WARPP WS-200 Manual de usuario

DC INVERTER TIG

WELDING MACHINE WS-200

INSTRUCTION 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.

Email:[email protected] Web Site: www.warpp.co.in

· -1-

CONTENTS

1. Contents ····································································································································································· 1

2. Safety warning ··························································································································································· 2

3. Machine description ················································································································································· 3

4. Technical parameters table ······································································································································ 4

5. Installation instruction ············································································································································· 5

6. Panel function instruction ······································································································································· 6

7. Operation instruction ··············································································································································· 7

8. Notes or preventive measures·································································································································· 8

9. Questions to be run into during welding ··············································································································· 9

10. Maintenance ···························································································································································· 10

11. Notes before checking ··········································································································································· 11

12. Troubleshooting and fault finding ·························································································································· 12

· -2-

SAFETY WARNING

On the process of welding or cutting, there will be possibility of injury, so please take protection

into consideration during operation. For more details please review the Operator Safety Guide,

which complies with the preventive requirements of the manufacturer.

Electric shock——May lead to death ！！

zSet the earth fitting according to applying standard.

zForbidden to touch the bare electric parts and electrode with uncovered skin, wet gloves or clothes.

zMake sure you are insulated from the ground and the workshop.

zMake sure you are in safe position.

Gases and fumes——May be harmful to health!

zKeep your head out of the gases and fumes.

zWhen arc welding, ventilators or air extractors should be used to avoid breathing gases.

Arc rays——Harmful to your eyes, burn your skin.

zWear suitable protective mask, light filter and protective garment to protect eyes and body.

zPrepare suitable protective mask or curtain to protect looker-on.

Fire

zWelding spark may cause fire, make sure there is no tinder stuff around the welding area.

Noise——Excessive noises will be harmful to hearing.

zUse ear protector or others means to protect ear.

zWarn looker-on that noise is harmful to hearing.

Malfunction——When trouble happens, contact with authorized professionals.

zIf trouble happens during installation and operation, please follow this manual instruction to check up.

zIf you fail to fully understand the manual, or fail to solve the problem with the instruction, you should contact the

suppliers or the service center for professional help.

WARNING！

Creepage-protecting switch should be added when using the machine！！！

· -3-

MACHINE DESCRIPTION

Welding machine is a rectifier adopting the most advanced inverter technology.

The development of welding equipment benefits from the appearance of the inverter power supply theory and

components. Inverter arc welding power source utilizes high-power component MOSFET to transfer 50/60Hz frequency

up to 100 KHz, then reduce the voltage and commutate, and output high-power voltage via PWM technology. Because of

the great reduce of the main transformer’s weight and volume; the efficiency increases by 30%. The appearance of

inverter welding equipment is considered to be a revolution for welding industry.

Welding power source can offer stronger, more concentrated and more stable arc. When stick and workpiece get short,

its response will be quicker. It means that it is easier to design into welding machine with different dynamic characteristics,

and it even can be adjusted for specialty to make arc softer or harder.

TIG welding machine is easy for arc initiation and has the functions of arc initiation current, arc stop current, welding

current, basic value current, current ascending time, current descending time, gas delay time, continuous adjustment.

What’s more, pulse frequency and pulse duty can also be adjusted independently. It has the characteristics of automatic

control of arc initiation, arc stop and stable arc, which make the best result for shape and inner quality of the welding

surface. Its exclusive design is specially suitable for bicycle industry.

The machine can be for multi-use, and can weld stainless steel, carbon steel, copper and other color metal, and also can

use for traditional electric welding. Its transfer efficiency is above 85%.

Thanks for purchasing our products and looking forward to your precious advice, we will try our best to perfect our

products and service.

WARNING！

The machine is mainly used in industry. It will produce radio wave, so the worker should make fully

preparation for protection.

· -4-

TECHNICAL PARAMETERS TABLE

Model

Parameters WS 200

Power voltage(V) single phase

AC220V±15%

Frequency（Hz）50/60

Rated input current（A）30.8

Output current.（A）10～200

Rated working volt.（V）18

No-load volt.（V）56

Force adjustment（A）——

Duty cycle（%）60

No-load loss （W）40

Arcing way HF

Efficiency （%）80

Power factor 0.73

Insulation grade F

Housing protection grade IP21

Weight（Kg）9

Dimensions （mm）395×153×301

· -5-

INSTALLATION INSTRUCTION

The machine is equipped with power voltage compensation equipment. When power voltage fluctuates between±15% of

rated voltage, it still can work normally.

When use long cable, in order to prevent voltage form going down, bigger section cable is suggested. If cable is too long,

it may affect the performance of the power system. So we suggest you to use configured length.

1. Make sure intake of the machine not blocked or covered, lest cooling system could not work.

2. Make good connection of shielded gas source. Gas supply passage includes cylinder, argon decompress flow

meter and pipe. Connecting part of pipe should used hoop or other things to fasten, lest argon leaks out and

air gets in.

3. Use inducting cable whose section is not less than 6 mm² to connect the housing to the ground. The way is

from the ground-connecting screw at the back to the earth device.

4. Correctly connect the arc torch or holder according to the sketch. When use MMA welding: Make sure the cable, holder

and fastening plug have been connected with the ground. Put the fastening plug into the fastening socket at the “-” terminal

and fasten it clockwise. When use pulse arc welding: Put the gas-electricity plug of the welding gun to the joint at the front

panel, and fasten clockwise. Put the air switch on the gun to the relevant joint at the front panel, and fasten the screw.

5. Put the fastening plug of the cable to fastening socket of “+”

polarity at the front panel, fasten it clockwise, and the earth

clamp at the other terminal clamps the work piece.

6. According to input voltage grade, connect power

cable with power supply box of relevant voltage

grade. Make sure so mistake and make sure the

voltage difference among permission range. After the

above job, installation is finished and welding is

available.

WARNING！

Before connecting operation please make sure all the power is turned off. The right order is

to connect the welding cable and ground cable to the machine first, and make sure they are

firmly connected and then put the power plug to the power source.

Earth Clamp

TIG Torch

Electrode Holder

Workpiece

Power Supply

(single phase~220V)

Installation Instruction of WS 200

Gas

Cylinder

· -6-

PANEL FUNCTION INSTRUCTION

Front Panel

1.Powerswitch

2.Powerindicatorled

3.Abnormalindicatorled

4. Welding current adjustment

5.MMA/TIGswitch

6.Positiveoutputterminal

7.Torchswitchsocket

8. Gas-electricity system output terminal

9.Negativeoutputterminal

· -7-

OPERATION INSTRUCTION

TIG Welding Description

1. Turn on the power switch of front panel, digital current meter is normal, fan begins torun.

2. Turn on argon switch, and adjust gas pressure to rated value.(refer to flow table).

3. Press switch of torch, electromagnetic valve is started. You will hear the sound of electricity-releasing HF sparkle and

at the same time, argon gets out the torch. NOTES: If the first time welding, you should press switch for a few

seconds before welding, until all the air in the gas passage is removed, and then start to weld. When you stop

welding, argon will still flow out for a few seconds, Which is designed to guarantee that weld spot is protected before

cooling down. So when the electric arc stops, keep the welding position for a while and then move the torch.

4. Choose the “pulse alter switch” according to the need. When the switch is on the down position, there is no pulse,

while between down and up position, there is middle frequency pulse (200Hz), while on the up position, there is low

frequency pulse 2Hz).

5. Adjust the switch of the Current Down Slope Adjustment according to the request of the work piece and welding.

6. Set suitable welding current according to the thickness of work piece and process demand.

7. Keep 2-4mm space between tungsten pole and work piece, press torch control switch, between electrode and work

piece HF electricity is released; After arc initiation, HF sparkle disappears soon and can start to work.

Sticking Description

1. Turn on the power switch on the front panel, and the fan begins to work.

2. Make sure function switch of front panel is on “down” position that is sticking. When welding jaw nips welding rod, it

begins to work.

3. According to work piece’s thickness, position, craftwork state, choose suitable welding current.

WARNING:

It is forbidden to pull out or put in the cable or connector during the process of welding, which will

threat life safety and damage the machine.

· -8-

NOTES OR PREVENTIVE MEASURES

1. Environment

1）The machine can perform in environment where conditions are dry with a dampness level of max 90%.

2）Ambient temperature is between -10 to 40 degrees centigrade.

3）Avoid welding in sunshine or drippings. Do not let water enter the gas

4）Avoid welding in dust area or the environment with corrosive gas.

5）Avoid gas welding in the environment with strong airflow.

2. Safety norms

Our welding machine has installed protection circuit of over voltage, over current and over heat. When voltage,

output current and temperature of machine are exceeding the rate standard, welding machine will stop working

automatically. Because that will be damage to welding machine, user must pay attention to following.

1) The working area is adequately ventilated！

Our welding machine is powerful machine, when it is being operated, it generated by high currents, and natural

wind can’t be satisfied with machine cool demands. So there is a fan in inter-machine to cool down machine.

Make sure the intake is not in block or covered, it is 0.3 meter from welding machine to objects of environment.

User should make sure the working area is adequately ventilated. It is important for the performance and the

longevity of the machine.

2) Do not over load！

The operator should remember to watch the max duty current (Response to the selected duty cycle).Keep

welding current is not exceed max duty cycle current. Over-load current will damage and burn up machine.

3) No over voltage！

Power voltage can be found in diagram of main technical data. Automatic compensation circuit of voltage will

assure that welding current keeps in allowable range. If power voltage is exceeding allowable range limited, it is

damaged to components of machine. The operator should understand this situation and take preventive

measures.

4) There is a grounding screw behind welding machine, with a grounding marker on it. Before operation, welding

crust must be grounded reliable with cable which section is over 6 square millimeter, in order to prevent from

static electricity, and accidents because of electricity leaking.

5) If welding time is exceeded duty cycle limited, welding machine will stop working for protection. Because

machine is overheated, temperature control switch is on “ON’’ position and the indicator light is red. In this

situation, you don’t have to pull the plug, in order to let the fan cool the machine. When the indicator light is off,

and the temperature goes down to the standard range, it can weld again.

· -9-

QUESTIONS TO BE RUN INTO DURING WELDING

Fittings, welding materials, environment factor, supply powers maybe have something to do with welding. User must try

to improve welding environment.

A. Black welding spot:

——Welding spot is not prevented from oxidizing .User may check as following:

1. Make sure the valve of argon cylinder is opened and its pressure is enough. Argon cylinder must be filled up to

enough pressure again if pressure of cylinder is below 0.5Mpa.

2. Check if the flow meter is opened and has enough flow .User can choose different flow according to welding current

in order to save gas .But too small flow maybe cause black welding spot because preventive gas is too short to cover

welding spot .We suggest that flow of argon must be kept min 3L/min.

3. Check if torch is in block.

4. If gas circuit is not air-tight or gas is not pure can lower welding quality.

5. If air is flowing powerfully in welding environment, that can lower welding quality.

B. Arc-striking is difficult and easy to pause:

1. Make sure quality of tungsten electrode is high.

2. Grind end of the tungsten electrode to taper. If tungsten electrode is not grinded, that will be difficult to strike arc and

cause unstable arc.

C. Output current not to rated value:

When power voltage departs from the rated value, it will make the output current not matched with rated value; When

voltage is lower than rated value, the max output may lower than rated value.

D. Current is not stabilizing when machine is being operated:

It has something with factors as following:

1. Electric wire net voltage has been changed.

2. There is harmful interference from electric wire net or other equipment.

E. When use MMA welding, too much spatter:

1. Maybe current is too big and stick’s diameter is too small.

2. Output terminal polarity connection is wrong, it should apply the opposite polarity at the normal technique, which

means that the stick should be connected with the negative polarity of power source, and work piece should be

connected with the positive polarity. So please change the polarity.

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