WARPP WARMIG-400 Instruction Manual

INSTRUCTION MANUAL FOR

MIG/MAG (CO2) WELDING

MACHINE

MODEL WARMIG-400

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

INDEX

1) INTRODUCTION 1

2) THE SYSTEM 1

3) PRE INSTALLATION REQUIRMENT 3

4) INSTALLATION 3

5) SAFETY 3

6) VOLTAGE SETTING CHART 4

7) FEED RATE CHART 4

8) OPERATION 5

9) FAULT FINDING 6

10) SPARE PART LIST 7

ILLUSTRATIONS

1) CONTROL WIRING INSIDE THE POWER SOURCE 1

2) CONTROLWIRING OF THE FEEDER 2

3) INSTALLATION DIAGRAM 3

4) VOLTAGE V/S CURRENT CURVE 4

5) TORCH ASSEMBLY DIAGRAM 5

INTRODUCTION.

WARMIG Series MIG / MAG (CO2) Machines are Switch type constant voltage type. They can be
used for MIG (Metal Inert Gas) Welding in SS and Al. and MAG (Metal Active gas) Welding in MS.
This machine mainly consists of following components in it.

1) Power Source.

2) Wire Feeder

3) Regulator Flow-meter

4) MIG Welding Torch

5) Inter Connecting Cable

THE SYSTEM

POWER SOURCE.

The power source has following components

Main Transformer

The main transformer is a constant voltage type transformer with the tapings on the primary

side to adjust the output voltage. Super Enameled Copper wirers are used for primary winding and

fiber glass coated strips are used for secondary windings. The coils are varnished with H Class

grade varnish for durability.

Rectifier Stack.

Rectifier stack is a full wave rectifier with six diodes (Three Modules in 250 Amps range). The

diodes are mounted on well designed heat sink for better performance.

Voltage adjusting Switch.

Two switches are used to adjust the out put voltage. The two switch operates in coarse fine

combination to give maximum number of voltage adjustments.

Ammeter.

Ammeter is provided on the front panel to read the out put current during welding

Voltmeter

Voltmeter is provided on the front panel to read the welding Voltage

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Cooling Fan.

Industrial heavy duty fan operating on single phase is provided for proper cooling of

transformer and Rectifier

WIRE FEEDER.

Wire Feeder has the following components.

Wire feeder motor with Mechanism.

WARMIG Series machines employ permanent magnet type DC Motors for wire feeding. The

feeding mechanism is two roll type and is designed for easy changing of rollers depending on the

wire size.

Drive Card.

The drive card used to drive the wire feeder motor is MOSFET based and the design is

rugged enough to absorb the voltage fluctuation. The electronic stopping circuitry is provided for

instant stopping of the wire feed.

Sequence Card.

The sequence card is controls the sequence of events in the welding process and it uses

only TTL Logic. Provision is made to adjust the BURN-OFF timing.

MIG Welding Torch.

The machines comes with 36KD Torch in 400 Amps and 25AK torch in 250 Amps

models. The details of the assembly drawing in shown in the fig.

NOTE: THE LINER OF THE TORCH HAS TO BE CLEANED ON A REGULAR BASIS

FOR GOOD WELDING RESULTS

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PRE INSTALLATION REQUIRMENT

.

The WARMIG Series machines comes with the complete package ready to use. What it

requires to put the machine in use is three-phase power supply, Gas cylinder and the MIG wire.

NOTE: THE MACHINE COMES WITH CO2 GAS REGULATOR ONLY

INSTALLATION.

The pictorial installation diagram is attached in this manual.

NOTE: PROPER INPUT CABLE TO BE USED TO CONNECT THE MACHINE TO THE

POWER SUPPLY AND SEPARATE EARTHING TO BE PROVIDED.

SAFETY.

All safety precautions are to be taken for the safety of welders and surrounding people.

Some of them are listed below.

1) Keep the welding area free from all inflammable materials.

2) Welders has to use proper welding helmets (with proper filter glass) as ultra violet radiation is a

part of welding process.

3) Proper Apron, Hand Gloves and shoes has to be used by the welder.

4) Welding area should be covered properly so that people working around do not affected by the

ultra violet radiation.

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