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

·１·

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

·２·

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

·３·

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

·４·

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.

·５·

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

·６·

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

·７·

4. Installation:

This series welder is small, light and portable. They will be more
convenient if place them on the trolleys. Ensure the location where to
place the welder is even.

IN MIG-I series welders wire diagram as Fig. 1:

Preparation prior to operation procedure:

(1) Connect the welder’s terminal plug(-) to the work piece by

welding cable

(2) Connect the welder’s terminal plug(+) to the wire feeder by

control cable

(3) Connect the welder’s control cable socket to the wire feeder by

control cable.

Fig.1: Wire diagram of IN MIG-I series welders

(4) Connect feeder’s gas hose to the regulator
(5) Connect the regulator’s heat-up cable to the welder’s “gas heat-up

power “cable socket. (on the rear panel)

(6) Connect the welder’s power cable to the disconnection

·８·

switchboard, while grounds the lead safely.

(7) Reset the circuit breaker on the welder’s rear panel.

5. Operating procedure:

Reset the circuit breaker on the switchboard, then the welder’s
indicator lamp will turn on, and the cooling fan will spin. Press on the
“Inch feeding” button on the feeder’s controller, the feeder begin to
feed wire. Preset the process parameters by regulating the controller,
tuning the knob, and flipping the switch to proper location on the front
panel of the welder. When the torch trigger is pulled, the feeder start to
feed wire, and CO2 will blow out of the nozzle, therefore it can be
used for welding. Operators can select parameters from table listed
below. Be sure to turn off the valve of gas bottle and unplug the power
cord while stop welding.

Table 2

Welding current（A）

Welding voltage（V）

Suitable wire（mm）

60~80

17~18

Ф1.0

80~130

18~21

Ф1.0、Ф1.2

130~200

20~24

Ф1.0、Ф1.2

200~250

24~27

Ф1.0、Ф1.2

250~350

26~32

Ф1.2、Ф1.6

350~500

31~39

Ф1.6

500~630

39~44

Ф1.6

Principle in Brief

Block diagram of principle

3~380V/50Hz

Rectifier

HF inverter

Main transformer

Rectifier&Filter

Control circuit

+

·９·

Fig. 2: Block diagram of principle

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 dynamically
responsive speed has been greatly increased, so the welder size and weight
are reduced noticeably. Power source enjoys good anti-fluctuating ability
and high-quality performance

Fig 3: Output characteristic

Operating Instruction

1. Front panel illustration and parts number reference

Take IN MIG-500 I for example, front panel is illustrated below, other
models are little different from this.

U(V

-

80

-

60

-

40

-

20

-

U2=14+0.05I2

I

·１０·

Fig.1: Figure of front panel

(1) “Output Amp” meter

Display relative feeding speed while in open load, and display
practical value of current while in welding.

(2) “Output volt” meter

Display preset value of volt while in open load, and display
practical value while in welding.

(3) “Induction” regulation knob

Altering welding stability, penetration and spatter volume.

(4) “Crater filling Amp” regulation knob

Adjusting current value in Auto-lock mode

(5) “Crater filling volt” regulation knob

Adjusting volt value in Auto-lock mode

(6) Wire feeder’s control cable socket

Connect to wire feeder’s control cable

(7) Terminal lug （＋）

Connect to wire feeder’s welding cable

(8) “Power” indication lamp

Lamp indicating whether power source is effectively connected
to power supply.

(9) “Protection” indicator lamp

Welding machine will automatically stop working when it is
overheat, and the lamp will be light on.

(10) “Auto lock/ Non-Auto lock” mode switch

Switch to “Non-Auto lock”, perform welding when push torch

trigger, stop welding when release the trigger. This mode is
suitable for short weld. To “Auto lock”, after successfully
starting arc by push torch trigger, then you can perform
welding by release the trigger, when you push torch trigger
again, torch will turn into crater-filling situation which was
preset by stop- arc knobs on the front panel. The welder will
stop welding when release the trigger. This mode is suitable for
welding long weld.

·１１·

(11) Mode selection switch

When the switch is on “Gas test”, the electromagnetic valve will
be opened, you can check if the airflow is normal. When on
“Wire test”, you can check up the welding machine’s state, it is
the same function as to push the weld torch trigger. When on
“normal”, the welding machine is on normal working state.

(12) Terminal lug (-)

Wire work piece by work lead

2. The rear panel and parts number reference

Fig.5: Rear panel

(1) Input warning sign

(2) 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 which means
power-on. Use switch on the disconnected switchboard or
switchbox (customers prepare by themselves) to start or stop
welding machine, avoiding using the air switch.

(3) Input power cable

The mixed-colored wire must be firmly grounded, the rest wires
connect to 3-phase power (380v/50Hz) respectively.

(4) Plastic cable pincers

·１２·

(5) Ground bolt

To ensure operators not to be harmed and welding machine to be
working normally, make sure the ground bolt grounded firmly by
ground lead specified in the table 1, or ground
wire(mixed-colored) of the input power cord grounded firmly.

(6) Cooling fan

Cool down the heat components in the welding machine.

(7) Gas Heater power cable socket

Power socket wire to CO2 regulator’s heater coil

(8) Name tag

3. Controller

This controller is fixed on the panel of wire feeder.
Panel illustration and parts number reference

Fig. 6: Panel of controller

(1) Current regulation knob

Adjusting welding current

(2) “Inching” button

Used for quick wire feeding

(3) Volt regulation knob

Adjusting welding volt

·１３·

Technical data

1. Main technical parameters

Table 3

№

Items

IN

MIG-250 I

IN

MIG-400 I

IN

MIG-500 I

IN

MIG-630 I

01

Voltage/

frequency

Three
phase

380V10

%/50Hz

Three
phase

380V10

%/50Hz

Three
phase

380V10

%/50Hz

Three
phase

380V10

%/50Hz

02

Rated input

power

8KVA

14.4KVA

25KVA

35.8KVA

03

Rated input

current

12A

21A

37A

54A

04

Rated duty

cycle

60%

60%

60%

100%

05

Output current

60～250A

60～350A

60～500A

60～630A

06

Output

voltage

12～30V

12～40V

15～50V

15～50V

07

Output open

voltage

58V

58V

70V

70V

08

efficiency

≧89%

≧89%

≧89%

≧89%

09

Power factor

≧0.87

≧0.87

≧0.87

≧0.87

10

Wire

diameter(mm)

Ф0.8～

Ф1.2

Ф1.0～

Ф1.6

Ф1.0～

Ф1.6

Ф1.0～

Ф2.0

11

Weight

20Kg

40Kg

50Kg

58Kg

12

Dimensions(m

m3)

495×232×

495

576×297×

574

636×322×

584

686×322×

584

·１４·

13

CO2 gas flow

rate

15～20L/min

14

Insulation

class of main

transformer

H

·１５·

Repair & Maintenance

In principle, welders’ maintenance and repair should be completed by
us or our authorized distributors. Customers can also be instructed by us or
our authorized distributors to solve the problems which they come across in
using.

1. Attentions:

(1) Rivet equipment name tag on the specified area of the case,

otherwise the inside parts will be damaged possibly.

(2) Connect welding cable to terminal lug firmly, otherwise the

terminal lug will be burn out which will lead to welding
process instability.

(3) Prevent jointer of welding cable and terminal lug from

contacting with other metals on the ground to avoid short
circuit.

(4) Operating carefully, don’t make welding and control cable

worn out or broken.

(5) Never let welding machine be bumped into or stacked up by

heavy objects.

(6) Ensure good ventilation

2. Periodical checkup and maintenance

(1) Removes dust from power resource with pressure air by authorized

maintainer every 3-6 months. Check if the jointers are loose.

(2) Check regularly if cables are worn out, knobs are loose, and

components of panel are damaged.

(3) Change contact tip and wire feeder roller in time, and clean liner

tube regularly.

3. Trouble shooting

3.1 Routine checking procedures prior to maintenance

Check if all front panel switches are on the proper positions

(1) Check if the input volt has the phase missing, and range are

between 340-420V.

(2) Check if the input cable is connected correctly and firmly with

the power source.

·１６·

(3) Check if the ground lead is connected correctly and firmly.

(4) Check if the welding cables are connected correctly and firmly.

(5) Check if gas regulator is in good situation and CO2 flows out

normally.

Warning: Don’t open up case uninstructed, the max volt inside machine is
600V. Take safe precautions to prevent from being electric shock while in
maintenance.
Shut down power source before changing welding cable or torch.

Appendix A: Common failures, probable cause & countermeasures

№

Trouble

Probable cause

Remedy

01

Indicator lamp does
not light on when
machine switches on.

(1) Phase missing
(2) Air switch is
damaged
(3) Fuse is broken

(1) Check power
supply
(2) Change Air
switch
(3) Change fuse
(2A)

02

Air switch tripped
Immediately after the
machine is switched
on.

(1) Circuit breaker is
lapsed.
(2) IGBT module is
damaged
(3) 3-phase rectifier
bridge is damaged.
(4) Voltage-sensitive
resistance damaged
(5) Welder’s control
board is damaged

(1) Change air
switch
(2) Change IGBT
module and driving
board
(3) Change
3-phase rectifier
bridge
Change
(4)
Voltage-sensitive
resistor
(5) Change Main
Control board

03

Air switch trips while
in welding

(1) Welding machine
operates in long term
overload
(2) Air switch is
damaged

(1) Operating
machine in rated
duty cycle
(2) Change air
switch

04 (1) Wire feeder’s

(1) Change control

·１７·

Welding current can
not be adjusted

control cable is broken
or controller is
damaged
(2) Control board is
damaged
(1) Conductive wire
connected the rectifier
is broken

cable or controller
(2) Change control
board
(3) Reconnect the
broken wires

05 Instable arc welding,
more spatter

(1) Incorrect welding
parameters
(2) Contact tip is worn
out severely

(1) Fine tune
parameters
(2) Change contact
tip

06 CO2 gas regulator
can’t heat

(1) CO2 regulator is
damaged
(2) Heater cable is
broken or shorten
(3) Thermal-sensitive
resistance in power
source is damaged

(1) Change regulator
repair heat cable
change
(2)
Thermal-sensitive
resistance

07

Push welding torch
trigger, wire feeding
is normal but airflow
is blocked

(1) Control board is
damaged
(2) Electromagnet
valve damaged

(1) Replace main
control board
(2) Replace
electromagnet valve

08

Push welding torch
trigger, wire feeder do
not work and there is
no open load volt
display

(1) Torch trigger is
damaged
(2) Feeder’s control
cable is broken
(3) Control board is
damaged

(1) Replace welding
torch
(2) Repair control
cable
(3) Replace main
control board

INMIG-250 I INMIG-400 I INMIG-500 I INMIG-630 I

Part Code Part Code Part Code Part Code

MAIN PCB PCB-MIG-250I PCB-MIG-400 I PCB-MIG-500I PCB-MIG-630I

DRIVE CARD PCB-DRV-01 PCB-DRV-01 PCB-DRV-01L PCB-DRV-01l

IGBT IGBT5012 IGBT7512 IGBT10012 IGBT15012

INPUT BRIDGE MODULE IBDG003 IBDG003 IBDG004 IBDG004

OUTPUT RECTIFIER MODULE FRM001 FRM001 FRM001 FRM001

FAN FAN001 FAN004 FAN005 FAN006

DC CAPACITOR CAP001 CAP001 CAP001 CAP001

AC CAPACITOR CAP002 CAP003 CAP003 CAP004

SNUBBER CARD PCB-SNB-01 PCB-SNB-01 PCB-SNB-02 PCB-SNB-03

MCB MCB001 MCB002 MCB002 MCB003

DIGITAL DISPLAY METER FOR CURRENT DSP001 DSP001 DSP001 DSP001
DIGITAL DISPLAY METER FOR VOLTAGE DSP007 DSP007 DSP007 DSP007

INPUT SURGE SUPPRESSOR ISS001 ISS001 ISS001 ISS001

SNUBBER CAPACITOR SCAP001 SCAP001 SCAP001 SCAP001

CONTROL TRANSFORMER CTRAX002 CTRAX002 CTRAX002 CTRAX002

CONTROL TRANSFORMER FOR WIRE
FEED MOTOR (BIG)

CTRAX003 CTRAX003 CTRAX003 CTRAX003

MOV MOV001 MOV001 MOV001 MOV001

SNUBBER PCB FOR OUTPUT FRM PCB-SNB-OUT-01 PCB-SNB-OUT-01 PCB-SNB-OUT-01 PCB-SNB-OUT-01

POTENTIOMETER FOR CRATER
CURRENT/CRATER VOLTAGE

POT001 POT001 POT001 POT001

POTENTIOMETER FOR INDUCTANCE POT33 POT33 POT33 POT33

KNOB FOR THE POT KNOB001 KNOB001 KNOB001 KNOB001

OVERCURRENT PROTECTION PCB PCB-OC-250 PCB-OC-400 PCB-OC-500 PCB-OC-630

MAIN TRANSFORMER MTRX005 MTRX006 MTRX007 MTRX008

FAN CAPACITOR CAP05 CAP05 CAP05 CAP05

TWO POLE SWITCH FOR PANEL/REMOTE &
V/A

PSW001 PSW001 PSW001 PSW001

Spare List of the INMIG-I Series

DESCRIPTION

TWO POLE THREE WAY SWITCH FOR
WIRE TEST/ GAS TEST / NORMAL
SELECTION

PSW002 PSW002 PSW002 PSW002

OUT PUT CONNECTOR MACHINE SIDE FST-PLG-F-02-S OUTCON001 OUTCON001 OUTCON001

OUT PUT CONNECTOR CABLE SIDE FST-PLG-M-02 NA NA NA

6 PIN CONNECTOR MALE (MACHINE SIDE) CON6PNM CON6PNM CON6PNM CON6PNM

6 PIN CONNECTOR FEMALE CABLE SIDE CON6PNF CON6PNF CON6PNF CON6PNF
SHUNT SHUNT001 SHUNT001 SHUNT002 SHUNT002

LED RED LEDR01 LEDR01 LEDR01 LEDR01

LED YELLOW LEDY01 LEDY01 LEDY01 LEDY01

PRIMARY THRUST COIL NIL NIL THCL-P-500 THCL-P-630

SECONDARY TRUST COIL THCL-250 THCL-400 THCL-500 THCL-630

WIRE FEEDER MOTOR WITH WIRE FEED
MECHANISM

WFMTR002 WFMTR002 WFMTR003 WFMTR003

24 V SOLANOID VALVE

SV002 SV002 SV002 SV002

EURO CONNECTOR FEEDER SIDE EURO-BRASS-01 EURO-BRASS-01 EURO-BRASS-01 EURO-BRASS-01

PRESUURE ARM

PRARM001 PRARM001 PRARM001 PRARM001

PRESURE HOLDER

PRHLD001 PRHLD001 PRHLD001 PRHLD001

SPOOL HOLDER

SUS TUBE

SUS001 SUS001 SUS002 SUS002

ROLER 0.8/1.0

INMIGRLR001 INMIGRLR001 INMIGRLR001 INMIGRLR001

ROLER 1.0/1.2

INMIGRLR002 INMIGRLR002 INMIGRLR002 INMIGRLR002

ROLER 1.2/1.6

Not Applicable Not Applicable INMIGRLR003 INMIGRLR003

POTENTIOMETER FOR
CURRENT/VOLTAGE

POT002 POT002 POT002 POT002

INCHING SWITCH

INCSW001 INCSW001 INCSW001 INCSW001

KNOB FOR THE POT ( Black ) KNOB002 KNOB002 KNOB002 KNOB002

WIRE FEEDER