INSTRUCTION MANUAL FOR

MIG/MAG (CO2) WELDING

MACHINE

MODEL WARMIG-400

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: 28542275.
E-mail:[email protected] Web Site:www.warpp.co.in
 INDEX

1) INTRODUCTION 1

2) THE SYSTEM 1

3) PRE INSTALLATION REQUIRMENT 3

4) INSTALLATION 3

5) SAFETY 3

6) VOLTAGE SETTING CHART 4

7) FEED RATE CHART 4

8) OPERATION 5

9) FAULT FINDING 6

10) SPARE PART LIST 7

ILLUSTRATIONS

1) CONTROL WIRING INSIDE THE POWER SOURCE 1

2) CONTROLWIRING OF THE FEEDER 2

3) INSTALLATION DIAGRAM 3

4) VOLTAGE V/S CURRENT CURVE 4

5) TORCH ASSEMBLY DIAGRAM 5

 INTRODUCTION.
WARMIG Series MIG / MAG (CO2) Machines are Switch type constant voltage type. They can be
used for MIG (Metal Inert Gas) Welding in SS and Al. and MAG (Metal Active gas) Welding in MS.
This machine mainly consists of following components in it.

1) Power Source.
2) Wire Feeder
3) Regulator Flow-meter
4) MIG Welding Torch
5) Inter Connecting Cable
THE SYSTEM
POWER SOURCE.
The power source has following components

Main Transformer

The main transformer is a constant voltage type transformer with the tapings on the primary
side to adjust the output voltage. Super Enameled Copper wirers are used for primary winding and
fiber glass coated strips are used for secondary windings. The coils are varnished with H Class
grade varnish for durability.

Rectifier Stack.

Rectifier stack is a full wave rectifier with six diodes (Three Modules in 250 Amps range). The
diodes are mounted on well designed heat sink for better performance.

Voltage adjusting Switch.

Two switches are used to adjust the out put voltage. The two switch operates in coarse fine
combination to give maximum number of voltage adjustments.

Ammeter.

Ammeter is provided on the front panel to read the out put current during welding

Voltmeter

Voltmeter is provided on the front panel to read the welding Voltage

1
Cooling Fan.

Industrial heavy duty fan operating on single phase is provided for proper cooling of
transformer and Rectifier

WIRE FEEDER.
Wire Feeder has the following components.

Wire feeder motor with Mechanism.

WARMIG Series machines employ permanent magnet type DC Motors for wire feeding. The
feeding mechanism is two roll type and is designed for easy changing of rollers depending on the
wire size.

Drive Card.

The drive card used to drive the wire feeder motor is MOSFET based and the design is
rugged enough to absorb the voltage fluctuation. The electronic stopping circuitry is provided for
instant stopping of the wire feed.

Sequence Card.

The sequence card is controls the sequence of events in the welding process and it uses
only TTL Logic. Provision is made to adjust the BURN-OFF timing.

MIG Welding Torch.

The machines comes with 36KD Torch in 400 Amps and 25AK torch in 250 Amps
models. The details of the assembly drawing in shown in the fig.

NOTE: THE LINER OF THE TORCH HAS TO BE CLEANED ON A REGULAR BASIS

FOR GOOD WELDING RESULTS

2
PRE INSTALLATION REQUIRMENT.

The WARMIG Series machines comes with the complete package ready to use. What it
requires to put the machine in use is three-phase power supply, Gas cylinder and the MIG wire.

NOTE: THE MACHINE COMES WITH CO2 GAS REGULATOR ONLY

INSTALLATION.
The pictorial installation diagram is attached in this manual.

NOTE: PROPER INPUT CABLE TO BE USED TO CONNECT THE MACHINE TO THE

POWER SUPPLY AND SEPARATE EARTHING TO BE PROVIDED.

SAFETY.
All safety precautions are to be taken for the safety of welders and surrounding people.
Some of them are listed below.

1) Keep the welding area free from all inflammable materials.

2) Welders has to use proper welding helmets (with proper filter glass) as ultra violet radiation is a
part of welding process.
3) Proper Apron, Hand Gloves and shoes has to be used by the welder.
4) Welding area should be covered properly so that people working around do not affected by the
ultra violet radiation.

3
VOLTAGE SETTING CHART.

COARSE
1 2 3 4 5 6
1 17.4 19.9 23.0 27.3 32.9 41.5
F
I 2 17.9 20.5 23.6 28.3 34.1 43.9
N 3 18.3 21.1 24.4 29.0 35.6 46.6
E
4 18.8 21.6 25.3 30.3 37.3 49.8

5 19.2 22.3 26.1 31.5 39.2 52.9

NOTE: Voltage indicated are NO-LOAD Voltages and the welding voltages will be lower
than this.

WIRE FEED RATE CHART

Wire feed rate in meters per minute as per the setting of feeder potentiometer is given below.

Sr. No. Position of Feed rate in Meters per

Potentiometer Minute
1 10 1.5
2 20 3.9
3 30 6.0
4 40 8.3
5 50 11.1
6 60 12.8
7 70 14.0
8 80 15.6
9 90 16.6
10 100 17.3

4
OPERATION.

1) Install the machine as shown in the installation diagram.

2) Load the MIG Wire on to the spool holder provided on the Wire feeder.
3) Keep the feeder mechanism in unlock position.
Pass the wire through the wire feed mechanism and then through the EURO On the front panel
of the feeder.
4) Now connect the torch to the EURO Connector.
Bring back the feeder mechanism to lock position
5) Press the inch switch provided on the feeder, (kindly note that the feed knob setting should not
be at zero) now the wire will start moving in to Torch. Keep it pressed till the wire comes out
the TIP of the torch.
6) Connect the regulator heater combination to the CO2 cylinder.
7) Release the CO2 gas
8) Now one dial of the regulator will show the pressure inside the cylinder, now tighten the screw
provided on the regulator till the other dial shows 1.5 Kg pressure.
9) Keep the feed knob to Zero position and press the torch trigger and release the valve provided
on the flow meter. Adjust the flow meter to have a gas of around 15 Ltrs/Min.
10) Now the machine is ready to use, Select the voltage required, set the feed rate, hold the torch on
to the job and press the torch trigger. Arc will be created now move the torch along the joint
evenly to get good weld finish.

5
 FAULT FINDING
Sr. Fault What to check
No.
1 Machine is switched on but neither the 1) Check for the proper three phase supply
mains indicator glows nor the fan is 2) Check the control fuse mounted on the control
operating transformer of the power source
2 The machine is Switched on but the 1) Check the three core inter connecting cable
indicator on the feeder do not glow connection at both the machine end and feeder
and on operating the inching button end.
the wire feeder 1) Check the glass fuse provided on the feeder
( the glass fuse is mounted on the panel between
the front panel of the feeder and the control box)
3 When the machine is started the wire Check the NC element connected to the inching
start to come out of the torch switch of the feeder ( If the NC contact is faulty
automatically with out triggering the the two wires connected to the this element can be
switch on the torch shorted for temporary relief)
4 When the torch trigger is pressed the Check the three core inter connecting cable
wire comes out of the torch but gas do connection at both the machine end and feeder
not flow and the voltage do not come end.
5 When the torch trigger is pressed the 1) Check for the proper three phase
wires comes out of the torch , gas connection
starts flowing but welding do not takes 2) Set the feeder knob to zero and set the
place COARSE and FINE SWITCH to the
maximum and press the trigger on the
torch, then volt meter should show a
voltage of around 55 volts in WARMIG-
400and 39 Volts in WARMIG-250. If the
voltage is less than this check the3 phase
supply and for proper operation of the
contactor.
6 Welding is taking place but the current The feed rate set is low increase the feed rate till
tends to drop in between and the arc you get proper and steady current
goes up to the TIP of the torch
7 Welding is taking place but a jerk is The wire feed set is high. Reduce the wire feed
felt while welding and the torch is rate till you get a steady welding current
pushed away from the job
8 Each time welding is finished long BURN-OFF time set is too high
wire comes out of the torch Blue color preset is provided on the sequence card
(a card with two relays). Adjust this to set it right.
NOTE: this adjustment has to be done only if it of
utmost importance and it is causing high
inconvenience to the welder

6
 LIST OF SPARES FOR WARMIG-MACHINES

WARMIG-250 WARMIG-400 WARMIG-600

Description Part No. Part No. Part No.
Sequence and drive card With 2/4 Track
C170203 C170203 C170203
Function
Wire feeder D.C Motor C2454 C2454 C2454
Solonoid Valve C2601 C2601 C2601
Control Transformer C140503 C140503 C140503
Digital Panel meter 0.75MVDC C2429
Digital Panel meter 200V DC C2430
Ampere meter (Analouge) C2427
Volt. Metere C2428 C2428
Primary Coil C1108 C1107 C1111
Secondary Coil C1115 C1114 C1118
Choke Coil C1128 C1127 C1129
Diode Monoblock C150703
Diode C150401 C150502
Exhaust fan C160403 C160403 C160403
Rotary Switch C2201
Rotary Switch 3 pole 5 way C2217 C2217
Rotary Switch 3 pole 6 way C2216 C2216
Rotary Switch C2206 C2206 C2206
Shunt
Power Plug Metal type Male (3 Pin) C2411 C2411 C2411
Power Plug Metal type Female (3 Pin) C2412 C2412 C2412
Power Plug Metal Type Male (2 Pin) C2413 C2413 C2413
Power Plug Metal Type Female (2 Pin) C2414 C2414 C2414
Out Put Connector C180303 C180101 C180202
Contactor C2302 C2303 C2303