WARPP INARC-1000 I Operating Manual Download

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INARC-1000 I/ 1250 I

·２６·

INARC-1000 I / 1250 I

Inverter Arc Welding Machines

OPERATING MANUAL

WARPP ENGINEERS PVT. LTD.

B-1005, Western Edge II, Near Metro Mall, Off. Western Express
Highway, Borivali (E), Mumbai-400 066.
Tel: 91-22-28542272 73/74. Fax: 91-22-28542275.
E-mail:[email protected] Web Site: www.warpp.co.in

Summary of Contents for INARC-1000 I

Page 1: ...er Arc Welding Machines OPERATING MANUAL WARPP ENGINEERS PVT LTD B 1005 Western Edge II Near Metro Mall Off Western Express Highway 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: ...ety Precautions 1 2 Principle Technical data 7 3 Features Applications 11 4 Installation Guide 12 5 Operating Instruction 16 6 Repair Maintenance 20 Appendix A EMC Suggestion for installation and use of welder 23 ...

Page 3: ...ng tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform require...

Page 4: ...place your body between your electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the work piece as close as possible to the area being welded 2 d 5 Do not work next to welding power source ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is o...

Page 5: ...achine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall ARC RA...

Page 6: ...re also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain 5 c Do not weld in locat...

Page 7: ...n to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned 6 e Vent hollow castings or containers before heating cutting or welding They may explode 6 f Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt high shoes and a cap over ...

Page 8: ...amage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame 7 d Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder 7 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 7 f Valve protection caps should be always be in place and hand tight expect when the cylinder ...

Page 9: ...amical 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 regula...

Page 10: ...put current 83A 120A Rated duty cycle 100 Range of output current 60 1000A 60 1250A Output voltage of open load 80 8V Full load efficiency 92 Power factor full load 0 88 Welding electrode diameter 3 6mm 3 8mm Carbon rod diameter 3 10mm Weight kg 95 100 Dimension mm3 767 352 757 767 352 802 Insulation class Main transformer H Transformer for ZKB QDB Output reactor B Table1 Parameter Specification ...

Page 11: ...INARC 1000 I 1250 I ９ 2 Main circuit diagram z INARC 1000 1250 I Figure 3 Main Circuit Diagram for INARC 1000 I 1250 I ...

Page 12: ...citor CT81 3KV 0 01uF K 2 10 C31 32 Polypropylene Capacitor MFD DA015uF 500V AC For 1000 MFD DA016uF 500V AC For 1250 2 11 T2 T3 Main Transformer MZ 1000 5 1 0 1 12 V5 10 V15 20 Fast Recovery Diode Module DKR200AB60 6 For 1000 8 For 1250 13 T1 Transformer for ZKB QDB ZX7 1000S 3 1 1 1 14 L7 8 Output Reactor ZX7 1000S 4 2 For1000 ZX7 1000S 5 2 For1250 2 15 FU1 Fuse 3A 6 30 1 16 EV1 2 Fan 200FZY8 S ...

Page 13: ...eam and fly casting such as burr Features and benefits Inverter technology ensures stable welding voltage high adjustability for arc regulation Low spatter Easy to arc starting and molten pool control with Smooth consistent arc 2 cycle 4cycle operating modes provided High duty cycle Wide range of current adjustment Non source power factor compensation technology high PF power factor Extendable cab...

Page 14: ... the insulation properties of accessories z Environments with adverse conditions do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated z The gradient of ground must be no more than 10 z Ensure no wind at the welding position or use screen to block the wind z When using water cooled torch must be care of n...

Page 15: ...er removal of input power DO NOT TOUCH live electrical parts z SHUT DOWN welding power source disconnect input power employing lockout tagging procedures z Lockout tagging procedures consist of padlocking line disconnect switch in open position z Removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device 1 4 Power Supply Requirements z Input volt mus...

Page 16: ...machine is to be placed is even dry and with good ventilation 2 1 MMA mode 1 Ensure firmly connection to welding cable 2 Adjust every switches and potentiometers on the front panel to proper position in line with selected mode 3 Turn on the circuit breaker on the power source 4 Connect input 3 phase power cable to switch box 2 2 Air arc gouging mode 1 Ensure firmly connection to ground cable and a...

Page 17: ...hose and water cooling machine if it is water cooled 3 Adjust every switches and potentiometers on the front panel to proper position in line with selected mode 4 Turn on the circuit breaker on the power source 5 Connect input 3 phase power cable to switch box Attention Cut off the power supply before connecting the welding cable Ensure the good connection between welding cable and connection term...

Page 18: ...mally welding 2 Fault on LED Lights up and stops welding automatically while machine is in breakdown 3 Current Voltage displayer z When the switch is on Current display the preset current during the open load display the welding current during the welding z When the switch is on Current display the output voltage value 4 Down slope time adjustment knob Adjust the crater filling time in TIG mode 5 ...

Page 19: ... Long position when in air arc gouging welding 9 Arc force current adjustment knob Adjust arc force current 10 Welding current adjustment knob Adjust welding current 11 Output terminal z In MMA welding it is connected to welding cable z In air arc gouging it is connected to the torch z In TIG welding it is connected to the workpiece 12 Output terminal z In MMA welding or in air arc gouging it is c...

Page 20: ...achine overload or failure Normally the Breaker flipped to upward means power on Switch on from the switch box to start or stop welding machine avoiding using the breaker 4 Ground bolt To ensure operators not to be harmed and welding machine to be working normally make sure the ground bolt is grounded firmly by ground cable 5 Fan Cool down the heat components in the welding machine 6 Gas inlet S s...

Page 21: ...e Customer should refer to parameters defined in table 5 and table 6 showing below Workpiece 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 Table 5 MMA welding parameters Table 6 Air arc gouging parameters Workpiece thickness mm Welding current A Carbon rod diameter mm 1 4 150 200 200 250 3 4 4 7 250 300 300 ...

Page 22: ... let welding machine be bumped into or stacked up by heavy objects Ensure good ventilation Under high temperature if work with large current for long period welder may shut down automatically due to thermal protection acts At this point let the machine runs under open load for a few minutes and it will be automatically recover Under high temperature if work with large current for long period welde...

Page 23: ...tions Check if the input volt has the phase missing and range are between 340 420V Check if the input cable is connected correctly and firmly with the power source Check if the ground lead is connected correctly and firmly Check if the welding cables are connected correctly and firmly Check if gas regulator is in good situation and gas flows out normally WARNING Have a qualified electrician do the...

Page 24: ...T Module 3 phase Rectify Module or other devices 2 Drive Board is damaged 3 Short circuit between cables 1 Check and replace 2 When IGBT Module is damaged please check the devices on Drive Board 3 Welding current is instable 1 Phase missing 2 The following devices may be damaged Potentiometers or switches on front panel 3 Main Control Board is damaged 4 Current Sensor is damaged 1 Check power sour...

Page 25: ...ements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury 2 Assessment of area Before installing arc welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signaling and telephone cables above be...

Page 26: ...anufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the arc welding equipment is in operation The arc welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintain...

Page 27: ...sing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by a direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations 6 Screening and shielding Selective screening and sh...

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