguard

equipment's

,

machine

cover

and

devices

are

allina

good

condition.

Be

sure

that

arms,

clothes

and

all

the

toolsdonot

touch

all

the

moving

and

rotating

components

including

V

belt,

gear

and

fan

etc.



Sometimes

some

partsofthe

equipment

havetobe

dismantled

during

maintenance,

but

you

still

have to keep the strongest safety awareness .



Do

not

put

your

hand

closetofans

anddonot

move

the

brake

handle

while

operating.



Please

remove

the

connection

between

the

engine

and

the

welding

equipment

to

avoid

sudden

starting

during

maintenance's

.



When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt by the hot

vapor.

8 Electromagnetic: Welding current going though any area can generate electromagnetic, as well

as

the

welding

equipment

itself.



Electromagnetic

would

affect

cardiac

pacemaker,

the

cardiac

pacemaker

users

should

consult

one’s

doctor

first.



The

effectofelectromagnetic

to

one’s

health

is

not

confirmed,

anditmight

have

some

negative

effecttoone’s

health.



Welders

may

use

following

method

to

reduce

the

hazardous

of

electromagnetic:

a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding cable is by

your left side, then the ground cable should be by your left side too.

d. The Welding cable and the ground cable are as short as possible.

e. Do not work near to the welding power source.

9 Lifting equipment: carton or wooden boxes package of the welding machines supplied by

WARPP

Engg.Thereisno

lifting

equipment

in

its

wrapper.

Users

can

moveitto

the

prospective

areabya

fork-lift

truck,

then

open

the

box.



If

there

are

rings,

the

machine

canbetransited

by

rings.

While

Our

Welding

Machine

Manufacture

reminds

users,

thereispotential

risktodamage

the

welding

machine.

Soitis

better

to

push

the

welding

machine

by

its

rollers

unless

special

situations.



Be

sure

that

the

appurtenances

are

all

removed

off

when

lifting.



When

lifting,

make

sure

that

thereisno

person

below

the

welding

machine,

and

remind

people

passing

byatany

moment.



Do not move the hoist too fast.

10

Noise: Our Welding Machine Manufacture reminds users: Noise beyond the limit (over 80 db)

can

cause

injury

to

vision,

heart

and

audition

depending

on

oneself.

Please

consult

local

medical

institution.

Use

the

equipment

after

doctor

’spermission

would

helptokeep

healthy.

COMBO-401 i/501 i OPERATOR’S MANUAL

4

CONTENTS

1. Usage notices ------------

-------------------------------------

5

Machine

Model

&

Process

Features

&

Advantages

Usage

Safety

Environmental

Area

Input

power

conditions

Installation

diagram

Components

name

and

Function

Introductions

2. Connections --------------------------------------------------10

Connections

of

the

power

supply

cable

and

the

ground

wire

Connection

of

the

manual

welding

output

cable

Connections

of

Gas-shielded

Welding

2.3.1 Connection of the output cable

2.3.2 Connections of the power source, wire feeder and the welding torch

2.3.3 Connections of the gas cylinder and the gas adjuster

3. Directions of the manual welding mode ---------------11

4. Directions of the Gas-shielded Welding mode---------11

Checking

items

,methods

and

requests

&

preparations

before

operation

4.1.1 Wears of safeguards

4.1.2 Checking after connections

4.1.3 Operation of switches & adjustment of gas flux

4.1.4 Installation of the welding wire

4.2 Directions of the basic welding

4.2.1 Welding operation with crater function

4.2.2 Welding operation without crater function

5. Directions of prolonged output cable -----------------13

6. Technical conditions ------------------------------------- 13

6.1 Technical parameters

6.2 Instructions of keywords

6.3 Examples of welding condition

7. Working principle ----------------------------------------16

7.1 Summarize of working principle

7.2 Main electric elementary diagram

8. Troubles and troubleshooting---------------------------16

9. Packing list -------------------------------------------------19

COMBO-401 i/501 i OPERATOR’S MANUAL

5

1. Usage Notices

1. 1 Machine Model is :

COMBO

401I/

501

I

Process

:

SMAW

GMAW

FCAW

Features & Advantages

Slow feeding speed with high open circuit voltage for better arc striking.

Unique feedback circuit for both voltage and current confirms stable welding process,less spatter good

weld bead and good adaptability for continues change in arc length.

Excellent F.T.T - Globule control circuit makes positive striking of arc.

crater current and voltage function for elimination of crater at the End of the weld.

PWM inverter technique with 20 khz operating frequency make the system much responsive.

It can be widely used in Gas-shielded welding, carbon arc air gouging and manual welding.

Usage

It is suitable for welding mild steel, stainless steel, aluminum and their alloy.

The machine can be used for all position welding with solid and flux cored wire.It can be used with Ф0.8 ,

Ф1.0 , Ф1.2 , Ф1.6 depends on model.

It can be used for manual metal arc welding with acid and basic types of electrodes.

Safety

For you and others safety, please follow the guide line mentioned below.
□ The machine have to be grounded properly.

To prevent electric shock, make sure the grounded bolt of the power source is grounded well.
□ use proper personal protection equipment.

To prevent injury of your eyes and skin from the ultraviolet radiation, strong sparks and splash, please make

sure to use proper personal protection equipment like helmet,hand gloves ,apron etc.
□ Protection against welding fume

The gases and fumes produced by welding are hazardous to health. Make sure that working space is properly

ventilated or use equipment like fume extractor for your safety.

□ The gas cylinder to be located in a fixed place or use proper trolley.
□ The machine and working area should be keep away from flammable things.
□ Prevent particles getting inside the machine and prevent cables from sharp things it may cut the cables .
□ Prevent the machine from damage by falling or hitting. Once it falls or hit, the machine cannot be used

again without professional checking.

Environmental Area

For satisfactory performance of the machine , please follow guide line mention below..

□

Keep

themachine

away

from

direct

sunlight

,

rain

and

dusty

atmosphere.

□ The environment temperature range should be -10℃～40℃.

□

Avoid

metal

particles

entering

into

the

power

source.

□

The distance between the power source and wall or other close things should be more than 30cm. The
distance between two machines should be more than 30cm.

□

Welding

area

should

be

protected

from

wind.

COMBO-401 i/501 i OPERATOR’S MANUAL

6

I

nput Power conditions

Power supply : 380-440VAC

The fluctuation range of frequency:＜±1%

The imbalance rate of three-phase voltage :＜±5%

While using engine generator, the output power should be two times larger than the rated input power of

the welding power source and compensation coil is needed.

Installation diagram

Connection between welding equipment s and other equipment's (Please refer to the Figure 1).

1.8 Components name and Function Introductions (Please refer to the Figure 2)

1. Voltage meter: to indicate the actual welding voltage

2. Current meter: to indicate the actual welding current

3. Current adjustment knob: When switch 10 is placed on the manual welding position, this knob can

adjust the manual welding current. When switch 10 is placed in the gas-shield welding position, this

knob can adjust the gas-shield welding current.

4. Crater voltage adjustment knob: adjust the crater voltage.

5. Arc characteristic adjustment knob: While used as gas-shield welding, it is to adjust and control

the current changing rate in different duration of the melt drop transfer in the welding process. It will

directly influence arc’s soft and rigid characteristics, quantity of spatter, shaping of welding seam and

the stability of arc. It is advised to use standard characteristic. Adjust it to the soft characteristic while

doing as small criterion welding, and adjust it to the rigid characteristic while doing as middle and

large criterion welding. (Note: the softer arc, the less spatter, vice versa.)

6. Under voltage indicator lamp: When the distribution voltage is lower than 320VAC, it lights, and

the output current will be cut automatically. After the voltage is back to normal, the machine will

work again.

7. Over heat indicator lamp: If it runs beyond excess of its rated duty cycle, or in a high temperature

environment, the thermal sensor’s temperature achieves 75℃±5℃, the heat protection circuit will

work, and the heat indicator LED will glow, the output current will be cut off. Wait until the machine

cool down and LED turned off, you can restart the machine after that. If the entrance of the gas path

is jammed or the fan doesn’t work, the LED will also glow.

8. Power source indicator lamp: As soon as the machine start, it lights.

9. Welding mode selection switch: It is to switch the welding process from manual welding to

gas-shield welding.

10. Welding wire diameter selection switch: It is to switch the standard welding wire’s diameter to

adopt the machine. It is actually to choose the suitable welding program. Turn the switch to the

diameter matched with the welding wire.

11. Welding wire type selection switch: It is to switch the standard welding wire’s type to adopt the

machine. Turn it to the solid position while using solid welding wire; turn it to the flux-cored position

while using flux-cored welding wire.

12. Crater mode selection switch

：：：：

It is to determine whether fill the arc holes at the end of welding. That

means to determine whether use crater function or not.

13. Gas-supply selection switch

：：：：

To check gas flow, turn it to "checking" position; to weld, turn it to

"welding" position.

14. Power overload protection switch: To cut off power and protect the machine in fault condition, it is

only used for protection, you should use other power switch while installing.

15. Control signal interface: Output interface of arc striking, to control automatic welding equipments.

The rated control load ability is 3A/250VAC or 3A/30VDC.(This interface is optional)