WARPP IN ARC-I series, IN TIG-I series Operating Manual

IN ARC-I / IN TIG-I Series

Inverter Ar c W elding Machines

Operating Manual

WARPP ENGINEERS PVT. LTD.

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

Web Site: www.warpp.co.in

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Thank you for selecting WARPP brand inverter welding machine. In order to keep you safe away from
unexpected accidents, and enjoy full benefits offered by our qua lity products during welding, please read the
instruction in details prior to operation. Complying with procedures defined in this manual is always
appreciated.

INDEX

1. Usage& Features……………………………………...…………………..(3)

2. Safety Precautions………………………………………………………...(3)

3. Installation…………….……………………………….………………….(5)

4. Definition of Product Model Number………………….…………………(6)

5. Principle in Brief…………….……………………………………………(6)

6. Operating Instruction………………………………….…………………..(7)

7. Repair and Maintenance.………………………….………….………….(12)

8. Main technical parameters……………………………………………….(15)

9. Appendix A: Common failures, probable cause & countermeasures…... (19)

10. Spare Part List…………………………………………………………(20)

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Usage & Features

This Series Inverter Arc welding machines include 2 welding combinations: IN ARC
(SMAW) & IN TIG (SMAW/TIG) with different specifications of rated current: 400A,
500A, 630A, etc., which are novelty high-efficient and energy-saving DC Arc welders,
not only are used in carbon steel and low alloy steel welding, but also used in stainless
steel, high alloy steel, copper, silver, molybdenum and titanium welding. As to its sound
static and dynamic characteristic and HF arc starting function, the series welders have
the following features:
¾ Invert technology can assured welding current high stability and arc length

consistency in fluctuating input primary power. Welding arc enjoys high
self-adjustability and mild strength.

¾ Low spatter
¾ Easy to start arc
¾ High deposit efficiency
¾ the machine can adjust its down- slope time while stopping arc. Weld formation are

pretty good.

¾ With remote control function, welding parameters can be adjusted in extended

distance.

¾ Light, small and portable.
¾ High power factor, high efficient and energy saving

Safety Precautions

General safety precaution:

z Please strictly comply with rules defined in this manual to avoid unexpected

accidents

z How to con nect to power supply, select working area and use pressure gas, please

comply with proper rules

z Not allow non-operator to ent er working area
z Welders’ installation, inspection, maintenance, and manipulation must be completed

by authorized person.

z Don’t use welding machine for unrelated purposes (Such as recharging, heating or

pipeline thaw, etc.)

z Must take safe precaution in case welder falling when it is put on the uneven ground

Avoid being electric shocked and burnt

z Never touch on the hot electrical units.
z Please instruct the authorized electrician to ground the welder frame by using

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proper-sized copper wire.

z Please instruct th e authorized electrician to connect the welder to power supply by

using proper- sized, well-insulated copper wire.

z When operating in the damp, space limited area, must ensure w ell-insulated betw een

body and work piece

z When operating in the high-rising location, must ensure safety by using safe net.
z Please power off the input voltage while no longer using.

Avoid breathing in hazardous welding fume or gas

z Please use specified ventilation to prevent being gas poisoned and asphyxiated

z Especially in the container where oxygen is depleted easily

Avoid being harmed by arc flash, hot spatter and slag

z Arc rays can injure your eyes and make your eyes feel uncomfortable.

z Hot spatter and slag can burn your skin. Please wear proper welding helmet, leather

gloves, long- sleeved suit, cap, apron and boot before welding.
Preventing from fire, explosion, container break accidents

z Don’t put flammable material in the working area. Hot spatter and hot weld can

easily start a fire.

z Cable must be connected the work piece firmly to ensure good conductivity in case

causing fire by resistance heat.

z Don’t weld in the flammable gas or weld container which contains flammable

material, otherwise it can cause explod e.

z Don’t weld encapsulated container, otherwise it can cause break.

z Ensuring a fire extinguisher at hand in case fire break out.

Avoid being hurt by moving parts.

z Never let the finger, hair, and cloth near the rotary cooling fan and wire feeder

rollers.

z When feeding wire, don’t let the bottom of gun near your eyes, face and body, to

prevent being harmed by wire.
Avoid gas bottle falling or gas regulator breaking

z Gas bottle must be firmly fixed on the ground, else if injure will exerts on.

z Never place bottle under high temperature or straight sun light.

z Never let y our face near gas outlet while turning on the gas valve to prevent from

being hurt by pressure gas.

z Customer should use the gas regulator provided by our company, and comply with

the proper instruction.

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O

Avoid being hurt by welding machine while in transport

z When moving the welding machine by fork-lift truck or crane, nobody can be

allowed for standing downright the route of the moving welder, in case being hurt
by the falling welding machine.

z The ropes or wires which used for hanging up the welding machine must be strong

enough to withstand corresponding tension strength. The rope or wire inclination
hanging on the tackle must be no more than 30°

Installation

1. Installing situation

1. Must place welding machine in the room where is no straight sunlight, no rain, less

dust, low humidity ,and temperature range of -10Ԩ～+40Ԩ

2. The gradient of ground must be no more than 15°

3. Ensure no wind at the welding position, or use screen to block the wind.

4. The distance between welder and wall must be more than 20cm, between welders

more than 10cm to ensure enough heat radiation.

5. When using water cooled gun, must be care of not being frozen.

2. Requirement of input volt:

(1) Input volt must be standard sine wave, effective value 380V±10%, frequency

50Hz/60Hz

(2) Unbalance degree of 3- phase volt must be no more than 5%

(3) Power supply:

z The size of fuse and breaker in the table are for reference only.

Product type 400 500 630

Power supply 3 phase AC380V

Min. power capacity 28KVA 38KVA 51KVA

Input

protection

Min.

Cable

size

Fuse 50A 63A 63A

breaker 63A 100A 100A

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Input side 4mm

6mm2 6mm2

utput side 50mm2 50mm2 70mm2

Earth lead 4mm2 6mm2 6mm2

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3. Installation

The machines are portably designed, can be effortlessly moved by operators without
fix-up. But it should be settled in even and dry places with well ventilation.

3.1 SMAW mode

(1) Ensure firmly connection to welding cable.
(2) Connect to remote controller( If needed)
(3) Adjust every knobs, and switches on the front panel to proper position in line

with selected mode.

(4) Turn on the air switch on the power source.
(5) Connect input 3 phase primary power cable to switch box.

3.2 TIG mode

(1) Ensure firmly connection to welding cable and TIG torch.
(2) Ensure firmly connection to gas hose and gas bottle and or water hose and

water supply as to using water-cooled welding torch.

(3) Connect to remote controller(If needed)
(4) Adjust every knobs, and switches on the front panel to proper position in line

with selected mode.

(5) Turn on air switch on the power source.
(6) Connect input 3 phase power cable to switch box and close it.

Attention: Before you plug the welding cable, please turn off the power and rightly
calibrate the plug key to the socket slot a t first, then insert and turn the plug clockwise until
it firmly seated. Make sure the plug and the socket are well-connected to be sound
conductivity in case that they are burnt out by over resistance heat.

Block diagram of principle

3~380V/50Hz Output

3 phase

Rectifier

HF

Inverter

Transformer

High frequency arc start

HF

Control circuit

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Principle in Brief

Rectifier &

Filter

3. Installation

The machines are portably designed, can be effortlessly moved by operators without
fix-up. But it should be settled in even and dry places with well ventilation.

3.1 SMAW mode

(1) Ensure firmly connection to welding cable.
(2) Connect to remote controller( If needed)
(3) Adjust every knobs, and switches on the front panel to proper position in line

with selected mode.

(4) Turn on the air switch on the power source.
(5) Connect input 3 phase primary power cable to switch box.

3.2 TIG mode

(1) Ensure firmly connection to welding cable and TIG torch.
(2) Ensure firmly connection to gas hose and gas bottle and or water hose and

water supply as to using water-cooled welding torch.

(3) Connect to remote controller(If needed)
(4) Adjust every knobs, and switches on the front panel to proper position in line

with selected mode.

(5) Turn on air switch on the power source.
(6) Connect input 3 phase power cable to switch box and close it.

Attention: Before you plug the welding cable, please turn off the power and rightly
calibrate the plug key to the socket slot a t first, then insert and turn the plug clockwise until
it firmly seated. Make sure the plug and the socket are well-connected to be sound
conductivity in case that they are burnt out by over resistance heat.

Block diagram of principle

3~380V/50Hz Output

3 phase

Rectifier

HF

Inverter

Transformer

High frequency arc start

HF

Control circuit

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Principle in Brief

Rectifier &

Filter

(A)

This series welding machines apply IGBT soft switch inverter technology. 3- phase input
volt are 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 current of welding,
arc-starting, arc force and time of down-slope as well as remote control availability add
significant values to customers. They can also perform down-slope, pre-gas flow and
post-gas flow function due to reasonable logic circuit design.
IN ARC Series arc welding machines output characteristic curve is as follows:

90–

20 –
0

U=20+0.04I

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1. Functional introduction

Operating Instruction

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Front panel illustration and parts number reference

1.1

(1) “ Amp/volt ” meter

When meter mode switch indicates to “Amp”, the meter display s preset value while
in open load, and display practical value of welding current while in actual working.
To “Volt”, display practical value while in welding.
(2) “Protection” indicator lamp
Welding machine will automatically stop working when it is overheat, and the lamp
will be light on.
(3) “Power” indicator lamp

Lamp indicating whether power source is effectively connected to power supply

(4) “Amp/Volt” meter mode switch
(5)”SMAW/TIG” Switch (Only in IN TIG Series).

When it is indicated to “SMAW”, the machine is to work on SMAW;
When it is on “TIG”, the machine is to work on TIG
4-step/ 2-step switch (Only in IN TIG Series).

(6) “Remote/ Panel control” switch ((200 series only equipped with Panel control)

When it is on “Panel control”, you can adjust current of welding, arc force or
down-slope time through the knobs and switches on the panel; when it is on “Remote
control’, you can adjust the above parameters through remote control box in a
extended distance from the welding areas
(8) “Welding current” regulation knob

Used to adjust welding current on panel control mode

(9) “Arc force current/ down-slope time” regulation knob

Used to adjust arc force current under SMAW or stop-arc time under TIG
(10) “Arc-starting current “regulation knob used to adjust arc starting current
(11) “Remote control/ TIG” cable socket
It is used to connect with remote control cable to adjust welding current, arc force
current or down-slope time through remote control box when it is on the “Remote
control” mode, used to weld in extended distance.
To weld in normal distance on TIG, it is used to connect TIG torch's control cable
directly.
(12)Welding cable (+) quick plug socket

It is used to connect with stick holder on SMAW mode. Connect to work leads on
TIG mode.

(13)Gas outlet (S series not equipped with it)

Connect to TIG torch gas hose.

(14)Welding cable (-) quick plug socket

It is connected to work lead on SMAW mode and connected to TIG torch welding
cable on TIG mode.

.

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(11) “Remote control/ TIG” cable socket
It is used to connect with remote control cable to adjust welding current, arc force
current or down-slope time through remote control box when it is on the “Remote
control” mode, used to weld in extended distance.
To weld in normal distance on TIG, it is used to connect TIG torch's control cable
directly.
(12)Welding cable (+) quick plug socket

It is used to connect with stick holder on SMAW mode. Connect to work leads on
TIG mode.

(13)Gas outlet (S series not equipped with it)

Connect to TIG torch gas hose.

(14)Welding cable (-) quick plug socket

It is connected to work lead on SMAW mode and connected to TIG torch welding
cable on TIG mode.

1.2 The rear panel and parts number reference
(1) Air switch
The function of air switch is to protect welding machine by automatic trip to turn-off
power supply while in machine overload or failure. Normally, the switch flipped to
upward means power-on. Use switch on the switch box to start or stop welding
machine, avoiding using the breaker.

(2) Input power cable

It is 4-pin cable. The mixed-colored wire must be firmly grounded, the rest wires
connect to corresponding 3-phase power supply (380v/50Hz).

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