WARPP INARC-1000 I, INARC-1250 I Operating Manual

INARC-1000 I/ 1250 I

INARC-1000 I / 1250 I

Inverter Arc Welding Machines

OPERATING MANUAL

WARPP ENGINEERS PVT. LTD.

B-1005, Western Edge II, Near Metro Mall, Off. Western Express
Highway, Borivali (E), Mumbai-400 066.
Tel: [phone]/74. Fax: [phone].
E-mail:[e-mail] Web Site: www.warpp.co.in

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Index

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

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

3. Features & Applications…………………………………………...(11)

4. Installation Guide………………………………………………….(12)

5. Operating Instruction …………...………………………………...(16)

6. Repair & Maintenance…………………………………………….(20)

Appendix A: EMC Suggestion for installation and use of welder…….(23)

INARC-1000 I/ 1250 I

Safety Precautions

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE

SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD

CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

BE SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION, OPERATION,

MAINTENANCE AND REPAIR PROCEDURES

For Engine Powered equipments

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance

work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the

engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on

contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is

spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep

hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts

when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required

maintenance. Remove guards only when necessary and replace them when the

maintenance requiring their removal is complete. Always use the greatest care when

working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler

by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding

generator during maintenance work, disconnect the spark plug wires, distributor cap or

magnet wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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INARC-1000 I/ 1250 I

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic

Fields(EMF). Welding current creates EMF fields around welding cables and welding

machines.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should

consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not

known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF

fields from the welding circuit:

2.d.1. Route the electrode and work cables together-Secure them with tape when possible.

2.d.2. Never coil electrode lead around your body.

2.d.3. Do not place your body between your electrode and work cables. If the electrode

cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the work piece as close as possible to the area being

welded.

2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK can kill

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is

large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under

electrically hazardous conditions (in damp locations or wearing wet clothing; on metal

structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,

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INARC-1000 I/ 1250 I

kneeling or lying, if there is a high risk of unavoidable or accidental contact with the work

piece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder

DC Manual (Stick) Welder

AC Welder with Reduced voltage control

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,

nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being

welded. The connection should be as close as possible to the area being welded.

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

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good,

safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two

welders because voltage between the two can be the total of the open circuit voltage of

both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the

rays of the arc when welding or observing open arc welding. Head shield and filter lens

should conform to standard.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and

that of your helpers from the arc rays.

4.c. protect other nearby personnel with suitable, non-flammable screening and/or warn them

not to watch the arc nor expose themselves to the arc rays or to hot spatter or material.

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INARC-1000 I/ 1250 I

FUMES AND GASES can be dangerous

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes

and gases. When welding, keep your head out of the fume. Use enough ventilation and/or

exhaust at the arc to keep fumes and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing or on

lead or cadmium and plated steel and other materials or coatings which produce highly

toxic fumes, keep exposure as low as possible and below Threshold Limit Va lu es (T LV )

using local exhaust or mechanical ventilation. In confined spaces or in some

circumstances, outdoors, a respirator may be required. Additional precautions are also

required when welding on galvanized steel.

5.b. The operation of welding fume control equipment is affected by various factors including

proper use and positioning of the equipment, maintenance of the equipment and the

specific welding procedure and application involved. Worker exposure level should be

checked upon installation and periodically thereafter to be certain.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,

cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors

to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use

enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this equipment and the

consumables to be used,

5.f. Also see item 1.b.

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INARC-1000 I/ 1250 I

WELDING AND CUTTING SPARKS can cause fire or explosion.

6.a. Remove fire hazardous from the welding area. If this is not possible, cover them to prevent

the welding sparks from starting a fire. Remember that welding sparks and hot materials

from welding can easily go through small cracks and openings to adjacent areas. Avoid

welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used

to prevent hazardous situations.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or

ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken

to insure that such procedures will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even though they have been “cleaned”.

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such

as leather gloves, heavy shirt, high shoes and a cap over your hair. Wear ear plugs when

welding out of position or in confined places. Always wear safety glasses with side shields

when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables

connected to the building framework or other locations away from the welding area

increase the possibility of the welding current passing through lifting chains, crane cables

or other alternate circuits. This can create fire hazards or overheat lifting chains or cable

until they fail.

6.h. Also see item 1.c.

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

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INARC-1000 I/ 1250 I

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process

used and properly operating regulators designed for the gas and pressure used. All hoses,

fittings, etc. should be suitable for the application and maintained in good condition.

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

support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage, A safe

distance from arc welding or cutting operations and any other source of heat, sparks, or

flame.

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

cylinder.

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

valve.

7.f. Valve protection caps should be always be in place and hand tight expect when the cylinder

is in use or connected for use.

FOR ELECTRICALLY powered equipment

8.a. Turn off input power using the disconnect switch at the fuse box before working on the

equipment.

8.b. Install equipment in accordance with the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the manufacturer’s recommendations.

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INARC-1000 I/ 1250 I

(A)

Principle & Technical data

INARC-1000 I series Block diagram of principle

3 phase

Rectifier

HF

Inverter

Figure 1: Block diagram of principle

This series welding machines apply IGBT soft switch inverter technology. 3- Phase input are

HF

Transforme

Control circuit

HF Arc-starting

Device

Rectifier

& Filter

rectified by rectifier, inverted into HF AC, reduced by HF transformer, rectified and filtered by

HF rectifier, then output DC power suitable for welding. After this process, the welder’s

dynamical responsive speed has been greatly increased, so the welder size and weight are

reduced noticeably result in energy saving.

Power source enjoy sound anti-fluctuating ability and high-quality performance during external

context changes (As to fluctuation in input power supply and extended welding cables). Easy

to arc start, stable arc length, pretty weld formation and capability of continuous regulation the

welding current and arc-force current.

90–

20 –
0

U=20+0.04I

I

Figure 2: Volt-Ampere curve

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