WARPP IN ARC-I series User manual

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IN ARC-I / IN TIG-I Series
InverterArc 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: [phone]/74. Fax: [phone].
E-mail:[email protected] 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………………….…………………(6)
5. Principle in Brief…………….……………………………………………(6)
6. Operating Instruction………………………………….…………………..(7)
7. Repair and Maintenance.………………………….………….………….(12)
8. Main technical parameters……………………………………………….(15)
9. Appendix A: Common failures, probable cause & countermeasures…... (19)
10.Spare Part List…………………………………………………………(20)

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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. As to its sound
static and dynamic characteristic and HF arc starting function, the series welders have
the following features:
¾Invert technology can assured welding current high stability and arc length
consistency in fluctuating input primary power. Welding arc enjoys high
self-adjustability and mild strength.
¾Low spatter
¾Easy to start arc
¾High deposit efficiency
¾the machine can adjust its down- slope time while stopping arc. Weld formation are
pretty good.
¾With remote control function, welding parameters can be adjusted in extended
distance.
¾Light, small and portable.
¾High power factor, high efficient and energy saving
Safety Precautions
General safety precaution:
zPlease strictly comply with rules defined in this manual to avoid unexpected
accidents
zHow to connect to power supply, select working area and use pressure gas, please
comply with proper rules
zNot allow non-operator to enter working area
zWelders’ installation, inspection, maintenance, and manipulation must be completed
by authorized person.
zDon’t use welding machine for unrelated purposes (Such as recharging, heating or
pipeline thaw, etc.)
zMust take safe precaution in case welder falling when it is put on the uneven ground
Avoid being electric shocked and burnt
zNever touch on the hot electrical units.
zPlease instruct the authorized electrician to ground the welder frame by using

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proper-sized copper wire.
zPlease instruct the authorized electrician to connect the welder to power supply by
using proper- sized, well-insulated copper wire.
zWhen operating in the damp, space limited area, must ensure well-insulated between
body and work piece
zWhen operating in the high-rising location, must ensure safety by using safe net.
zPlease power off the input voltage while no longer using.
Avoid breathing in hazardous welding fume or gas
zPlease use specified ventilation to prevent being gas poisoned and asphyxiated
zEspecially in the container where oxygen is depleted easily
Avoid being harmed by arc flash, hot spatter and slag
zArc rays can injure your eyes and make your eyes feel uncomfortable.
zHot spatter and slag can burn your skin. Please wear proper welding helmet, leather
gloves, long- sleeved suit, cap, apron and boot before welding.
Preventing from fire, explosion, container break accidents
zDon’t put flammable material in the working area. Hot spatter and hot weld can
easily start a fire.
zCable must be connected the work piece firmly to ensure good conductivity in case
causing fire by resistance heat.
zDon’t weld in the flammable gas or weld container which contains flammable
material, otherwise it can cause explode.
zDon’t weld encapsulated container, otherwise it can cause break.
zEnsuring a fire extinguisher at hand in case fire break out.
Avoid being hurt by moving parts.
zNever let the finger, hair, and cloth near the rotary cooling fan and wire feeder
rollers.
zWhen 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
zGas bottle must be firmly fixed on the ground, else if injure will exerts on.
zNever place bottle under high temperature or straight sun light.
zNever let your face near gas outlet while turning on the gas valve to prevent from
being hurt by pressure gas.
zCustomer should use the gas regulator provided by our company, and comply with
the proper instruction.

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Avoid being hurt by welding machine while in transport
zWhen 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.
zThe 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 -10Ԩ～+40Ԩ
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 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 380V±10%, frequency
50Hz/60Hz
(2) Unbalance degree of 3- phase volt must be no more than 5%
(3) Power supply:
zThe size of fuse and breaker in the table are for reference only.
Product type 400 500 630
Power supply 3 phase AC380V
Min. power capacity 28KVA 38KVA 51KVA
Input
protection Fuse 50A 63A 63A
breaker 63A 100A 100A
Min.
Cable
size
Input side 4mm26mm26mm2
O
utput side 50mm250mm270mm2
Earth lead 4mm26mm26mm2

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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.
(4) Turn on the air switch on the power source.
(5) Connect input 3 phase primary power cable to switch box.
3.2 TIG mode
(1) Ensure firmly connection to welding cable and TIG torch.
(2) Ensure firmly connection to gas hose and gas bottle and or water hose and
water supply as to using water-cooled welding torch.
(3) Connect to remote controller(If needed)
(4) Adjust every knobs, and switches on the front panel to proper position in line
with selected mode.
(5) Turn on air switch on the power source.
(6) Connect input 3 phase power cable to switch box and close it.
Attention: Before you plug the welding cable, please turn off the power and rightly
calibrate the plug key to the socket slot at first, then insert and turn the plug clockwise until
it firmly seated. Make sure the plug and the socket are well-connected to be sound
conductivity in case that they are burnt out by over resistance heat.
Principle in Brief
Block diagram of principle
3~380V/50Hz Output
3 phase
Rectifier
HF
Inverter
HF
Transformer
Rectifier &
Filter
Control circuit
High frequency arc start

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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.
(4) Turn on the air switch on the power source.
(5) Connect input 3 phase primary power cable to switch box.
3.2 TIG mode
(1) Ensure firmly connection to welding cable and TIG torch.
(2) Ensure firmly connection to gas hose and gas bottle and or water hose and
water supply as to using water-cooled welding torch.
(3) Connect to remote controller(If needed)
(4) Adjust every knobs, and switches on the front panel to proper position in line
with selected mode.
(5) Turn on air switch on the power source.
(6) Connect input 3 phase power cable to switch box and close it.
Attention: Before you plug the welding cable, please turn off the power and rightly
calibrate the plug key to the socket slot at first, then insert and turn the plug clockwise until
it firmly seated. Make sure the plug and the socket are well-connected to be sound
conductivity in case that they are burnt out by over resistance heat.
Principle in Brief
Block diagram of principle
3~380V/50Hz Output
3 phase
Rectifier
HF
Inverter
HF
Transformer
Rectifier &
Filter
Control circuit
High frequency arc start

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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. Power source enjoy sound
anti-fluctuating ability and high-quality performance during external context changes (As to
fluctuation in input power supply and extended welding cables).Easy to arc start, stable arc
length, pretty weld formation and capability of continuous regulation the current of welding,
arc-starting, arc force and time of down-slope as well as remote control availability add
significant values to customers. They can also perform down-slope, pre-gas flow and
post-gas flow function due to reasonable logic circuit design.
IN ARC Series arc welding machines output characteristic curve is as follows:
Operating Instruction
1. Functional introduction
90–
20 –
0
U=20+0.04I
I
(
A
)
Imin
Imax

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1.1 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” indicator lamp
Welding machine will automatically stop working when it is overheat, and the lamp
will be light on.
(3) “Power” indicator lamp
Lamp indicating whether power source is effectively connected to power supply
(4) “Amp/Volt” meter mode switch
(5)”SMAW/TIG” Switch (Only in IN TIG Series).
When it is indicated to “SMAW”, the machine is to work on SMAW;
When it is on “TIG”, the machine is to work on TIG
4-step/ 2-step switch (Only in IN TIG Series).
(6) “Remote/ Panel control” switch ((200 series only equipped with Panel control)
When it is on “Panel control”, you can adjust current of welding, arc force or
down-slope time through the knobs and switches on the panel; when it is on “Remote
control’, you can adjust the above parameters through remote control box in a
extended distance from the welding areas
(8) “Welding current” regulation knob
Used to adjust welding current on panel control mode
(9) “Arc force current/ down-slope time” regulation knob
Used to adjust arc force current under SMAW or stop-arc time under TIG
(10) “Arc-starting current “regulation knob used to adjust arc starting current.
(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.
(12)Welding cable (+) quick plug socket
It is used to connect with stick holder on SMAW mode. Connect to work leads on
TIG mode.
(13)Gas outlet (S series not equipped with it)
Connect to TIG torch gas hose.
(14)Welding cable (-) quick plug socket
It is connected to work lead on SMAW mode and connected to TIG torch welding
cable on TIG mode.

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(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.
(12)Welding cable (+) quick plug socket
It is used to connect with stick holder on SMAW mode. Connect to work leads on
TIG mode.
(13)Gas outlet (S series not equipped with it)
Connect to TIG torch gas hose.
(14)Welding cable (-) quick plug socket
It is connected to work lead on SMAW mode and connected to TIG torch welding
cable on TIG mode.
1.2 The rear panel and parts number reference
(1) 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 means power-on. Use switch on the switch box to start or stop welding
machine, avoiding using the breaker.
(2) Input power cable
It is 4-pin cable. The mixed-colored wire must be firmly grounded, the rest wires
connect to corresponding 3-phase power supply (380v/50Hz).

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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” mode from “TIG”, then back to “TIG” to complete shift.
2.1.2 Scratch arc-start with down-slope working style
Reference to 2.2.2 operation procedure
2.1.3 Scratch arc-start with non-down-slope working style
Reference to 2.2.3 operation procedure
2.2 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.
(2)Shift HF arc-start to scratch arc-start
Switch to “SMAW” mode from “TIG”, then back to “TIG” to complete shift.
2.2.2 High frequency arc-start
Procedure flow sheet shows below :( Next page)
Repair and Maintenance
In principle, welders’ maintenance and repair should be completed by us or our authorized
distributors. Customers can also solve the problems instructed by us or our authorized
distributors.
1. Attention:
(1) Rivet equipment name tag on the specified area of the case, otherwise the inside
parts will be damaged.
(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 not to make welding and control cable to be worn out or

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(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
(3) “Arc force current/ down-slope” regulation knob
(4) Socket 1
Connect to remote control cable.
(5) Socket 2
Connect to welding torch control cable which has a plug. There are 2 control wires
welded to lug 1 and lug 2 respectively on the plug
2. Operating instruction
Turn on the air switch on the switch box, the “Normal” indication lamp will light
on and cooling fan rotate. Before welding normally, set up parameters by adjusting
knobs and switches on the control box and front panel according to the selected
mode. Customer should refer to parameters defined in table 1 and table 2 showing
below:
Table 1 SMAW welding parameters
Work piece thickness
（mm）＜1 2 3
4～5 6～12 ≥13
Electrode diameter
（mm）1.5 2 3.2
3.2～4 4～5 5～6
Welding current（A）20～40 40～50 90～110 90～130 160～250 250～400

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Table 2 TIG welding parameters
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 .
As to large welding current and long cable of stick holder, where volt potential
difference is very high between the two ends of cable, arc force current should be
adjusted in the range of 7- 10.
2.1 Working styles on TIG mode of ST series
Can be divided into 2 working styles: scratch arc-start with down-slope and
scratch arc-start without down-slope.
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” mode from “TIG”, then back to “TIG” to complete shift.
2.1.2 Scratch arc-start with down-slope working style
Reference to 2.2.2 operation procedure
2.1.3 Scratch arc-start with non-down-slope working style
Reference to 2.2.3 operation procedure
Work piece
thickness（mm）
Welding current
（A）
Tungsten electrode
diameter（mm）
Max Argon gas
flow rate（L/min）
1～3 40～50
50～80 1～2 4
6
3～6
80～120
120～160
160～200
200～300
2～4
7
8
9
10
6～9 300～400 4～6 12

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2.2 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.
(2)Shift HF arc-start to scratch arc-start
Switch to “SMAW” mode from “TIG”, then back to “TIG” to complete shift.
2.2.2 High frequency arc-start
Procedure flow sheet shows below :( Next page)
Repair and Maintenance
In principle, welders’ maintenance and repair should be completed by us or our authorized
distributors. Customers can also solve the problems instructed by us or our authorized
distributors.
1. Attention:
(1) Rivet equipment name tag on the specified area of the case, otherwise the inside
parts will be damaged.
(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 not to make welding and control cable to be worn out or
Broken

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Auto-lock Non-Autolock
Fig. HF arc-start procedure flow sheet
(5) Never let welding machine be bumped into or stacked up by heavy objects.
(6) Ensure good ventilation
(7) Temperature of cooling water is no more than 30 and no less than 0. The water
must be clean without impurity for fear of blocking water circulation which will
result in torch damage.
The machines can halt automatically, when work with large current for a long time.
Overheat protection lamp will light on. The machines will recovery after running up several
minutes in open load.
Pull TIG torch trigger
Pre-gas flow, HF/ scratch arc-start
Release trigger Hold on trigger
Release trigger
Hold on trigger
Down-slope
Down -slope
Release
Up -slope
Until crater fill
Post-gas flow
Release trigger
Reset power source
Until crater fill
Post-gas flow
Push trigger
Welding Welding
Up-slope

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(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. The machine will be ready after
running under open load for several minutes.
(9) Be sure to turn off argon and water as well as power source when finish welding.
2. Periodic inspection and maintenance
(1) Removes dust from power resource with pressure air by authorized maintainer
every 3-6 months. Check if the bolt is loose.
(2) Check frequently if control cables are worn out, adjusting knobs are loose, and
components of panel are damaged.
(3) Check output cable periodically, if jointers are loose or plugs are distortion, please
repair in time, otherwise the sockets will burn out.
(4) Clear up or change contact tips and tungsten electrodes timely.
3. Trouble shooting
3.1. Checking procedure prior to maintenance
(1) Check if the panel switches and potentiometers are on the proper position
(2) Check if the input volt has phase missing, and range are between 340-420V.
(3) Check if the input cable connects correctly and firmly with the power source.
(4) Check if the welding cables connect correctly and firmly.
(5) Check if water circulation and CO2 flows out smoothly.
Warning:
Don’t open up case uninstructed, the max volt inside machine is 600V. Take safe
precautions to prevent from being electric shocked while in maintenance.
Never discharge high voltage to welder case with welding torch! Shut down power
source before changing or repairing welding cable or torch

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Technical data
Main technical parameters
Description Parameters
400 500 630
Primary power voltage/frequency 3 phase 380V±10%/50Hz
Rated output capacity 14.4KW 20KW 27.7KW
Rated input current 28A 38A 52A
Rated duty cycle 60%
Range of output current 20～400A 20～500A 50～630A
Output voltage of open load 80±8V
Full-load efficiency 89%
Power factor（full-load）0.95
Welding electrode diameter 2～6mm 2～6mm 2～6mm
Tungsten electrode diameter 1～6mm 1～6mm 1～6mm
Weight 43Kg 47Kg 55Kg
Dimension 636×322×582 mm 576×297×557 mm
Max argon flow rate 25L/min
Insulation grade
Main transformer H
Power source transformer、
output reactance B

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zIN ARC / IN TIG-400 I
No. Tab Item Qua. Memo
1 K1 Air switch 1
2 D1 3-phase rectifier module 1 Small
3 L1 Polypropylene capacitor 1
4 C30 Polypropylene capacitor 1
5 C4 IGBT module 1
6 M1、M2 Voltage sensitive resistance 2
7 R1 Ceramic dielectric capacitor 1
8 C8～C17 Ceramic dielectric capacitor 10
9 T1 Main transformer 1
10 T4 Power source transformer 1
11 T5 Insulation transformer (IN TIG) 1
12 D1～D4 Fast recovery diode module 2
13 L2 Current exchange inductor (IN
TIG) 1
14 F1 Fuse size 1
15 YHB
Arc-start board components (IN
TIG) 1
16 T3 Stray transformer (IN TIG) 1
17 M axial airflow fan 1
18 Switch 4
19 Digital displayer 1
20 SW Thermal relay 1
21 Potentiometer 1
Current
adjustment
22 Potentiometer 2
Force
arc-starting
adjustment
23 Electromagnet valve (IN TIG) 1
24 Main control board 1
25 Driving board 1

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zIN ARC / IN TIG-500 I
No. Tab Item Qua. Memo
1 K1 Air switch 1
2 D1 3-phase rectifier module 1 big
3 L1 Polypropylene capacitor 1
4 C30 Polypropylene capacitor 1
5 C4～5 IGBT module 2
6 M1、M2 Voltage sensitive resistance 2
7 R1 Ceramic dielectric capacitor 1
8 C8～C19 Ceramic dielectric capacitor 12
9 T1 Main transformer 1
10 T4 Power source transformer 1
11 T5 Insulation transformer (IN TIG) 1
12 D1～D6 Fast recovery diode module 3
13 L2 Current exchange inductor (IN
TIG) 1
14 F1 Fuse size 1
15 YHB Arc-start board components (IN
TIG) 1
16 T3 Stray transformer (IN TIG) 1
17 M axial airflow fan 1
18 Switch 4
19 Digital displayer 1
20 SW Thermal relay 1
21 Potentiometer 1 Current
adjustment
22 Potentiometer 2 Force arc-starting
adjustment
23 Electromagnet valve (IN TIG) 1
24 Main control board 1
25 Driving board 1

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zIN ARC / IN TIG-630 I
No. Tab Item Qua. Memo
1 K1 Air switch 1
2 D1 3-phase rectifier module 1
3 L1 Polypropylene capacitor 1
4 C30 Polypropylene capacitor 1
5 C4～5 IGBT module 2
6 M1、M2 Voltage sensitive resistance 2
7 R1 Ceramic dielectric capacitor 1
8 C8]～C21 Ceramic dielectric capacitor 14
9 T1 Main transformer 1
10 T3 Power source transformer 1
11 T5 Insulation transformer (IN TIG) 1
12 D3～D8 Fast recovery diode module 4
13 L2 Current exchange inductor (IN
TIG) 1
14 F1 Fuse size 1
15 YHB Arc-start board components (IN
TIG) 1
16 T3 Stray transformer (IN TIG) 1
17 M1 axial airflow fan 1
18 Switch 4
19 Digital displayer 1
20 SW Thermal relay 1
21 Potentiometer 1 Current adjustment
22 Potentiometer 2 Force arc-starting
adjustment
23 Electromagnet valve (IN TIG) 1
24 Main control board 1
24 Driving board 1