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)

COMBO-401 i/501 i OPERATOR’S MANUAL

7

16. Gas heater supply : Power socket of the gas heater, its output voltage is 36VAC.

17. Fuse holder : 3A glass fuse holder.

18. Input connection line of three phase power: connect it to distribution box, the green-yellow line

should be connected to protective ground line well.

19. Adjustment knob of welding current: To adjust the welding current.

20. Adjustment knob of welding voltage: To adjust the welding voltage.

21. Manual wire feeding button

：：：：

Press the button, the wire feeder begins to feed wire. The speed of wire

feeding can be adjusted by the welding current adjustment knob. While using thinner wire, the

feeding speed should be slowed down to avoid distorting the wire.

Figure 1: connection between the welding equipment and other equipment s

COMBO-401 i/501 i OPERATOR’S MANUAL

8

COMBO-401 i/501 i OPERATOR’S MANUAL

9

2.

Connections

(The user should choose the power cables, switches, fuses and power switches as specified in table )

2.1 Connections of the power supply cable and the grounding cable

Methods and requirements

Make sure that power supply panel is off before connecting.

Do not connect with wet hands.
Do not place anything on the power supply cable.
Make sure all the connections are proper.
Connect the green-yellow wire of the three-phase input cable to the grounding wire on the switchboard

properly.

2.2 The output cable connection of manual welding

Methods and requirements:

Please make sure the power switch is off before connecting.
Connect the copper connector of workpiece cable to the ‘+’ and ‘--’ output socket that on the welding power

source. When it is negative connection，the welding electrode holder should be connected to the ‘+’. When it is

positive connection，the welding electrode holder should be connected to the ‘--’

The welding cable and workpiece should be properly connected by bolts, and have good contact.

2.3 Connections of Gas-shielded Welding

2.3.1 Connection of the output cable

Methods and requirements

Please make sure the power switch is cut off before connecting.
Connect the copper connector of wire feeder cable to ‘+’ output that on the welding power source;
Connect the copper connector of workpiece cable to ‘--’ output that on the welding power source, connect the

other side to workpiece with bolts;

Insert the aviation plug(six cores) of control cable into the control socket(six cores) of wire feeder, then tighten

the ring nut, connect the other side of control cable to wire feeder.

2.3.2 Connections of the power source, wire feeder and welding torch(please refer to figure 1)

Methods and requirements

Make sure the power switch is cut off before connecting;

Wire feeders that produced by our company are requested to match with the certain welding machine.

Otherwise the welding performance maybe bad and even damage the machine;

Insert the aviation plug(six cores) of control cable into the control socket(six cores) of wire feeder, then

tighten the ring nut;

Aim the control plug of the welding gun at the guide slot, then insert it into the control output socket (2 pins),
then tighten the ring nut. After the connector of welding torch aiming at guide slot, you can insert it completely.
And then turn 90° by clockwise rotation and tighten the bolts; Connect the gas pipe of welding torch to the gas
output connector of wire feeder, and then tighten the nuts.

2.3.3 Connections of the gas cylinder and gas adjuster

Methods and requirements

Install the gas regulator to the gas cylinder.
Connect the gas heater to the heater’s power source socket on the back panel of the machine.
Connect the gas hose of the wire feeder to the gas output connector of the gas heater.

3.

Directions

of

the

manual

welding

mode

Specification

COMBO-401 i COMBO-501 i

Switch capacity（A） 40 63

Fuse capacity（A

）

32 40

Section surface of power supply cables（mm

2

）

4 6

Section surface of grounding cables（mm

2

）

4 6

COMBO-401 i/501 i OPERATOR’S MANUAL

10

Turn on the power switch of distribution box.
Turn the welding machine switch to the manual welding model.
Before welding, make sure the output terminal of the welding machine is connected to the welding
cable properly according to the section 2.2 above. adjusted welding current by the current adjustment knob on
the panel.

Please use proper personal protection equipment.

4. Directions of the Gas-shielded Welding mode

( Please read this manual carefully and strictly operate according to it ））））

4.1 Checking items ,methods and requests & preparations before operation

4.1.1 Wears of safeguards

a)

Wear

fur

gloves

and

safety

shoes

to

protect

the

skin

and

bare

parts;

b)

Wear

a

helmet

with

proper

shield

filter

glass

that

match

with

different

welding

current

to

protect

eyes;

c)

There

should

be

ventilation

in

the

welding

areatoprevent

breathing

the

deleterious

gas

.

4.1.2 Checking after connection:

a)

Check

out

all

the

items

according

to

the

section

2.3“Connections

of

Gas-shielded

Welding

”,make

sure

there’s no error.

b)

Check

out

all

the

items

according

to

the

section

1.6“Input

power

condition

”tomeet

all

the

requirement.

4.1.3 Operations of the switches & adjustment of gas flow.

First, turn on the welding machine;
Second, select the “gas-shield” mode on welding machine;
Third, select “welding wire’s type ” and the “welding diameter” as per requirement by respective switch to
meet the type and diameter of welding wire;
Fourth, turn the “Gas-supply” switch to “check” position;
Fifth, turn on the gas valve of the cylinder, and then adjust the knob of the flow meter slowly to meet the
value needed;
Sixth, turn the “gas supply” switch to “welding” position.

4.1.4 Installation of the welding wire

For the identification of operational components please refer to Figure 3 .

Methods and requirements

First, select proper size roller match with feeding wire, install the roller and make sure selected groove

should be outer side ;

Second, pull down the handle of wire feeder, and then lift the press-arm;

Third, install the welding wire reel to the welding wire reel’s axis, adjust the baffle of the welding wire

reel’s axis to be spread，screw down the manual nut. The out end of the wire is below. The welding wire will

comes out at clockwise rotation;
Fourth, let welding wire go through the wire rectification wheel (or guide pipe), wire feeding wheel slot, then
insert into the guide tip;

Fifth, press the welding wire with press-arm, and then pull up the handle to press the press-arm,

circumgyrate the handle with suitable strength;
Sixth, check up the tip of welding torch, whose diameter should meet the diameter of the wire;
Seventh, press “manual wire feeding” button on the control box of wire feeder, adjust “welding current

adjustment” knob for a right feeding speed. You can loosen the button until there is 15—20mm wire outside

of welding torch.

COMBO-401 i/501 i OPERATOR’S MANUAL

11

Figure 3 : Installation sketch map of welding wire

4.2 Directions of the basic welding

Welding can be performed by the “crater” switch and welding torch switch on the panel

in two methods : a) with crater self-lock and b) without crater function.

4.2.1 Welding operation with crater function

1) Features instruction:

a)

The

main

features

of

the

welding

function

is

the

ability

to

fillupthe

hollows

when

ending

weld,

which

can be propitious to connect the start-point and end-point of the welding seam continuously;

b)

Mainly

usedinwelding

middling

thickness

plate;

c)

The

self-lock

willbecanceled

if

the

arcisstopped

for

more

than

0.5s.

2) Operation regulations

a)

Select

the4Tmode

;

b)

press

the

welding

torch

switch,

it

begins

to

feed

gas(gas

pre-flow

time).

After

feeding

gas

for

some

time, welding voltage appears, then coming into the arc starting state and begins to feed wire slowly.
After successful arc starting, the wire feeding speed will become normal, and then welding current
appears. Then you can release the welding torch`s switch, welding goes into the self-lock state.
Simultaneously, you can adjust the “welding voltage adjustment” knob and “welding current
adjustment” knob for the best welding performance;

c)

When

welding

is

finishing,

press

the

welding

torch

switch

again,

anditcome

into

crater

adjustment

state.

Then, set the crater voltage and current by adjusting the relative knobs on the welding power panel (or
adjust them to the needed values respectively in advance, commonly to the 60 ～ 70% of the normal

welding current ) , thus you can control and adjust the effect of filling up hollows at the end of welding.
Then release the welding torch`s switch again, wire feeding stops immediately, it will come back to
burn state, the welding voltage will decrease and become back burn voltage. When the welding current
becomes zero, arc quenches, gas feeding stops, and the welding finishes.

4.2.2 Welding operation without crater function (operate with welding torch`s switch
synchronously)

1) Features instruction:

a)

Press

the

welding

torch`s

switch

to

start

welding,

and

loosen

ittostop

welding

.

b)Itis

suitable

for

orientation

welding

and

spot

welding

of

thin

plate

.

c)

There

isnocrater

process.

2) Operation regulations:

a)

Select

the2Tmode

;

b) press the welding torch switch, it begins to feed gas ( gas pre-flow time ) . After feeding gas for some

COMBO-401 i/501 i OPERATOR’S MANUAL

12

time, welding voltage appears, then coming into the arc starting state and begins to feed wire slowly. After
successful arc starting, the wire feeding speed will become normal, and then welding current appears. But
you can`t release the switch now.Simultaneously, adjust the “welding voltage adjustment” knob and the
“welding current adjustment”knob for the best performance of welding;
c) When welding is finishing, release the welding torch switch, wire feeding stops immediately, and
become back burn state, The welding voltage will decrease and becomes back burn voltage. When welding
current becomes zero, arc quenches, gas sending stops, and the welding finished.

5 . Directions of prolonged output cable

The connection cable on this series of machine is allowed to be lengthened between power source and wire

feeder, but the below regulations have to be followed.

a)

The

resistance

of

cable

will

increase

with

length

,

and

also

increase

of

the

cable

’svoltage

drop

.

Moreover,the cross section area of the cable effect the voltage drop;

b)

When

lengthening

the

cable,

get

the

cable

with

higher

cross

section

area

;

c)

When

lengthening

cable,

place

the

cable

straigh

t

don’t

make

in

coil

form

.

6 . Technique conditions

6.1 Technical parameters

TYPE

PARAMETER

COMBO-401 i COMBO-501 i

Shield rank IP21S

Rated input voltage Three-phase power 3~415VAC 50Hz

Rated input capacity 16.5KVA 26.3KVA

Gas-shield

welding

Output

current

60～400A 60～500A

Output

voltage

17～39V 17～39V

manual welding

Output

current

60～400A 60～500A

Output

voltage

22.4～34V 22.4～40V

Crater current 80～400A 80～500A

Crater voltage 17～40V 17～40V

Duty cycle 100% 100%

Rated current 400A 500A

Suited welding wire’s

diameter

Solid 0.8mm

1.0mm 1.2mm

Solid 1.0mm

1.2mm 1.6mm

Flux-cored

0.8mm 1.0mm

1.2mm

Flux-cored

1.0mm 1.2mm

1.6mm

Outline

(length×width×height)

640×290×530（mm）640×320×570（mm

）

Weight 39Kg 45Kg

* Its rated duty cycle is 60％, that means in a 10 minutes working period，the machine will run for 6 minutes

under rated welding current and rest for 4 minutes. If the Rated duty cycle is 100%,that means in a 10

minutes working period，the machine will run for 10 minutes under rated welding current without rest. If the

machine works over the rated duty cycle, the inner temperature will rise and exceed the fixed threshold. In

COMBO-401 i/501 i OPERATOR’S MANUAL

13

order to avoid worsening the performance or even burning out the machine, there is heat protection on this
series of welding machine. When the inner temperature exceeds the set temperature, the heat protection will
shutdown the machine, the overload indicator LED glows, at this time the machine has no output. Wait until
the temperature is below the set temperature and the overload indicator LED will turned off, the machine
recovers and you can do welding again.

6.2 Crater ON function

Normally there is a small depressing at the end of the weld when welding is done at higher currents. The
depression is called crater, the arc crater are caused because of the arc force and solidification of metal in all
direction. To minimize the crater the machine has crater fill function.
Normally crater fill voltage and current set at 60 to 70 % of the welding voltage and current. When crater is
set ON ( 4 step mode ) the welding voltage and current will automatically switch to lower voltage and
current ( crater voltage and current ) at the end of the welding.

To guaranteed better arc striking every time the wire feeding is normally done at lower speed. When the
torch trigger is pressed irrespective of the current ( wire speed ) set , wire will be fed slowly and it switches
over to the set speed once the arc is struck.

What is burn-back time?

After welding, wire feeder is not stop even if the welding torch switch is shut down because of inertia. So
there will be some more wire drive out from the torch, thus the wire will stick to the workpiece, or it will
cause difficulty in arc striking next time. In order to avoid this , it is necessary to deal with welding machine
operation , so that after releasing the welding torch switch, the output voltage will still exist for a short time
to burn the wire. This process time is burn-back time. This time varies because of differences in welding
conditions, the resistance of welding feeding tube and the length of output cable.

6.3 Examples of welding condition

Data in table 1, table 2 is the reference value under the standard condition.

When welding, please correct the values according to work pieces and the welding position to get the right

welding conditions.

COMBO-401 i/501 i OPERATOR’S MANUAL

14

Table 1:

Thicknes

s

(mm)

Length

(mm)

Wire

diameter

(mm)

Welding

current

(A)

Welding

voltage

(V)

Welding

speed

(cm/Min)

Stick

out

(mm)

Gas flow

(L/ Min)

T type welding

Slow speed

1.0 2.5～3 0.8 70～80 17～18 50～60 10 10～15

1.2 3～3.5 1.0 85～90 18～19 50～60 10 10～15

1.6 3～3.5 1.0,1.2 100～110 18～19.5 50～60 10 10～15

2.0 3～3.5 1.0,1.2 115～125 19.5～20 50～60 10 10～15

2.3 3～3.5 1.0,1.2 130～140 19.5～21 50～60 10 10～15

3.2 3.5～4 1.0,1.2 150～170 21～22 45～50 15 15～20

4.5 4.5～5 1.0,1.2 180～200 23～24 40～45 15 15～20
6 5～5.5 1.2 230～260 25～27 40～45 20 15～20

8, 9 6～7 1.2,1.6 270～380 29～35 40～45 25 20～25

12 7～8 1.2,1.6 300～380 32～35 35～40 25 20～25

High speed

1.0 2～2.5 0.8 140 19～20 150 10 15

1.2 3 0.8 140 19～20 110 10 15

1.6 3 1.0, 1.2 180 22～23 110 10 15～20

2.0 3.5 1.2 210 24 110 15 20

2.3 3.5 1.2 230 25 100 20 25

3.2 3.5 1.2 260 27 100 20 25

4.5 4.5 1.2 280 30 80 20 25
6 5.5 1.2 300 33 70 25 25

Put up weld (thin plate)

Slow speed

0.8 0.8 60～70 16～17 40～45 10 10～15

1.2 0.8 80～90 18～19 45～50 10 10～15

1.6 0.8 90～100 19～20 45～50 10 10～15

2.3 0.8 100～130 20～21 45～50 10 10～15

1.0,1.2 120～150 20～21 45～50 10 10～15

3.2 1.0,1.2 150～180 20～22 35～45

10

～

15

10～15

4.5 1.2 200～250 24～26 40～50

10

～

15

10～15

High speed

2.3～3.2 1.2

220 24 150 15 25

300 26 250 15 25

Corner weld

Slow speed

1.6 0.8 65～75 16～17 40～45 10 10～15

2.3 0.8 80～100 19～20 40～45 10 10～15

3.2 1.0, 1.2 130～150 20～22 35～40 15 10～15

4.5 1.0, 1.2 150～180 21～23 30～35 15 10～15

COMBO-401 i/501 i OPERATOR’S MANUAL

15

Table 2:

7. working principle

7.1 Summarize of working principle

The input three-phase AC 415VAC50Hz(60Hz) is rectified and supplied to the IGBT inverter to produce 20
kHz AC. This AC is transformed by the high–frequency transformer and rectified; then goes into the output
terminal of DC power source.

7.2 Main electric elementary diagram

Please refer to appendix 1.

8. Troubles and troubleshooting

8.1 Please check with multimeter if there are any troubles:

Three-phase power should be 380 to 440 VAC, check if there is phase missing or exceeding voltage range;

Whether the fuse on the back panel of the welding machine is ok or not;
Whether the three-phase power switch at the switchboard is damaged; Whether the fuse and electrical power wire
are installed properly, Otherwise it will cause phase missing and the welding machine will work abnormally.
The control cable of the wire feeder is may be broken, check the continuity of related six pins of the connector
plugs at the both ends of the control cable , whether the welding cable is connected properly, and the workpiece is
connected tightly.
Whether the torch switch and the wire connected are damaged or open circuit; whether the nozzle, conduct tip ,
conduct tip’s seat and shunt are burned out and damaged.

Thick

-ness

(mm）

Wire

diameter

(mm)

Root

gap

G（mm）

Welding

current

(A)

Welding

voltage

（V）

Welding

speed

(cm/Min)

Wire out

(mm）

Gas

flux

(L/Min)

I type butt welding

Slow

speed

0.8 0.8 0 60～70 16～16.5 50～60 10 10

1.0 0.8 0 75～85 17～17.5 50～60 10 10～15

1.2 0.8 0 80～90 17～18 50～60 10 10～15

1.6

0.8095～10518～1945～501010～15

2.0 1,1.2 0～0.5 110～120 19～19.5 45～50 10 10～15

2.3 1,1.2 0.5～1 120～130 19.5～20 45～50 10 10～15

3.2 1,1.2 1～1.2 140～150 20～21 45～50 10

～

15

10～15

4.5

1,1.21～

1.5

170～18522～2340～501515

6 Face 1.2 1.2

～

1.5

230～260 24～26 40～50 15 15～20

Inside 1.2 1.2

～

1.5

230～260 24～26 40～50 15 15～20

9 Face 1.2 1.2

～

1.5

320～340 32～34 40～50 15 15～20

Inside 1.2 1.2

～

1.5

320～340 32～34 40～50 15 15～20

High

speed

0.8 0.8 0 89 16.5 120 10 15

1.0 0.8 0 100 17 120 10 15

1.2 0.8 0 110 18 120 10 15

1.6 1,1.2 0 160 19 120 10 15

2.0 1,1.2 0 180 20 80 15 15

2.3 1,1.2 0 200 22 100 15 20

3.2 1.2 0 240 25 100 15 20

COMBO-401 i/501 i OPERATOR’S MANUAL

16

ATTENTIONS:

This welding machine adopts large capacity,high voltage and electrolytic capacitor filter, it can not be opened

until the three-phase power is shut down more than 10 minutes.

8.2 Common troubles and troubleshooting

Troubles Reasons Troubleshooting

1．After Turn on

power, the indicator

lamp doesn’t light,

the digital meter

doesn’t light.

1．Phase lack

；

2．Power switch is damaged

；

3．Power control fuse (3A) is blown

；

1．Check the three-phase power

；

2．Replace input power switch

；

3．Replace Power control fuses

；

2．Welding machine
does not work ， the

undervoltage

indicator lamp lights

1．Phase lack；
2．Three-phase power is under voltage；

1. Check the three-phase power

to make sure it meet the

requirements of the machine

；

3. There is no output

voltage and there

is noise inner the

machine

1．The fast recovery diode of the main
circuit is damaged；

1.Check and replace the damaged

fast recovery diode;

4．Welding machine

doesn’t work，over

heat indicator lamp

lights

1．The temperature is too high；
2 ． When welding ，cooler fans rotate

slowly or don’t work, which leads to
bad cooling；
3．Temperature relay is damaged；

1．Welding machine will become
normal after rest for some time；

2. Check the fans power or

change cooling fans；

3．Replace temperature relay；

5 ． Welding wire

feeder works, but

there is no wire

feeding or the

feeding isn’t

stable.

1．Wire press wheel is not pressed

tightly

；

2．The type of wire feeding slot doesn’t

match the welding wire

；

3．The tip is jammed because of the

spatters

；

4．The wire feeding roller is damaged

；

5．The wire feeding tube of the welding

torch is jammed

；

6．The curving semidiameter of the

welding torch cable is too small

；

1．Press tightly

；

2. Replace wire feeder wheel

slot

；

3．Clean the spatters in the tip

；

4．Change wire feeding roller

；

5．Blow off the dust with the dry

compressed air or replace a right

one with the same type

；

6. Make the curving

semidiameter of welding torch

cable over 300mm

；

6．The feeder don’t

work after pressing

down the torch

switch or there is no

open circuit voltage

1．The control cable of the wire feeder

is broken；
2．Short circuit of welding gun switch;
3．The PCB is broken；

1．Replace the control cable；
2 ． Check control wire of the

welding torch switch；

3．Repair or replace the PCB；

7．Many pores in the

welding seam

1．CO2gas is not pure

；

2．The gas flow is not enough

；

3．There is rust or oil in the welding

seam

；

4．The wind is strong when welding

；

5．The path of CO2is jammed or air

1．Use pure CO2gas

；

2．Adjust the gas flow

；

3．Clean the welding seam

；

4．The precaution against wind

should be adopted

；

5．Check the path;

COMBO-401 i/501 i OPERATOR’S MANUAL

17

leak；
6．Valve doesn’t work；
7．The nozzle is distorted；

6．Check the voltage 24VDC of
the valve winding；
7．Replace the nozzle；

8 ． Current /voltage

is out of control

1．Control cable of wire feeder is

broken

；

2．Current /voltage adjust potentiometer

is damaged

；

3．The PCB is damaged

；

1．Replace the control cable

；

2．Replace the potentiometer

；

3．Repair or replace the PCB

；

9. Wire feeding

starts without

pressing down the

welding torch switch

1．The wire connecting welding gun is

short circuit

；

2．Control cable of the wire feeder has

short circuit

；

3．The manual button of wire feeding is

damaged

；

1．Repair or change welding gun；
2 ． Repair or change control
cable；
3．Change the manual button of
wire feeding；

10．The current isn’t

stable, and there is

too much spatter

1．Welding criterion is wrong；
2．The quality of wire is bad；
3 ． There is rust or oil on the welding
device or wire；
4．Too much fluctuation of distribution
voltage；
5．The stick out of the wire is too long ；
6． wrong position of the wire diameter
select switch；
7．The type of wire feeding slot
doesn’t match the welding wire；
8．Problems in the protective gas；
9．Incorrect type of the tip or the

aperture of the tip becomes too big;
10 ． Too much feculency in the wire
feeding tube ， the resistance of the
feeding wire is too large；
11．The ground cable becomes loose；

1 ． Adjust the welding criterion
again；
2．Change wire；
3．Clean the welding device and
wire；
4 ． The fluctuation of the line
voltage can’t exceed ±15%；
5．The stick out should be about

10 times than the wire
diameter；

6． select a right position of wire

diameter select switch；
7 ． Replace wire feeding wheel
slot；
8．Use the purer gas；
9．Replace tip；
10．Clean the wire feeding tube；
11．Fix the cable connected to the
ground tightly；

11．Gas heater frosts

1. The input power fuses of the heater
(5A) is burned ；

2. The resistance wire of the heater is

broken ；

1. Replace the fuse with the same

type

；

2. Repair or replace the heater

；

ATTENTION:

Only qualified technicians are allowed to perform troubleshooting work on the machine.If for any reason you do

not understand the test procedures or are unable to perform the tests/repairs safely, contact our service
department for technical assistance.

1

COMBO-401 i/501 i OPERATOR’S MANUAL

18

QF1

C5

V2

SKM**GB128D

V3

SKM**GB128D

R1

100K/2W

R2

100K/2W

C10

C6

TM1

TA2

V4

V5

C2

C9

C1

C8

C3

L1

L2

C7

40n×2

L3

FU1

1.5A

EV1

风风

C4

风15V

1

Out

3

-15V
2

0V

4

TA1

TC1

18V

18V

36V

17V

380V

220V

190V

风 风风 风

2838 39

37

风 风

29

HL2HL1 HL3

KT1

3635

RP3

4.7K

风 风 风风

RP2

10K

风 风 风风

58 5655 54

303132

80.

81.

44

52515049

PV1

69.7071

72

G2 E2 G1E1G4 E4 G3E3 2425

G1

G2

G3

G4

G1G2G3G4 E1E2E3E4

E1

E2

E3

E4

1

2

3

4

5

6

7

8

9

10

11

27

13

14

15

16

17

18

19

20

21

22

23

24

25

AP1

NB-IGBT风 风 风 风 风 风

ZX7-AP4

79

68.6745

27V

27V

8V

26V

4746

风 风 风 风 风

RT1

RA

10K

RB

390/2

SB1 SB2

DA

1N4007

DB

1N4007

RC

4.7K

RP5

5K

RP4

5K

风 风 风 风

风 风 风 风

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-

+

MG1

YV1

1 2 6 4 53

775366.83 42 78

风 风 风

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SA1

风 风

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RP1

30K

风 风 风风

40 416261.

SA4SA5

63

风 风 风 风风 风 风 风 风 风

SA3

风 风 风风

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风 风 风风

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PA1

737475

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+ -

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风 风 风风 风 风

59 60.

29

84

57

L4

26

COMBO-401 i/501 i OPERATOR’S MANUAL

19

Picture 1- Right View.

Picture 2- Left View.

COMBO-401 i/501 i OPERATOR’S MANUAL

20

Picture 3- Top View

Picture 4- Front View.

COMBO-401 i/501 i OPERATOR’S MANUAL

21

COMBO I Parts List.

Combo 401I Combo 501I

S.No

Description. Part Code Part Code

1.

Main PCB PCB-COMBO-401 PCB-COMBO-501

2.

IGBT IGBT10012 IGBT10012

3.

INPUT BRIDGE MODULE IBDG007 IBDG003

4.

Output Rectifier Module. FRM001 FRM001

5.

FAN FAN002 FAN002

6.

DC CAPACITOR C-200UF/400V C-200UF/400V

7.

MCB MCB001 MCB001

8.

DIGITAL DISPLAY METER FOR
CURRENT & VOLTAGE.

DSP005 DSP005

9.

THERMAL CUTOUT SENSOR C2373 C2373

10.

Snubber PCB. PCB-SNB-OUT-05 PCB-SNB-OUT-05

11.

CONTROL TRANSFORMER CTRAX-B68 CTRAX-B68

12.

MAIN TRANSFORMER MTRXB68 MTRX-B68

13.

FAN CAPACITOR CAP05 CAP05

14.

HALL SENSOR CS-500A/4V CS-500A/4V

15.

Snubber Capacitor C-8UF/800VDC C-4UF-500 VDC

16.

Snubber capacitor box C-0.027uF-1KV C-0.027uF-1KV

17.
LED INDICATOR

LED-R-5MM, LED-Y-5MM,
LED-G-5MM

LED-R-5MM, LED-Y-5MM,
LED-G-5MM

18.

Panel Switch

PSW001 PSW001

19.

Wire wound Resistor R-0.5OHMJ R-0.5OHMJ

20.

Wire wound Resistor

R-1KJ R-1KJ

21. 6 Pin Connector (F) machine
side. CON-6PNF CON-6PNF

22.

AC CAPACITOR

CAP003 CAP003

23. POTENTIOMETER FOR
CURRENT

POT001 POT001

24. POTENTIOMETER FOR
CRATER VOLT

POT004 POT004

25. POTENTIOMETER FOR
INDUCTANCE

POT-33K POT-33K

26.
OUT PUT CHOKE CHK001 CHK001

27.
SECONDARY THRUST COIL

THCL-S-501 THCL-S-501

28.

O/P Connector OUTCON001 OUTCON001

29.

Snubber PCB FOR Output FRM PCB-SNB-OUT-05 PCB-SNB-OUT-05

COMBO-401 i/501 i OPERATOR’S MANUAL

22

WIRE FEEDER DETAIL

Combo 401I Combo 501I

S.No

Description. Part Code Part Code

1.

Wire feeder Motor WFMTR002 WFMTR002

2.

SOLENOID VALVE

SV002 SV002

3.

6 PIN CONNECTOR (M) CON-6-CM-M-01 CON-6-CM-M-01

4.

POTENTIOMETER FOR
WELDING VOLTAGE

POT001 POT001

5.

POTENTIOMETER FOR
WELDING CURRENT

POT001 POT001

6. INCHING SWTTCH INCSW001 INCSW001

7. SPOOL HOLDER SPOOL HOLDER-001 SPOOL HOLDER-001

Head Office : -

Warpp Engineers Pvt Ltd.
Manufacturers of Welding And Related Plasma Products.
Unit no 5 & 6, Rajprabha Meenakshi Industrial Estate no 3,
Near Mohan Bhagat School, Naik Pada, Waliv Phata,
Vasai (E). District Palghar. Pin-401208.
TEL: [phone].
E mail: [e-mail]
Website: www.warpp.co.in