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WARPP COMBO-401 i Operator's Manual

Inverter co2/mig/mag gas shield welding machines
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COMBO-401 i /501 i
Inverter CO2/MIG/MAG Gas Shield
Welding Machines
OPERATOR'S MANUAL
(PLEASE READ CAREFELLY BEFORE OPERATION)

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Summary of Contents for WARPP COMBO-401 i

  • Page 1 COMBO-401 i /501 i Inverter CO2/MIG/MAG Gas Shield Welding Machines OPERATOR’S MANUAL (PLEASE READ CAREFELLY BEFORE OPERATION)
  • Page 2 COMBO-401 i/501 i OPERATOR’S MANUAL Safety Depends on You Our arc welding and cutting equipment s are designed and built with safety in mind. However, your overall safety can be increased by proper installation. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND FOLLOWING THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
  • Page 3 COMBO-401 i/501 i OPERATOR’S MANUAL Arc welding can be hazardous. All performing welding workers ought to have health qualification that provided by authority organization. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker wearers should consult with their doctor before operating. Be sure that all installation, operation, maintenance and repair procedures are performed only by qualified individuals.
  • Page 4 Do not work near to the welding power source. Lifting equipment: carton or wooden boxes package of the welding machines supplied by WARPP Engg. There is no lifting equipment in its wrapper. Users can move it to the prospective area by a fork-lift truck, then open the box.

  • Page 5: Table Of Contents

    COMBO-401 i/501 i OPERATOR’S MANUAL CONTENTS 1. Usage notices -------------------------------------------------5 Machine Model & Process Features & Advantages Usage Safety Environmental Area Input power conditions Installation diagram Components name and Function Introductions 2. Connections --------------------------------------------------10 Connections of the power supply cable and the ground wire...

  • Page 6: Usage Notices

    COMBO-401 i/501 i OPERATOR’S MANUAL 1. Usage Notices Machine Model is : 1. 1 COMBO 401 I / 501 I Process : SMAW GMAW FCAW Features & Advantages Slow feeding speed with high open circuit voltage for better arc striking.

  • Page 7: Input Power Conditions

    COMBO-401 i/501 i OPERATOR’S MANUAL nput Power conditions Power supply : 380-440VAC The fluctuation range of frequency: ＜±1% The imbalance rate of three-phase voltage :＜±5% While using engine generator, the output power should be two times larger than the rated input power of the welding power source and compensation coil is needed.
  • Page 8 COMBO-401 i/501 i OPERATOR’S MANUAL 16. Gas heater supply : Power socket of the gas heater, its output voltage is 36VAC. 17. Fuse holder : 3A glass fuse holder. 18. Input connection line of three phase power: connect it to distribution box, the green-yellow line should be connected to protective ground line well.
  • Page 9 COMBO-401 i/501 i OPERATOR’S MANUAL...

  • Page 10: Connections

    COMBO-401 i/501 i OPERATOR’S MANUAL Connections (The user should choose the power cables, switches, fuses and power switches as specified in table ) COMBO-401 i COMBO-501 i Specification Switch capacity（A） Fuse capacity（A） ） Section surface of power supply cables（mm ）...

  • Page 11: Directions Of The Gas-Shielded Welding Mode

    COMBO-401 i/501 i OPERATOR’S MANUAL Turn on the power switch of distribution box. Turn the welding machine switch to the manual welding model. Before welding, make sure the output terminal of the welding machine is connected to the welding cable properly according to the section 2.2 above. adjusted welding current by the current adjustment knob on the panel.

  • Page 12: Directions Of The Basic Welding

    COMBO-401 i/501 i OPERATOR’S MANUAL Figure 3 : Installation sketch map of welding wire 4.2 Directions of the basic welding Welding can be performed by the “crater” switch and welding torch switch on the panel in two methods : a) with crater self-lock and b) without crater function.

  • Page 13: Directions Of Prolonged Output Cable

    COMBO-401 i/501 i OPERATOR’S MANUAL time, welding voltage appears, then coming into the arc starting state and begins to feed wire slowly. After successful arc starting, the wire feeding speed will become normal, and then welding current appears. But you can`t release the switch now.Simultaneously, adjust the “welding voltage adjustment” knob and the “welding current adjustment”knob for the best performance of welding;...

  • Page 14: Examples Of Welding Condition

    COMBO-401 i/501 i OPERATOR’S MANUAL order to avoid worsening the performance or even burning out the machine, there is heat protection on this series of welding machine. When the inner temperature exceeds the set temperature, the heat protection will shutdown the machine, the overload indicator LED glows, at this time the machine has no output. Wait until the temperature is below the set temperature and the overload indicator LED will turned off, the machine recovers and you can do welding again.
  • Page 15 COMBO-401 i/501 i OPERATOR’S MANUAL Table 1: Thicknes Wire Welding Welding Welding Stick Length Gas flow diameter current voltage speed (mm) (L/ Min) (mm) (mm) (cm/Min) (mm) 2.5～3 70～80 17～18 50～60 10～15 3～3.5 85～90 18～19 50～60 10～15 3～3.5 1.0,1.2 100～110 18～19.5...

  • Page 16: Working Principle

    COMBO-401 i/501 i OPERATOR’S MANUAL Table 2: Thick Wire Root Welding Welding Welding Wire out -ness diameter current voltage speed (mm） flux G （mm） （V） (mm） (mm) (cm/Min) (L/Min) 60～70 16～16.5 50～60 75～85 17～17.5 50～60 10～15 80～90 17～18 50～60 10～15 95～105...
  • Page 17 COMBO-401 i/501 i OPERATOR’S MANUAL ATTENTIONS: This welding machine adopts large capacity,high voltage and electrolytic capacitor filter, it can not be opened until the three-phase power is shut down more than 10 minutes. 8.2 Common troubles and troubleshooting Troubles Reasons Troubleshooting 1 ．...
  • Page 18 COMBO-401 i/501 i OPERATOR’S MANUAL leak； 6．Check the voltage 24VDC of 6．Valve doesn’t work； the valve winding； 7．The nozzle is distorted； 7．Replace the nozzle； 1 ． Control cable of wire feeder is broken； 1．Replace the control cable； 8 ． Current /voltage 2．...
  • Page 19 COMBO-401 i/501 i OPERATOR’S MANUAL...
  • Page 20 COMBO-401 i/501 i OPERATOR’S MANUAL Picture 1- Right View. Picture 2- Left View.
  • Page 21 COMBO-401 i/501 i OPERATOR’S MANUAL Picture 3- Top View Picture 4- Front View.
  • Page 22 COMBO-401 i/501 i OPERATOR’S MANUAL COMBO I Parts List. Combo 401I Combo 501I S.No Description. Part Code Part Code Main PCB PCB-COMBO-401 PCB-COMBO-501 IGBT IGBT10012 IGBT10012 INPUT BRIDGE MODULE IBDG007 IBDG003 Output Rectifier Module. FRM001 FRM001 FAN002 FAN002 DC CAPACITOR...
  • Page 23 COMBO-401 i/501 i OPERATOR’S MANUAL WIRE FEEDER DETAIL Combo 401I Combo 501I S.No Description. Part Code Part Code Wire feeder Motor WFMTR002 WFMTR002 SOLENOID VALVE SV002 SV002 6 PIN CONNECTOR (M) CON-6-CM-M-01 CON-6-CM-M-01 POTENTIOMETER FOR WELDING VOLTAGE POT001 POT001 POTENTIOMETER FOR...

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Combo-501 i

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