WARPP INARC 200 IDS Operation Manual

INVERTER DC MMA

ARC WELDING MACHINE

OPERATION MANUAL

INARC 200 IDS

M/s WARPP ENGINEERS PVT. LTD.
B-1005, WESTERN EDGE II, NEAR METRO MALL,
BORIVALI ( E), MUMBAI-400 066
TEL:[phone].
EMAIL:[e-mail] Website:www.warpp.co.in

CONTENT

1. SAFETY

1.1 SIGNAL EXPLANATION

1.2 ARC WELDING DAMAGE

1.3 THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS

2. SUMMARY

2.1 BRIEF INTRODUCTION

2.2 WORKING PRINCIPLE

2.3 VOLT-AMPERE CHARACTERISTIC

3. INSTALLATION & ADJUSTMENT

3.1 PARAMETERS

3.2 DUTY CYCLE & OVER HEAT

3.3 WELDING POLARITY CONNECTION WAY

3.3.1 MMA

3.3.2 TIG

4. OPERATION CONTROLAND CONNECTORS

4.1 LAYOUT FOR FRONT & REAR PANEL

4.2 WELDING CURRENT ADJUSTMENT

4.3 WELDING OPERATION

4.3.1 STRIKING ARC WAY

4.3.2 MANIPULATION OF ELECTRODE

4.4 WELDING PARAMETERS

4.4.1 JOINT FORM IN MMA

4.4.2 ELECTRODE SELECTION

4.5 ARC WELDING DEFECT AND PREVENT METHOD

4.6 OPERATION ENVIRONMENT

4.7 OPERATION NOTICES

5. MAINTENANCE & TROUBLESHOOTING

5.1 MAINTENANCE

5.2 TROUBLESHOOTING

5.3 ELECTRICAL PRINCIPLE DRAWING

§1 SAFETY

§1.1 Signal Explanation

●The above signals mean warning ! Notice! Running parts and getting an electric shock or thermal parts

will take damage for your body or others. The corresponding notices are as follows. It is quite a safe
operation after taking several necessary protection measures.

§1.2 ARC WELDING DAMAGE

●The following signals and word explanations are to some damages for your body or others happening

on the welding operation. While seeing these, please remind of yourself or others to be dangerous.

●Only ones who are trained professionally can install, debug, operate, maintain and repair the
equipment.

●During the operation, non-concerned people should be lift, especially for children.

●After shut off the machine power, please maintain and examine the equipment according to §5

because of the DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL

●Never touch electrical parts.

●Wear dry, hole-free gloves and clothes to insulate yourself.

●Insulate yourself from work and ground using dry insulation. Making certain the insulation is large

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

●Take carefully when using the equipment in small place, falling-off and wet circumstance.

●Never close the machine power before installation and adjustment.

Ensure to install the equipment correctly and ground the work or metal to be welded to a good electrical
(earth) ground according to the operation manual.

●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.

●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.

●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 the floor level, use a safety belt to protect yourself from a fall should you get a
shock.

FUMES AND GASES CAN BE DANGEROUS.

●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 electrode which require
special ventilation such as stainless or hard facing or on lead or cadmium plated steel and other metals
or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold

Limit Values 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.

●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.

●Shielded 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.

●Read and understand the manufacturer’s instructions for this equipment and the consumables to be
used, including the material safety data sheet and follow your employer’s safety practices.

ARC RAYS CAN BURN

●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.

●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 rays or to hot spatter or metal.

SELF-PROTECTION

●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.

●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.

DO NOT adds 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.

WELDING SPARKS can cause fire or explosion.

●Remove fire hazards 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 material from welding can easily go
through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire
extinguisher readily available.

●Where compressed gases are to be used at the job site, special precautions should be used to
prevent hazardous situation.

●When no 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.

●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”.

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

●Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather

gloves, heavy shirt, cuff less trousers, 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.

●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 cables until they fail.

ROTATING PARTS MAY BE DANGEROUS

●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.

●Always keep cylinders in an upright position securely chained ro an undercarriage or fixed support.

●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.

●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 be in place and hand tight except when the cylinder is in use or

connected for use.

§1.3 The knowledge of electric and magnetic fields

Electric current flowing through any conductor cause localized Electric and Magnetic Fields (EMF).
The discuss on the effect of EMF is ongoing all the world. Up to now, no material evidences show that
EMF may have effects on health. However, the research on damage of EMF is still ongoing. Before any
conclusion, we should minimize exposure to EMF as few as possible.

In order to minimize EMF, we should use the following procedures:

●Route the electrode and work cables together – secure them with tape when possible.

●All cables should be put away and far from the operator.

●Never coil the power cable around your body.

●Make sure welding machine and power cable to be far away from the operator as far as possible

according to the actual circumstance.

●Connect the work cable to the work piece as close as possible to the area being welded.

●The people with heart-pacemaker should be away from the welding area.

2 SUMMARY

§2.1 Brief Introduction

This machine are general MMA arc welder which adopts the latest pulse width modulation (PWM)
technology and the insulated gate bipolar transistor (IGBT) power module. It can change work frequency
to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet
medium frequency transformer. Thus, it is characterized with portable, small size, low consumption and
etc.

This machine have excellent performances: constant current output makes welding arc more stable;
fast dynamic response speed reduces the impact from the arc length fluctuation to the current; accurate
stepless current adjustment and pre-setting function. There are also some automatic protection
functions for under voltage, over current, over heat, etc. inside the welders, when the problems listed
before occurred, the alarm on the front panel is light and at the same time the output current will be cut
off. It can self-protect and prolong the using life and greatly improved the reliability and practicability of
the welders.

This machine can also realize TIG operation. While MMA operation, if the electrode touches
workpiece over two seconds, the welding current will drop to the minimum current automatically to
protect the electrode. While TIG operation, the minimum current will be outputted firstly until the arc is
ignited by lifting method, the output current will rise to the preset value, which can protect the electrode.
At the same time, the arc force and hot start will be provided with MMA operation.

MMA --------- Manual Metal Arc welding
PWM ------------ Pulse – Width Modulation
IGBT ------------- Insulation Gate Bipolar Transistor
TIG --------------- Tungsten Inert Gas welding

§2.2 Working Principle

The working principle of this machine is shown as the following figure. Single phase 220V/230V±10%
work frequency ( 50/60 HZ ) AC is rectified into DC (about 300V), then is converted to medium frequency
AC ( about 20KHz ) by inverter device ( IGBT module ), after reducing voltage by medium transformer
( the main transformer ) and rectified by medium frequency rectifier ( fast recovery diodes), and is
outputted by inductance filtering. The circuit adopts current feedback control technology to insure current
output stably. Meanwhile, the welding current parameter can be adjusted continuously and steplessly to
meet with the requirements of welding craft.

§2.3 Volt-Ampere Characteristic

This machine have excellent volt-ampere characteristic, seeing the following graph. In MMA welding, the
relation between the rated loading voltage U2 and welding current I2 is as follows:
When I2=<600A, U2=20+0.04I2 (V); when I2 > 600A, U2=44 (V)