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Related Manuals for WARPP IN ARC-I series
Summary of Contents for WARPP IN ARC-I series
- Page 1 IN ARC-I / IN TIG-I Series Inverter Arc Welding Machines Operating Manual WARPP ENGINEERS PVT. LTD. B-1005, Western Edge II, Western Express Highway, Near Metro Mall, Borivali (E), Mumbai-400 066. Tel: 91-22-28542272/ 73/74. Fax: 91-22-28542275. E-mail:sales@warpp.co.in Web Site: www.warpp.co.in...
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Page 2: Table Of Contents
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. -
Page 3: Usage& Features
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. - Page 4 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 input voltage while no longer using.
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Page 5: Installation
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. -
Page 6: Principle In Brief
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. - Page 7 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.
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Page 8: Operating Instruction
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. - Page 9 Front panel illustration and parts number reference (1) “Amp/volt” meter When meter mode switch indicates to “Amp”, the meter displays 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”...
- Page 10 (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.
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Page 11: Repair And Maintenance
2.1.1 Shift between two working styles: (1) Shift from down-slope to non-down-slope Switch to “TIG” mode, pull TIG torch trigger, then loose it, open load voltage of power source will disappear to indicate working style being shifted to non-down-slope. (2) Shift from non-down-slope to down-slope Switch to “SMAW”... - Page 12 (1) “Amp” meter It displays preset value while in open load, and displays practical value of welding current while in actual working. (2) “Welding current” regulation knob “Arc force current/ down-slope” regulation knob Socket 1 Connect to remote control cable. Socket 2 Connect to welding torch control cable which has a plug.
- Page 13 Table 2 TIG welding parameters Work piece Welding current Tungsten electrode Max Argon gas （A） thickness（mm） diameter（mm） flow rate（L/min） 40～50 1～3 1～2 50～80 80～120 120～160 3～6 2～4 160～200 200～300 6～9 300～400 4～6 Attention: On SMAW, when welding current is low and cable length of stick holder is short(no more than 40m), arc force current should be adjusted in the range of 1-7 .
- Page 14 Working styles on TIG mode of type STG series Can be divided into 2 working styles: scratch arc-start and high frequency arc-start. 2.2.1 Shift between two working styles: Shift scratch arc-start to high frequency arc-start (1)Switch to “TIG” mode, then pull TIG torch trigger, then loose it, open load voltage of power source will disappear to indicate working style is shifted to HF arc-start.
- Page 15 Pull TIG torch trigger Pre-gas flow, HF/ scratch arc-start Auto-lock Non-Auto lock Hold on trigger Release trigger Welding Welding Hold on trigger Release trigger Down-slope Down -slope Release fill trigger Until crater fill Until crater Push Post-gas flow Post-gas flow Up -slope Release trigger Up-slope...
- Page 16 (8) If the air switch on rear panel trips when the machine has worked with large current for a long time, operator should power off the switch, then start the machine in 5 minutes. Remember before starting the machine, turn on the air switch on the rear panel, power on the switch box.
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Page 17: Main Technical Parameters
Technical data Main technical parameters Parameters Description Primary power voltage/frequency 3 phase 380V±10%/50Hz Rated output capacity 14.4KW 20KW 27.7KW Rated input current Rated duty cycle Range of output current 20～400A 20～500A 50～630A Output voltage of open load 80±8V Full-load efficiency 0.95 Power factor（full-load）... - Page 18 IN ARC / IN TIG-400 I Item Qua. Memo Air switch 3-phase rectifier module Small Polypropylene capacitor Polypropylene capacitor IGBT module Voltage sensitive resistance M1、M2 Ceramic dielectric capacitor Ceramic dielectric capacitor C8～C17 Main transformer Power source transformer Insulation transformer (IN TIG) Fast recovery diode module D1～D4 Current exchange inductor (IN...
- Page 19 IN ARC / IN TIG-500 I Item Qua. Memo Air switch 3-phase rectifier module Polypropylene capacitor Polypropylene capacitor IGBT module C4～5 Voltage sensitive resistance M1、M2 Ceramic dielectric capacitor Ceramic dielectric capacitor C8～C19 Main transformer Power source transformer Insulation transformer (IN TIG) Fast recovery diode module D1～D6 Current exchange inductor (IN...
- Page 20 IN ARC / IN TIG-630 I No. Tab Item Qua. Memo Air switch 3-phase rectifier module Polypropylene capacitor Polypropylene capacitor IGBT module C4～5 Voltage sensitive resistance M1、M2 Ceramic dielectric capacitor C8]～C21 Ceramic dielectric capacitor Main transformer Power source transformer Insulation transformer (IN TIG) Fast recovery diode module D3～D8 Current exchange inductor (IN...
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Page 21: Appendix A: Common Failures, Probable Cause & Countermeasures
Appendix A: common failures, probable cause & countermeasures № Phenomena Reason Solving methods After power on, it Phase missing power source, in Check power source doesn’t work. Check if cooling fan, Fuse（2A）in welder is broken. power source transformer Cable is broken and main control board are good or not. - Page 25 Front Panel of ARC series Protection on LED (LED2) Power on LED (LED1) Remote / Digital Display Digital Display Panel Control (DSP001) Switch (KD1) Arc-starting Current Potentiometer (W3) Amp / Volt / V l Switch (KD2) Arc-force Current / Down-slope Time Welding Current Potentiometer (W2) Potentiometer (W1)
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Page 26: Front Panel
Front Panel VOLTAGE/AMPERE SMAW/TIG SELECTION SWITCH (PSW01) SWITCH (PSW01) SWITCH (PSW01) 2 / 4 TRACK LED YELLOW SELECTION SWITCH (LED Y01) (PSW01) Digital Display REMOTE/PANEL Meter (DSP001) SELECTION SWITCH (PSW01) LED RED (LED R01) POTENTIOMETER FOR CURRENT (POT001) POTENTIOMETER FOR POTENTIONMETER STRIKING CURRENT FOR ARC FORCE... - Page 27 Left View Left View Fan (FAN Main 002) Transformer Thrust Coil Output Choke (CHK 001) Snubber PCB For O/P FRM (PCB-SNB- OUT-01) Isolation PCB (PSB- Output Rectifier Output Rectifier ISO-01) Module (FRM001)
- Page 28 Right View Thermal Cut- Thermal Cut Over Current Over Current HF T HF Transformer Protection (CTRAX007) HF PCB (PCB- HF-01) SNUBBER CARD Resonant Coil IGBT IGBT AC Capacitor Input Bridge Module Fan Capacitor (CAP05) Shunt Solonaid Valve Insulation Insulation (SV001) Transformer MOV (MOV001) (INSTRX001)
- Page 29 Top View CONTROL Input Surge TRANSFORMER Drive CARD Suppressor (ISS (CTRAX001) (PCB-DRV-01) Fuse (F1) Main PCB...
- Page 30 Rear Panel Rear Panel...
- Page 31 List for the spares of INTIG I Series machines DESCRIPTION INTIG-315 INTIG-400 I INTIG-500 I INTIG-630 I Part Code Part Code Part Code Part Code MAIN PCB PCB-TIG-315I PCB-TIG-400I PCB-500I PCB-TIG-630I DRIVE CARD PCB-DRV-01 PCB-DRV-01 PCB-DRV-01L PCB-DRV-01L IGBT IGBT7512 IGBT7512 IGBT10012 IGBT15012 INPUT BRIDGE MODULE...
- Page 32 DESCRIPTION INARC-315 INARC-400 I INARC-500 I INARC-630 I Part Code Part Code Part Code Part Code MAIN PCB PCB-ARC-315I PCB-ARC-400I PCB-ARC-500I PCB-ARC-630I DRIVE CARD PCB-DRV-01 PCB-DRV-01 PCB-DRV-01L PCB-DRV-01L IGBT IGBT7512 IGBT7512 IGBT10012 IGBT15012 INPUT BRIDGE MODULE IBDG003 IBDG003 IBDG004 IBDG004 OUTPUT RECTIFIER FRM001 FRM001...