WARPP IN MIG I Series, IN MIG-500 I, IN MIG-250 I, IN MIG-400 I, IN MIG-630 I Operating Manual

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IN MIG I Series Inverter

CO2 MAG 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] /73714. 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
quality 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…………………….(8)

5. Principle in Brief…………….…………………………...(8)

6. Operating Instruction…………………………………….(9)

7. Technical Data…………………………………………...(12)

8. Repair& Maintenance.………………………….………..(16)

Appendix A: Ordinary failures, probable cause &

countermeasures

Usage & Features

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IN MIG I series inverter CO2/MAG welders are high-quality performers
that can be used for all-purpose, semi-automatic CO2 gas shield welding
with solid or flux-cored wire(Ф1.2-Ф2.0mm)for welding mild steel and
low alloy steel work pieces. This series welder enjoys reasonable static
characteristic and sound dynamic characteristic.

 Inverter technology can ensure fairly good stability of output volt

when fluctuation occurs in input primary volt or arc length changes,
as well as startling arc self-adjustability and stable welding
process.

 Less spatter, high deposit efficiency.
 Less weld distortion, good weld formation.
 High success rate of arc-starting due to stronger pulse strike
 Reducing molten ball while stopping arc
 Reducing labor intensity while welding long weld by using

auto-lock function

 Stable wire feeding due to consistent output of power circuit
 Small, light and portable
 Energy-saving, low expense and flexible to various input primary

quality.

Safety Precautions

General safety precaution:

 Please strictly comply with rules defined in this manual to avoid

unexpected accidents

 How to connect power supply ,select working area and use

pressure gas, please comply with proper rules

 Not allow non-operator to enter working area

 Welder installation, inspection, maintenance, and manipulation

must be completed by authorized person.

 Don’t use welding machine for unrelated purpose (Such as

recharging, heating or pipeline thaw, etc.)

 Must take safe precaution in case welder falling when it is put on

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the uneven ground

Avoid being electric shocked or burnt

 Never touch on hot electrical units.

 Please instruct the authorized electrician to ground the welder

frame by using proper-sized copper wire.

 Please instruct the authorized electrician to connect the welder to

power supply by using proper-sized, well-insulated copper wire.

 When operating in the damp, space limited area, must ensure

well-insulated between body and work piece

 When operating in the high-rising location, must ensure safety by

using safe net.

 Please power off the machine while no longer welding.

Avoid breathing in hazardous welding fume or gas

 Please use specified ventilation to prevent being gas poisoned and

asphyxiated.

 Especially in the container where oxygen is depleted easily.

Avoid being harmed by arc flash, hot spatter, slag

 Arc rays can injure your eyes and make your eyes feel

uncomfortable. Hot spatter and slag can burn your skin.

 Please wear proper welding helmet, leather gloves, long- sleeved

suit, hat, apron and boots before welding.

Preventing from fire, explosion, container break accidents

 Don’t put flammable material in the working area. Hot spatter and

hot weld can easily start a fire.

 Cable must be connected the work piece firmly to ensure good

conductivity in case causing fire by resistance heat.

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

flammable material, otherwise it can cause explode.

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

 Ensure a fire extinguisher at hand in case a fire breaks out.

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Avoid being hurt by moving parts

 Never let the finger, hair, and cloth near the rotary cooling fan and

wire feeder’s rollers.

 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

 Gas bottle must be firmly fixed on the ground, else if injure will

exerts on.

 Never place bottle under high temperature or sun light.

 Never let your face near gas outlet while turning on the gas valve

to prevent from being hurt by pressure gas.

 Operators should use gas regulator provided by our company, and

comply with the proper instruction.

Avoid being hurt by welding machine while in transport

 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.

 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 -10℃～+40℃

(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

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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 380-440V,

frequency 50Hz/60Hz

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

3． Power supply:

Table1: The size of fuse and breaker in the table are for reference only.

Product type

IN

MIG-250 I

IN

MIG-400 I

IN

MIG-500 I

IN

MIG-630 I

Power supply

3 phase AC380V

Min. capacity

Power network

12KVA

22KVA

38KVA

54KVA

Generator

20KVA

30KVA

50KVA

70KVA

Input volt

protection

Fuse

20A

30A

50A

60A

Circuit breaker

20A

32A

63A

100A

Cable size

(cross-section)

Input volt

≥1.5mm2

≥2.5mm2

≥6mm2

≥10mm2

Output volt

25mm2

35mm2

70mm2

95mm2

Ground lead

≥1.5mm2

≥2.5mm2

≥6mm2

≥10mm2