WARPP IN ARC-I series Operating Manual Download Page 26

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Front Panel

VOLTAGE/AMPERE

SWITCH (PSW01)

SMAW/TIG SELECTION

SWITCH (PSW01)

LED YELLOW

(LED Y01)

2 / 4 TRACK

SELECTION SWITCH

(PSW01)

Digital Display

Meter (DSP001)

LED RED (LED R01)

REMOTE/PANEL

SELECTION SWITCH

(PSW01)

(

)

POTENTIOMETER

FOR CURRENT

(POT001)

POTENTIOMETER FOR

STRIKING CURRENT

(POT001)

POTENTIONMETER

FOR ARC FORCE

(POT001)

Output Terminal (+)

(OUTP)

7 PIN CONNECTOR

OUTPUT

7 PIN CONNECTOR

MALE (CON7PNM)

OUTPUT

TERMINAL (-)

(OUTN)

Summary of Contents for IN ARC-I series

Page 1: ... 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 ...

Page 2: ...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 Par...

Page 3: ...ine can adjust its down slope time while stopping arc Weld formation are pretty good With remote control function welding parameters can be adjusted in extended distance Light small and portable High power factor high efficient and energy saving Safety Precautions General safety precaution z Please strictly comply with rules defined in this manual to avoid unexpected accidents z How to connect to ...

Page 4: ...ccidents z Don t put flammable material in the working area Hot spatter and hot weld can easily start a fire z Cable must be connected the work piece firmly to ensure good conductivity in case causing fire by resistance heat z Don t weld in the flammable gas or weld container which contains flammable material otherwise it can cause explode z Don t weld encapsulated container otherwise it can cause...

Page 5: ...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 v...

Page 6: ... 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 calibr...

Page 7: ... 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 calibr...

Page 8: ...ng 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 perf...

Page 9: ...bs 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...

Page 10: ...ries 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 switc...

Page 11: ... 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 b...

Page 12: ... 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 w...

Page 13: ...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 work...

Page 14: ...rc 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 cabl...

Page 15: ...h 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...

Page 16: ...ed 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 a...

Page 17: ...d 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 r...

Page 18: ...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 ...

Page 19: ...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 ...

Page 20: ...in 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...

Page 21: ...k and replace When IGBT module is damaged please check 12Ω 5 1Ω resistance or SR160 on driving board is damaged or not 3 Welding current is unstable Phase missing The following components may be damaged Potentiometers switches on front panel and remote control cable potentiometer on remote controller Main control board is damaged Check power source Check and replace 4 Welding current is not adjust...

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Page 25: ...tal Display A V l Panel Control Switch KD1 Digital Display DSP001 Arc starting Current Potentiometer W3 Amp Volt Switch KD2 Arc force Current Down slope Time Welding Current Potentiometer W1 p Potentiometer W2 Control Socket P20 Output Terminal OUTN P20 Output Terminal OUTP OUTP ...

Page 26: ...ACK SELECTION SWITCH PSW01 Digital Display Meter DSP001 LED RED LED R01 REMOTE PANEL SELECTION SWITCH PSW01 POTENTIOMETER FOR CURRENT POT001 POTENTIOMETER FOR STRIKING CURRENT POT001 POTENTIONMETER FOR ARC FORCE POT001 Output Terminal OUTP 7 PIN CONNECTOR OUTPUT 7 PIN CONNECTOR MALE CON7PNM OUTPUT TERMINAL OUTN ...

Page 27: ...Left View Left View Fan FAN Main 002 Transformer Thrust Coil Output Choke CHK 001 Snubber PCB Isolation PCB PSB Output Rectifier For O P FRM PCB SNB OUT 01 ISO 01 Output Rectifier Module FRM001 ...

Page 28: ...SNUBBER CARD Over Current Protection PCB HF PCB PCB HF 01 HF Transformer CTRAX007 IGBT Resonant Coil IGBT Input Bridge AC Capacitor Module Fan Capacitor p CAP05 Solonaid Valve Shunt Insulation MOV MOV001 DC Capacitor CAP001 SV001 Insulation Transformer INSTRX001 ...

Page 29: ...Top View p Drive CARD PCB DRV 01 CONTROL TRANSFORMER CTRAX001 Input Surge Suppressor ISS 01 Main PCB Fuse F1 ...

Page 30: ...Rear Panel Rear Panel FAN MCB ...

Page 31: ... 01 PCB HF 01 PCB HF 01 PCB HF 01 HF PCB CAPACITOR PCB22 01 PCB22 01 PCB22 01 PCB22 01 SOLONAID VALVE SV001 SV001 SV001 SV001 INSULATION TRANSFORMER INSTRX001 INSTRX001 INSTRX001 INSTRX001 MOV MOV001 MOV001 MOV001 MOV001 ISOLATION PCB PCB ISO 01 PCB ISO 01 PCB ISO 01 PCB ISO 01 SNUBBER PCB FOR OUTPUT FRM PCB SNB OUT 01 PCB SNB OUT 01 PCB SNB OUT 01 PCB SNB OUT 01 POTENTIOMETER FOR POT001 POT001 PO...

Page 32: ...ISS001 ISS001 ISS001 SNUBBER CAPACITOR SCAP001 SCAP001 SCAP001 SCAP001 CONTROL TRANSFORMER CTRAX001 CTRAX001 CTRAX001 CTRAX001 MOV MOV001 MOV001 MOV001 MOV001 ISOLATION PCB PCB ISO 01 PCB ISO 01 PCB ISO 01 PCB ISO 01 SNUBBER PCB FOR OUTPUT FRM PCB SNB OUT 01 PCB SNB OUT01 PCB SNB OUT 02 PCB SNB OUT 02 POTENTIOMETER FOR CURRENT STRIKING CURRENT ARC FORCE POT001 POT001 POT001 POT001 KNOB FOR THE POT...

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