WARPP INARC-400 I User manual

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User’s Manual
INARC –400 I / 630 I
Inverter Based Arc Welding Machines
WARPP ENGINERERS PVT.LTD.
Survey No. 36, House No. 15/3,Unique Industrial Estate
Dhumal Nagar Vasai (East) Distt. Palghar (Maharashtra) INDIA –
PIN -401208
Tel : [phone] - 69 / 8551812002
Customer Care Tel : [phone]
Email : [email protected]n . Website : www.warpp.co.in

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PREFACE
Thanks for purchasing our product & looking forward to your precious advice for improvement of our
product. We will dedicate to produce the best products and offer the best services.
The machine has been carefully inspected both mechanically and electrically before it left the factory.
The machine should be initially inspected upon receipt, if any damage which may have occurred in
transit inform “ WARPP ENGINEERS PVT.LTD. OR It’s Dealer immediately. Check for the
accessories supplied against those listed in packing slip.
Caution :Before attempting to connect the equipment to any Power source,read instructions carefully.
In case any defect or deficiency, contact “WARPP ENGINEERS PVT.LTD.” or its authorized Agent.
Make sure to quote model number and serial number of the equipment in all correspondence.
THE DESIGN OF THIS EQUIPMENT IS SUBJECT TO CONTINUOS DEVELOPMENT AND
IMPROVEMENTS, CONSEQUENTLY “WARPP ENGINEERS PVT.LTD.” RESERVES THE
RIGHT TO INCORPORATE MINOR CHANGES FROM THE INFORMATION CONTAINED IN
THIS MANUAL.
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INDEX
1. Safety Precautions
2. Product Description & Features
3. Working Condition & Environment Required
4. Technical Specification
5. Working Principle
6. Installation
7. Controls
8. Parameters & its operational meaning
9. How to operate the machine
10. Do’s & Don’ts
11. Trouble Shooting
12. Wiring Diagram
13. Maintenance
14. Spare Part List
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1. Safety Precautions
General safety precaution :
 Please strictly comply with rules defined in this manual to avoid unexpected
accidents
 How to connect to power supply, select working area and use pressure gas, please
comply with proper rules
 Not allow non-operator to enter working area
 Machine’s installation, inspection, maintenance, and manipulation must be
completed by authorized person.
 Don’t use welding machine for unrelated purposes (Such as recharging, heating or
plate cutting, etc.)
 Must take safe precaution in case machine falling when it is put on the uneven ground
Avoid being electric shocked and burnt :
 Never touch on the hot electrical units.
 Please instruct the authorized electrician to ground the m a c h i n e 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 inthe 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 longerusing.
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 and 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, cap, apron and boot 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.

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 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 cause break.
 Ensuring a fire extinguisher at hand in case fire breakout.
Avoid being hurt by moving parts :
 Never let the finger, hair, and cloth near the rotary cooling fan and wire feeder
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 straight sunlight.
 Never let your face near gas outlet while turning on the gas valve to prevent from
being hurt by pressure gas.
 Customer should use the 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°
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This Series Inverter Arc welding machines is meant for Shielded Metal Arc Welding
(SMAW) only having rated current of 400 Amps & 630 Amps. Which are novelty
high-efficient and energy-saving DC Arc machines, not only are used in carbon steel,
but also for stainless steel with its sound static and dynamic characteristic. This series
machines have the following features:
i)
Invert technology can assured welding current high stability and arc
length consistency in fluctuating input supply. Welding arc enjoys
high self-adjustability and high strength.
ii) Low spatter
iii) Easy to start arc
iv) High deposit efficiency
v) Machine is having Adjustable Arc Striking
vi) With remote control function, welding parameters can be adjusted at
extended distance.
vii) Light, small and portable.
viii) High power factor, high efficient and energy saving
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2. Product Description & Features

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3. Working Condition & Environment Required
1) Please note that this equipment to be installed in a clean place free from dirt & moisture
2) Avoid direct exposure to sunlight
3) Care should be taken to see that it is not exposed to rain
4) Whenever the machine to be used at a site make sure proper shade is provided for the machine
5) Do not keep the machine near oven, furnace where temperature may be higher and it can affect the performance
of the machine
6) Always keep the machines at lease with a gap of 300 mm around the machine as it is required for free
circulation of air
7) Keep the machine in a flat position and if it is placed in an inclined position then the degree of inclination shall
not be more than 15 degree
8) These machine can operate in the temperature range of 0 ~ 50 degree centigrade. When used over 40 degree
centigrade the duty cycle of the machine may be lower than what is mentioned in the catalogue
9) Always connect the machine to the electric supply through a preferably D type MCB of suitable capacity
10) Use cables with proper cross section based on the input power requirement of the machine( Please refer to
technical specification page for input power of the machine)
11)When long cables are used you need to select higher cross sectional area of conductors to avoid voltage drop
during the usage.
Selection guide for type of MCB
MCB Type
Tripping Current
Application
B Type
3 to 5 times the rated
current
Purely resistive load like lighting and general
purpose outlets
C Type
5 to 10 times the rated
current
Moderate inductive load like air
conditioners, residential / commercial pumps
D Type
10 to 20 times the rated
current
Heavy inductive loads like heavy induction
motor and welding machines
Selection of cable size for input supply
Please note that the cable size required for input supply depends on following:
1) Whether the machine is single phase or three phase
2) Input KVA of the machine
3) Distance from electrical supply point
First calculate the current the machine will draw based on the input KVA given (refer to technical specification

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page for this)
If the machine is a single phase machine then each KVA would require around 4.6 Amps of current. That means if
input KVA of the machine is 5 KVA, then it would draw 23 Amps at full load
If the machine is a three phase machine then each KVA would require around 1.4 Amps of current. That means if
the input KVA of the machine is 5 KVA, then it would draw around 7 amps of current at full load
Cable capacity for copper cable can be taken as 5 Amps / Sq mm when cable length is less than 10 meters. That
means 1 sq mm cable can carry a current of 6 Amps of current
Now you have input current of the machine based on its input KVA
You can calculate the conductor size by this formula,
Input current / capacity of conductor
Example : From the above for a single phase machine of 5 KVA you would need 23/6 = 3.8Sq mm cable. ( You can
choose 4sq mm cable)
From the above for a three phase machine of 5 KVA you would need 7/6=1.16Sq mm cable. ( You can choose 1.5
sq mm copper cable for each phase)
Note: When the length of the cable is short the required cross section for input cable will come down
Below table will help you in selecting the right size of welding cable based on the length and current
to be used
Welding Cable selection chart
Welding
Current in
Amps
Recommended Cable size ( Sq mm) based on
length (in Mtrs)
1 ~ 15 Mtrs
15 ~ 30 Mtrs
30 ~ 45 Mtrs
45 ~ 60 Mtrs
60 ~ 75 Mtrs
100
16
25
25
35
50
150
16
25
35
50
50
200
35
35
50
50
70
300
50
50
70
70
95
400
70
70
70
95
120
600
95
95
95
800
140
140
1000
140
190
1200
190
240
1500
240
285
Note:
Table given is just for reference and the actual result may vary depending on the quality
of conductor
Multiple cables can be used where ever single cable of that
capacity is not available
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4. Technical Specification
Description
Parameters
INARC 400 I
INARC 630 I
Primary power voltage/frequency
3 phase 400V ±10% / 50Hz
Rated Input Power
18.4 KVA
35KVA
Rated input current
22A
45A
Rated duty cycle
60%
Range of output current
20～400A
30 ～ 630A
Open Circuit Voltage (OCV)
75 –85 VDC
Full-load efficiency
89%
Power factor （at full-load ）
0.95
Welding electrode diameter
2～5mm
2 ～ 6mm
Weight
43Kg
55Kg
Dimension
610×300×590 mm
690×330×590 mm
Class of Insulation
Class - H
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5. Working Principle
Block Diagram
These power sources are used for various types of welding and they are based on IGBT inverter Technology. In
these types of machines input supply is first converted in to DC by a rectifier circuit. The rectified voltage is
then filtered and fed to an inverter section. This section will convert the DC to high frequency AC. In this case
it is 20 K Hz AC. This AC voltage is fed to a specially designed high frequency transformer which steps down
the voltage to acceptable welding voltage and increases the current to required level. The output of the
transformer is fed to a high frequency rectifier circuit which converters this AC to DC for various welding
applications.
In the case of machines having capability to deliver both and AC & DC outputs for welding, this DC is fed to
one more inverter circuit OR electronic polarity control circuit which converts this in to low frequency AC
output for Aluminum TIG application. In this case controls are provided for adjusting the AC frequency, AC
balance along with other regular controls.

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Block diagram with waveforms at different stages is given below for reference :
Different types of power sources are available for welding and most commonly used are as under
-Constant current (CC) power source
-Constant Voltage (CV) power source
-CC/CV power source
Please refer to the below chart for process-wise recommended power source types
Process
Power source type
SMAW
CC
GTAW
CC
GMAW /FCAW
CV
SAW
CV is commonly used and sometimes CC is used
Plasma Cutting
CC

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Constant Current (CC) type power source
Constant current characteristics is also called as drooping characteristics. Typical V/I curve of such power
source is shown below. Here the current remains stable even if the arc length varies. When there is change in
arc length, change in the voltage is more when compared to change in current and hence they are called
constant current type power source
Relationship between the voltage and current for different process in CC type power source is as under
SMAW:
V = I * 0.04 + 20
GTAW:
V = I * 0.04 + 10
Constant Voltage (CV) type power source
Constant voltage characteristics are also called as Flat characteristics. Typical V/I curve of such power source
is shown below. Here the voltage remains stable even if the arc length varies. When there is change in arc
length, change in the current is more when compared to change in voltage and hence they are called constant
voltage type power source

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Relationship between the voltage and current for different process in CV type power source is as under
GMAW:
V = I * 0.05 + 14
FCAW:
V = I * 0.05 + 18
Note: Some power source have both CC and CV characteristics. The explanation given above is general and
the capability of the machines depends on the model number of the machine purchased by you.

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6. Installation
Installation :
1.
Placetheweldingmachineintheroomwherethere isnostraightsunlight,norain,
less dust, low humidity ,and temperature range of 0° - 50°C.
2. The gradient of ground must not be 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 300 mm.
5. Connect the 3 phase Input supply to the machine. Supply voltage must be in the
range of 400 V +_ 10% as mentioned in the Technical specification of this
manual.
6. Power supply:
 The size of fuse and breaker in the table are for reference :
7. Connect the electrode holder to the +Ve terminal & earthing cable to the +Ve terminal of the
machine
8. Connect remote controller (If needed).
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Product type
INARC 400 I
INARC 630 I
Power supply
3 phase AC 400 V
Min. power capacity
18.4KVA
35KVA
Input
protection
Fuse
30A
63A
breaker
32A
63A
Min.
Cable
size
Input side
4mm2
6mm2
Outputside
50mm2
70mm2
Earth lead
4mm2
6mm2

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INSTALLATION DIAGRAM OF INARC 400 I

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7. Controls
1
2 3 4
5
6
11
10
9
7
8
Front panel Details :
1. A/V Meter (Display) : It displays the output current or arc voltage during welding or
OCV if not welding
2. Power LED : This indicator will on as soon as MCB of the machine is switched on
3. Protection LED : This LED will on if there is problem in the machine
4. A/V Switch : This is selector switch to see the welding current or welding voltage.
5. Panel/Remote Switch : This is also selector switch to set the output current of the
machine. If it is kept on panel current can be adjusted from panel & if it is kept on
remote then current can be adjusted through remote pendant away from the
machine.
6. Welding Current Pot : This pot is meant for output current adjustment from panel

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7. 7 Pin Connector : This is socket for remote control. it is optional accessories.
8. - Ve Terminal : This terminal is provided to connect the holder cable
9. + Terminal : This terminal is provided to connect the earthing cable connected to
be job.
10. Arc Force : This pot is provided to adjust the arc force during welding
11. Start Current : This pot is provided to adjust the start current. It will increase the
initial high current with respect to set welding current.
Rear Panel
1. Cooling Fan : It is provided to cool the machine while welding
2. MCB : This is provided to switch on or switch off the machine
3. Input Cable : This is provided to give the input supply to the machine

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8. Parameters & its Operational meaning
Shielded Manual Metal Arc Welding (SMAW) or Electric Welding can be done by this Power Source.
TIG welding process can be done by lift arc or scratch arc process.
Welding parameters can be adjusted with the help of various pots available on the front panel.
a) WELDING CURRENT : Welding current of the welding process can adjusted with Welding
current pot Pot as per below chart :
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 ）
30 ～ 50
40 ～ 60
90 ～ 110
90 ～ 130
160 ～ 250
250 ～ 400
a) ARC FORCE : Arc force is the extra voltage required during welding when welders hand is
becoming up & down . It is in the percentage graduation according to arc voltage. It can be
adjusted with the help of ARC FORCE POT provided on the front panel of the machine.
b) START CURRENT : Start current is extra initial current to smooth start of welding. It is in the
percentage as per welding current
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9. How to operate the machine
1. Switch on the main switch for input supply provided for the machine
2. Switch on the MCB of the machine provided on the rear side of the machine
3. Set the output current as per required welding rod from panel or through remote
4. Start welding on the plate or job. Adjust the welding current as per requirement.
5. Switch off the machine when welding is over.
6. Switch off the main switch.

10. Do’s & Don’ts
Do’s
Don’ts
Clean the machine with compressed air @ < 3
Kg/Cm2
Don’t keep any foreign material or plate on the
top cover of the machine
Use proper polarity & current
Never use the higher current than recommended
Use proper welding cable size
Never use long cable if not required
Use proper welding angle
Never use long arc
Make firm connection of welding cable
Never use the joint of cable unless proper
technique is used to join the cable
Keep the machine in proper shade to protect it
from rain & direct sun light
Don’t keep the machine in open ground or site