WARPP INARC IH SERIES User manual

INVERTER DC MMA
ARC WELDING MACHINE
OPERATION MANUAL
WARPP ENGINEERS PVT. LTD.
B-1005, Western Edge II, Near Metro Mall, Off. Western
Express Highway, Borivali (E), Mumbai-400 066.
Tel:[phone] / 73/74 Fax:[phone].
Website:www.warpp.co.in Email:[e-mail]

Safety precautions
● Please read this instruction carefully for correct use.
● The objective of the precautions listed in this instruction is to ensure the safe use of
machine and prevent you and others from being harmed or injured.
● Safety consideration for the welding machine in design and manufacture. Work to the
precautions in this instruction, otherwise it will cause major accident.
● If used incorrectly, the harm and damage will occur in three different ways. So the
caution symbol and warning labels are listed in this instruction.
Caution symbols Warning labels Content
High danger If used incorrectly, potential major harm will result in
death or serious injury and major danger accident
once it occurs.
Danger If used incorrectly, potential scourge harm will result
in death or serious injury and danger accident once it
occurs.
Caution If the welding machine is used incorrectly, the harm
with mild degree, slight wound and other dangerous
accidents and the damage of articles will be caused.
*The symbol above is applicable to the general occasion.
The serious injury mentioned above refers to eyesight damage, trauma, harm,
electric shock, fracture and poisoning and so on which will leave sequel and is in need of
making treatment in need of making treatment in hospital of going to hospital for long
period, slight wound refers to burn and electric shock and so on which is not in need of
being in hospital but treatment for long period. The damage of articles refers to the loss of
property and damage of machine.
On the usage of machine, the symbols shown as following indicate [must do] and
[forbid doing.
Compulsion Must do
For example [ grounding]
Forbidden Forbid doing
*The symbols above are used in the general occasions
Danger Work to the following items in case of the major personal

Accident
1. Safety consideration for the welding machine in design and manufacture.
Work to the precautions in this instruction, otherwise it will cause death, serious
injury and other major personal accident.
2. For the construction power source of input, the choice of equipment location, the
application keeping and configure of high pressure gas, the keeping of workpiece
after welding and the treatment of rejection and so on, please observe the relative
regulations and the standards inside your company.
3. The unconcerned personnel never go in the welding working location.
4. The person using heart pacemaker do not be close to the welding machine in
operation and the surrounding of welding operation location without permission of
doctor. The produced magnetic field when the welding machine is electrified will
produce the bad effect on the action of pacemaker.
5. Invite the professional or expert person to install, examine and repair and maintain
the welding machine.
6. To ensure safety, please correctly understand the content in this instruction and
invite the personnel with safety usage knowledge and skill to operate this
machine.
7. Do not use machine in the work except the welding.
Danger: Work to the following items in case of electric shock
*Once contact the position with electricity, the fatal electric shock or heat
injury will be caused.
1. Never contact electrified position.
2. Invite electric personnel to earth welding machine and parent metal according to
regulations.
3. In installation and examination and repair, must turn off the power of electric
switch box first, then the operation was made after 5 minutes.
4. Never use the cable which lacks of capacity of where conductor exposes for the
damage of insulation jacket.
5. For cable connection part, please ensure insulation.
6. Never use welding machine on the condition of dismounting machine shell.
7. Please use dry insulation glove.
8. Please use safety net at high place operation.

9. Make maintenance and examination and repair, only the damaged part can by
use until it is repaired well.
10. Please shut off all input powers when the machine is unused.
11. When use AC arc welding machine in the confined place or high place, please use
electric shock-proof device.
1. When make welding or supervise welding, please use the safety appliance with
enough shading degree.
2. Please emphasize particularly on wearing protective glasses.
3. Please wear protective glove, long sleeve clothes, welding spats, apron and other
safety appliances in welding, which are made of leather.
4. Protective barrier are set around the welding location to prevent arc light from end
angering others.
5. When noise is great, please use sound insulation apparatus.
1. To prevent gas poisoning and suffocation and other accidents, please use regulated
exhaustion facilities, and breath protection appliance is coordinated for use.
2. In operation in the confined location, please accept the examination by supervision
personnel and fully change gas and coordinate in using breath protection appliance.
3. Never make weld within degrease, cleaning and atomization working area.
4. When weld the steel plate with electroplate or coating, the harmful dust and gas will
produce, please use protection appliance for breath.
*Arc light will cause the inflammation of eye or heat injury of
skin and other personal damages.
*Splashing and weld slag will burn eye or skin
*Noise will be harmful to hearing
Caution: To avoid weald dust and gas endanger you and others,
please use safety appliance
*Weld dust and gas endanger health
*In operation in the confined location, lack of oxygen will result in
suffocation.
Caution: To prevent fire, explosion, cracking and other accidents from taking
place, please be sure to observe the following regulations.
*Splashing or heat parent metal just welded will cause fire.
*When current loop produce non full contact on the bad connection of cable
and steel bar and other parent metals, the heat after electrifying will be
caused.
*Never weld on the container filling combustibility substance, otherwise
explosion will be caused.
*Never weld seal container, for example groove (box), pipe, otherwise
cracking will be caused.

1. Never place combustible in the weld location.
2. Never weld near combustible gas.
3. Never close to the combustible when the heat parent metal is just welded.
4. When weld dooryard, ground and wall, please eliminate the combustible on the back.
5. The connection of cable shall surely be insulation.
6. The connection of cable of parent metal side shall approach welding position as
possible.
7. Never weld the gas pipe and seal groove and so on which stores gas.
8. The fire extinguisher shall be placed near weld work location to protect against
accident.
1. Please use gas bottle correctly according to regulations.
2. Please use he gas adjustor equipped or recommended by our company.
3. Please read the operation instruction for gas adjustor before use, observe
precautions.
4. Please use the special gas bottle support structure to fix gas bottle.
5. Never put gas bottle in the place where temperature is high or sunlight shines directly.
6. Make sure you face keep away from the outlet of gas when the valve of gas bottle is
opened.
7. Please install the gas bottle protecting jacket when the gas bottle is unused.
8. Never put welding torch on the gas bottle, electrode cannot contact gas bottle.
1. Never use welding machine on the condition of dismounting machine shell.
2. Invite the professional or expert person to install, examine and repair and maintain the
welding machine.
3. Never finger, hair, clothes, etc approach cooling fan and the electrode wheel of
electrode feeding machine and other rotation positions.
Caution:To prevent gas bottle from dumping, gas adjustor from
cracking and other accidents, please be sure to observe the
following regulations.
*The dumping of gas bottle will result in personal accident.
*If gas bottle stores high pressure gas, incorrect use will cause
the ejection, thus causing personal accident.
Caution: Contact of rotation position will cause injury, please
observe the following regulations
*Never ringer, hair, clothes, etc approach cooling fan and the
electrode wheel of electrode feeding machine and other rotation
positions.
Caution :The end of welding wire will cause injury, please be
sure to observe the following regulations
*If the welding wire emits from welding torch, the eye, face
and other exposure parts of the body will be stabbed.

1. In affirming whether the welding wire is fed, do not peek into the small hole of current
contact nozzle. Otherwise welding wire will prick eye and face.
2. When welding wire is fed by hand or welding torch is opened, please do not put the
end of welding torch dose to eye, face and other exposure parts of the body.
1. In cutting work, the finger shall leave the nozzle and electrode on the end of cutting
torch.
2. Never make cutting work near place where parent metal is held by hand.
3. When change nozzle and electrode, please first turn off power.
1. To prevent splashing and iron powder and so on from going in the power, please
separate weld power from weld work and snagging work.
2. To prevent insulation deterioration caused by powder accumulation, please be sure to
maintain and examine and repair regularly.
3. If splashing, iron powder, etc go in the power, please be sure to turn off power switch
of welding machine and switch of distributor case, then blow off with air.
Caution: Plasma weld will result in burn, please be sure to observe the
following regulations
*Never put such any part of body as finger close to plasma work,
otherwise burn will cause.
Caution: To prevent fire caused by the deterioration of insulation of
welding power, please be sure to observe the following regulations.
* If splashing produced in welding and iron powder produced in
snagging work go in the power, the deterioration of insulation will be
produced, thus causing fire

Working Directions
■ Load Duration Factor
Load duration factor refers to the ratio that practical work time accounts for
the whole work time (10 minutes is 1 cycle). For example, 60% load duration
factor means that weld is made for 6 minutes and then zero load is for 4
minutes. Rating load duration rate compares with rating current. When the
equipment is used below rating current, if even the equipment may be used in
case of high load duration factor. At this time the calculation equation of load
duration rate as following:
■ Placement of Welding Machine
In placement, please pay attention to the following items:
(a) Lay in the place as possible where the ground is flat and vibration is little
and which is more than 20cm far from wall.
(b) Please put it in the clean and dry place where iron powder, dust, paint are
little.
(c) Please put the machine in the place where rain pouring can be avoided
and which is not subject to the erosion of sea water
■ Connection
■ 1. Grounding
The grounding terminal is set on the bottom of side plate of back of machine shell,
please earth with copper wire with above 4m ㎡area.
Rated input voltage 300～600 V and grounding resistance 10 .
Please entrust full-time staff (electrician) to earth.
1. Connection of power
One welding machine is equipped with one distribution box including switch,
fuse and other current protectors, whose output end is connected with input
end of welding machine. As for the capacity of distribution box and cable
section, please refer to table

2. Especially for fuse and other current protectors, for the sake of safety,
please use the protector with proper capacity rather than the protector with
the too great capacity.
3. Connection of welding end
One end connects with the cable of welding tongs, another end connects with
welded object by connection cable. To ensure safety, in operation the welded object
must be earthed.
. Technical Performance
1. Performance Characteristic
A new generation Inverter DC Argon Arc Welding machine adopts the advanced
soft switching inverter based on the core fitting of imported IGBT and microcrystal
magnetic cores with the 20KHZ inverter frequency. The product owns high load
duty cycle with arc igniting current and current thrust control function. It owns the
advantages of automatic compensation function for voltage fluctuation, stable arc,
even weld crater, little splash and good weld formation. And on the other hand, it
first applies the digital circuit control technique for the purpose of quality of welding,
which not only reduces the weight and volume much and improves the portability
but simplifies the operation of facility, getting good arc ignition and welding
performance to improve the welding precision.
Due to adopting the digital circuit control, the pre-welding set value can be
displayed by the number. The actual value is displayed during the welding, and
the value is locked automatically after welding, which makes convenience for
presetting and control of welding criterion.
Its top inverting frequency of 20KHZ reduces the current fluctuation
influence for arc much, which makes arcing and arc static current very low(20a) .
The arc burns steadily and quietly with dense arc and small heat affected zone.
Considering all aspects of factors’ influence for the welding machine in designing,
the advanced design is adopted in some minutiae. The inner bare line adopts the
insulating varnish with high insulating strength, and the shell adopts the
waterproof design for protection that can cope with rugged environment. In
addition, fully considering the economy of welding machine use in the design, the
power consumption efficiency of all digital TIG welding machines reaches 90%,
and the power factor reaches 0.89. finally these serials advanced design passes
the strictest test and reaches the following standard: shell protection grade: IP21S,
suitable for field use, insulation grade: F, waterproof and preventing foreign
materials.

Brief introduction to characteristics:
● Striking current continuously adjustable
● Thrust current continuously adjustable
● Welding current continuously adjustable
● Digital display current and voltage
● Overheat indication and overload protection
2. Main Parameters
(Form1)PerformanceParameters
Content of Parameters Unit IN ARC 400 IH
Output
On-load voltage V 70±5%
Rated
Current output
A 400
Rated
Load voltage
V 36
Regulation range
Of welding current
A 20-400
Load
continuous rate
% 60%
Input
Power
parameters
Three-phase 380V 50/60Hz
Rated
capacity input
KVA 18
Rated
current input
A 28
Efficiency ≥90%
Power factor ≥0.89
Grade shell protection IP21S
Insulation grade F
Overall dimension mm 570×320×530
Weight Kg 34
3. Summary of Principle
The invention of inverter arc welding benefits from appearance of the inverter theory
and device. The inverter arc welding power source works rectifying 50/60HZ working
frequency to direct current, inverting to HF by the high power switching device
IGBT( the frequency can reach 20KHZ), then reduce voltage and rectification, output
the dc high-power supply by PWM, the weight and volume of main transformer are
remarkable decreased, and the efficiency is raised over 30%.
380v50Hz Three-phase
rectifier
High frequency
inverter
High frequency
transformer
Waves filtering
rectifier
Control circuit

Welding machine Principle Block Diagram (Picture 1)
Welding machine Output Characteristic (Picture 2)
. Plank structure and statement
1. Front panel structure and statement
Frontpanel(Picture3)
(1) Power light: indicate whether the power is connected or not, the light is
on when connecting.
(2) Over load light: the welding machine stops working when the
temperature in the welding machine is too high when the light is on. The
light is on.
(3) Off and on of REM: when the switch is not the welding standard can be
regulated only by the button of remote control package; when the switch
is off, the welding standard can be regulated only by the button of
welding machine panel.
(4) Display option switch: the digital millimeter will display the current or
voltage parameters according to marking.
(A): Current
(V): Voltage
ON: Remote Control (REM)
OFF: Near Control (REM)
A: Welding Current (A)
ARC FORCE
HOT START: Arc Striking Current

(5) Negative electrode output: the socket connecting welded work pieces
via output cable at manual welding.
(6) Positive electrode output: the socket connecting soldering tongs at
manual welding.
(7) ARC FORCE: it can change the time of arc stopping of argon arc
welding to adjust the button.
(8) HOT START: arc striking current.
(9) A: regulate the welding current.
(10) Digital multimeter: display the current setting value at the time of current
parameters on-load, display the actual current value at the time of
welding. Display the no-load voltage at the time of voltage parameters
on-load, display the actual current value at the time of welding.
2. Back panel structure and statement
Back panel (Picture 4)
(1) Nameplate: indicate all indexes of power.
(2) Grounding screw: to ensure personal safety and normal use of arc welding power
source, please make sure connect the screw to ground reliably by the conductor,
or connect the grounding line in the input cable to ground reliably.
(3) Power cord: the cable is four core cables. The effect yarn is used for zero
terminating, and the left 3 wires are connected to the three-phase 380V/50HZ
power.
(4) Power switch: the switch is connected to the position of incoming line of
three-phase power. The switch works for protecting the welding machine by
automatic power off in case of the welding machine overload or any faults. In
general case, the switch is pushed upward to the position of connection, starting
and stopping of welding machine shall be controlled by the power switch on the
user distribution panel or cabinet as possible , and don’t use the switch as the
power switch.
. Check the welding machine before using
1. Examination under power off
(1) Check whether circuit and gas path make a correct and reliable connection
or not.
ON: Switch on
OFF: Switch off

(2) Check whether the automatic air switch is put upward onto the position of
connection or not.
(3) Check whether option switches regulating operating mode and control
mode on the front panel are in the right position.
2. Examination under power-supply and no load
(1) If power-on is successful, the indicating lamps of power lights up.
(2) The digital ampere meter on the front pane of the welding power shows
preset value and the fan rotates in the specified direction
Only if all these steps are finished without any problems can the equipment, a
normal one, be used in welding.
. Inside Structure and Statement
Internal schematic diagram for left side (Picture)
Internal structure images for right side (Picture6)

Schematic diagram for intermediate plates (Picture 7)
. Installation and debugging
1. Environment
(1) The welding operation shall be operated in a relatively dry environment, and the air
humidity should not exceed 90 percent.
(2)The ambient temperature should be between -10%℃and 40℃.
(3)Do not weld under the sunlight or in the rain, and do not let water or rain go into
welding machine.
(4)Do not weld in dust or under the environment containing corrosive gases.
(5)Do not weld at the vibrant and easy-collision places.
2. Security key points
The welding machine has been installed protection circuit against over current and
overheat, which will automatically stop working when the temperature is higher than
the standard and welding machine will enter the state of protection when the flow is
excessive. But excessive use (such as welding current excessive) would have still
caused damage to the welding machine, so you need to pay attention to the
followings:
(1) To keep good ventilation!
Since the size of the welding machine is small, natural ventilation can not
meet the need of cooling it when strong current goes through it, we use a cooling
fan to make it work smoothly.
User should confirm the ventilation is not covered or blocked. The distance
between the machine and the surrounding objects must be kept no less than 0.3
meters. The user should always keep it good ventilation, which is very important to
work efficiency and service life of the machine.
(2) To prohibit electric current from overloading!
User should observe the strongest load current (relatively to the selected load
sustained rate) at any time, so as to ensure the welding current against exceeding
the allowed maximum.
The life expectancy of welding machine will be significantly shorten, or even
be burned, by overload current.

(3) To prohibit over voltage!
The power voltage is listed in the main technique parameters such as these in
form 1, in normal conditions; the voltage auto-compensation circuit in the welder limits
the welding current within normal range. If the power voltage exceeds the normal
range, the welding machine will be damaged. As a result, the operator should be fully
aware of the situation and proper protective measures should be taken.
There is one grounding screw on the back of every welder with the grounding mark.
Before use, selecting one cable with the cross section of more than 4m ㎡, connect the
shell of welding machine to ground to discharge electrostatic or avoid possible accidents
due to current leakage.
(4) If the welding machine exceeds the standard continuous loading time, the welding
machine would enter protective state and stop working. If this situation happens, it
indicates that the welding machine exceeds sustained rate of standard load. And
excessive heat trigger the temperature detect switch, which make the welder stop
working. At the same time, the yellow dictator at the front board goes out.
In this case, do not plug of the power so that the cooling fan starts to cool the
welding machine. When the yellow indicator lit up, it indicates the temperature lower
down to the normal range and welding work can be continued.
3. Equipping circuit configuration

Equipping circuit configuration of arc welding (Picture8)
4. Installation and Debugging
(1) After opening the case, check the types and quantity in the case according
to contents of packaging card.
(2) INARC IH series welding machine adopts three-phase four wire system
AC380 (50Hz) network sources, and the connecting wire is shown as
Picture 8.
Among them the yellow/ blue double-color line is the protection grounding
line, connecting with the shell in the power, please make sure connect the
protection line to the protective grounding terminal on the installment site;
Or the professional electrician can connect M6 connecting bolt with
grounding mark on the inferior of the back panel to the protective grounding
terminal by the cable with the proper specification
Form 2 Power equipment and connection power
INARC -400 IH
Input power(v) Three-phase 380±10%
Power equipment
Capacity(KVA)
20
Input cable wire(㎜2) 3×5+1
Output cable wire(㎜2) 35
Grounding line(㎜2) 6
Automatic air
(release current)(A)
40

(3) Select the phase sequence properly to make the fan keep rotating (The
wind direction is the back panel in and the panel out).
(4) According to the welding technological requirements and species of
electrode, select the straight polarity DC (The work pieces connect
end) or the reverse connection method (The work pieces connect end).
5. Welding operation
(1) Turn on the power and switch on the welding machine the power light will
shine and the fan start to work regularly.
Note: The power light rather than protection light will shine.
(2) With regard to short-range welding, electrical current and thrust force can
be adjusted on the panel by shifting the remote switch to hort-range. For
long-range welding, as it is inconvenient to regulate current and thrust force,
you are recommended to use a remote controller designated by the
Company.
Note: If such a remote controller is needed, please place an order of it
together with the welding machine.
(3) In consideration of thickness of the material to be welded and electrode
diameter, adjust the current to an appropriate level in reference of data
shown in form 3.
(4) Thrust current can be regulated at a range from 0to 200A and superposed
on the welding current. If current is too high, intensified splashing may lead
to inferior formation of weld; on the contrary, if the magnitude is too low, the
melted welding stick becomes fluid and drop transfer is not proceeding
smoothly.
(5) Advise to use larger stiffness arc when welding with cellulose type coating
electrode (clockwise turn thrust current knob to the right-of-center position).
(6) In order to make non-splash welding, adopt small stiffness arc when
welding on stainless steel or dominant mode filling materials (clockwise turn
thrust current knob to the left-lf-center position).
(7) Striking current: when welding current is lower than 200A, adjust striking
current according to the requirements of welding technique in order to
improve the success rate of striking arc.
Note: Do not force too strongly when adjusting knob to avoid damaging the
welding machine or components.

(Form 3) Option of the welding wire with welding current
Diameter
of electrode (㎜)
Welding
current(A)
Diameter of
electrode(㎜)
Welding current(A)
2.0 30-60 4.0 120-180
2.5 50-100 5.0 180-250
3.2 80-120 6.0 250-400
Ⅶ. Routine Maintenance and Repair
Regular maintenance and inspection are done to ensure the machine to
work safely and efficiently. Check whether the power of the welding machine is
off before checking the external connectors. Check the internal wiring five
minutes after the power of the welding machine is turned off, so that the
capacitors of the machine are fully discharged to avoid electric shock accidents
and ensure the safety of the staff.
(Form 4) Reference Guide for Maintenance
Line maintenance items A regular maintenance is done every one or two
months
1.The function of the power switch
2.Whether the cooling fan is rotating normally
3.Whether the abnormal vibration, noise or
smell exists
4.Whether the cable connector is overheated
5.Whether welded cable is abnormally hot
6.Whether a wire connector is loose
1.Remove dirt:
Compressed air is used to remove dirt, in particular
the dirt on inductor, transformers, power transistors
and printed circuit boards.
2.Maintenance of the circuit connectors
Check whether the input terminal, the output
connector, the external connections are loose or
rusty. Tighten the loose places and remove the rust
to ensure good contact
3. Check whether the grounding line is well
. Troubleshooting
Troubleshooting workers can check first and then make maintenance according to
orm 5. if the faults can not be cleared please contact with the distributor or the
producer.
Note:
1. Before checking the inner circuit of machine, make sure shut off the
three-phase power of welding machine to guard against electric shock
because the inner circuit can produce high voltage.
2. Before the machine leaves the factory, the control circuit has been connected
precisely. When connecting, do not overexert, do not change the position of
adjustable device on the circuit board at random to avoid accident.

(Form5) Maintenance form
Faults phenomena Faults cause/ measures
The current indicator light is off. The
fan does not rotate and the digital
multimeter does not display.
 Whether the power switch closed or not
 Check whether the input cable and the connecting power
network have electric or not
 Check whether the input cable has open circuit point or not
The protection indicator light is on. Long-time overload situation, thermal protection circuit starts,
decease the welding current and improve the working environment.
Too strong welding current, too long and thin output cable. Decease
the welding current, and shorten the input cable or increase its cross
sectional area.
The output current is not steady or
controlled by the potentiometer, and
the current intensity frequently
changes.
The potentiometer is damaged and shall be changed, the output
cable joint is loosening, and the input three-phase cable line has a
bad contact.
The switch of power cannot be
closed.
IGBT module burns out, and the input three-phase rectifier is
damaged.
The volume of welding current is
nonadjustable.
Current rockwork is damaged or cast off wire, and the main control
board is damaged.
The current indicator light is on and
the fan no rotate
The fan does not work, the input power is normal or not, and the
connecting wire of fan is split or not.
Sodium hydroxide electrode has big
spattering.
The polarity is mistakenly connected, and exchanges the polarities
of grounding line and handing wire.
Note: 1. People other than maintenance personnel of professional electricians of our
company shall not open the shell.
3. Turn off the powers of the welding machine and the distributing box.

Main
Tf
T
rans
f
ormer
(MTAX-B08)
Output Choke
(CHKB08)
Fan (FAN002)
(CHKB08)
Output Rectifier
Module (FRM001)
Snubber PCB for
Output FRM (PCB-
SNB-OUT03)

Over current
Protection PCB
(PCB
-
OC
-
400)
Potentiometer
for
Current/Striking/
MCB (MCB001)
(PCB
OC
400)
Arc Force
(POT001)
Fan Capacitor
(CAP05)
Capacitor
(CAP-ELE-02)
Snubber Card
(PCB-SNB-B08)
Shunt
(SHUNT001) MOV (MOV001)
Input Bridge
Module with
Surge
suppressor
PCB (PCB-IB-01)
IGBT (IGBT7512)
DC Capacitor
(CAP001)
Isolation PCB
(PCB-ISO-B08)