WARPP DCWF-V1 Operating Manual
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Digital Cold Wire Feeder
Operating Manual
Model No - DCWF-V1.
Warpp Engineers Pvt Ltd.
Source of Reliable welding and cutting equipment.
B-1005, 10th Floor, Western Edge 2, Near Metro Mall, Off western Express Highway, Borivali
(East). Pin code 400066.
TEL: 022-28542272 / 73 / 74.
E mail: sales@warpp.co.in Website: www.warpp.co.in
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Thank you for selecting WARPP brand Digital cold wire feeder. In order to
keep you safe away from unexpected accidents, and enjoy full benefits offered by our
quality products during welding, please read the instruction in details prior to
operation. Complying with procedures defined in this manual is always appreciated.
IMPORTANT
Read this manual carefully before installing, commissioning or operating this
product.
NOTICE :-
The installation, operation and maintenance guidelines set out in this manual will
enable you to maintain the equipment in peak condition and achieve maximum
efficiency with your welding operation. Please read these instructions carefully to
become aware of every advantage.
CAUTION :-
Only experienced personnel familiar with the operation and safe practice of welding
equipment should install and / or use this equipment.
Table of Contents
Section 1 .................................................................................................................. 3.
Safety Precautions ................................................................................................... 3.
A. Arc Welding ...................................................................................................... 3.
B. Electric Shock .................................................................................................... 3.
C. Arc Rays ............................................................................................................. 4.
D.Fume sand Gases ..................................................................................................4.
E. Cylinders .............................................................................................................. 5.
F. Welding ................................................................................................................. 5.
G. Moving Parts ........................................................................................................ 6.
H. EMF Information ................................................................................................. 6.
Section 2 ................................................................................................................... 7.
System Components ................................................................................................. 7.
Maintenance ............................................................................................................. 7.
Warning..................................................................................................................... 7.
Caution...................................................................................................................... 7.
Digital Cold Wire Feeder picture .............................................................................. 8.
Section 3 ................................................................................................................... 8.
A. Digital cold wire feeder Features ......................................................................... 8.
B. How to operate the digital key pad ....................................................................... 9.
C. SETTING ............................................................................................................ 10.
D. SPEED MODE SETTING .................................................................................. 10.
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E. PULSE MODE SETTING .................................................................................. 10.
F. Important Note. ................................................................................................... 12.
Section 4 ................................................................................................................. 13.
1) Wire Feeder structure .......................................................................................... 13.
2) Wire Feeder Roller and Installation ..................................................................... 13.
Section 5 .................................................................................................................. 14.
Brake force of wire spool adjustment ...................................................................... 14.
Section 6 ................................................................................................................... 15.
Specifications ........................................................................................................... 15.
Appendix A ............................................................................................................... 16.
Section 1
Safety Precautions :-
WARNING
These Safety Precautions are for your protection. They summarize precautionary
information from the references listed in
Additional Safety Information section. Before performing any installation or
operating procedures, be sure to read and follow the safety precautions listed below as
well as all other manuals, material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
A. Arc Welding
Arc Welding can be hazardous. Protect yourself and others from possible serious
injury or death. Keep children away. In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precautions are taken. The safety information
given below is only a summary of the more complete safety information that will be
found in the Safety Standards listed at the end of this section. Read and follow all
Safety Standards. Have all installation, operation, maintenance and repair work
performed only by qualified people.
B. Electric Shock
Touching live electrical parts can cause fatal shocks or severe burns. The electrode
and work circuit is electrically live whenever the output is on. The input power circuit
and machine internal circuits are also live when power is on. When using mechanized
wire feed, the wire, wire reel, drive roll housing and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly grounded
equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and appropriate body protection.
3. Disconnect input power before installing or servicing this equipment.
4. Properly install and ground this equipment according to the operation manual.
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5. Always verify the supply ground-check and be sure that input power cord ground
wire is properly connected to ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet.
6. When making input connections, attach proper grounding conductor first - double
check connections.
7. Frequently inspect input power cord for damage or bare wiring. Replace cord
immediately if damaged - bare wiring can kill.
8. Turn off all equipment when not in use.
9. If earth grounding of the work-piece (JOB) is required, ground it directly with a
separate cable - do not use work clamp or work cable.
10. Do not touch electrode if you are in contact with the work, ground, or another
electrode from a different machine.
11. Use only well-maintained equipment. Repair or replace damaged parts at once.
Maintain unit according to manual.
12. Wear a safety harness if working above floor level.
13. Keep all panels and covers securely in place.
14. Clamp work cable with good metal to metal contact to work-piece or worktable as
near the weld as practical.
C. Arc Rays
Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can
injure eyes.
Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin. Noise from some processes can
damage hearing. Chipping, grinding and weld cooling throw off pieces of metal or
slag.
1. Use approved ear plugs or ear muffs if noise level is high.
2. Use a welding helmet fitted with a proper shade of filter to protect your face and
eyes when welding or watching.
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers protect others from flash and glare; warn others
not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant material (wool and
leather) and foot protection where necessary.
D. Fumes and Gases
Fumes and gases can be hazardous to your health. Welding produces fumes and gases.
Breathing these fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes
and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDS) and the suppliers instruction for
metals, consumables, coatings, cleaners, and degreasers.
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5. Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator. Always have a trained watch person nearby.
6. Do not weld in locations near cleaning, or spraying operations. The heat and rays of
the arc can react with vapors to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead or cadmium plated steel,
unless the coating is removed from the weld area, the area is well ventilated, and if
necessary, while wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
E. Cylinders
Cylinders can explode if damaged. Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of
the welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never weld on a pressurized cylinder - explosion will result.
5. Use only correct shielding gas cylinders, regulators, hoses and fittings designed for
the specific application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected
for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment
as per applicable Standards.
F. Welding
Welding can cause fire or explosion. Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc.
The flying sparks, hot work-piece (JOB), and hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before doing any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft. (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Do not weld on closed containers such as tanks, drums, or pipes, unless they are
properly prepared.
7. Connect work cable to the work as close to the welding area as practical to prevent
welding current traveling long, possibly unknown paths and causing electric shock
and fire hazards.
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