COMBO SERIES

CC/CV BASED
WELDING MACHINE

OPERATING MANUAL

WARPP ENGINEERS PVT. LTD.

B-1005, Western Edge II, Near Metro Mall, Off. Western Express
Highway, Borivali (E), Mumbai-400 066.
Tel: 91-022-28542272 /73/74. Fax: 022-28542275.
Email:sales@warpp.co.in Web Site: www.warpp.co.in
 Safety Precautions

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM

POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.BE
SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES

For Engine Powered equipments

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance
work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the
engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do not spill fuel when filling 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 required
maintenance. Remove guards only when necessary and replace them when the
maintenance requiring their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler
by pushing on the throttle control rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning the engine or welding
generator during maintenance work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

·１·
 ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic

Fields(EMF). Welding current creates EMF fields around welding cables and welding
machines.
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should
consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not
known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
2.d.1. Route the electrode and work cables together-Secure them with tape when possible.
2.d.2. Never coil electrode lead around your body.
2.d.3. Do not 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 on. Do
not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves
to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under
electrically hazardous conditions (in damp locations or wearing wet clothing; on metal
structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,
·２·
 kneeling or lying, if there is a high risk of unavoidable or accidental contact with the work
piece or ground) use the following equipment:
Semiautomatic DC Constant Voltage (Wire) Welder
DC Manual (Stick) Welder
AC Welder with Reduced voltage control
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being
welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine 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 RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding. Head shield and filter lens
should conform
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and
that of your helpers from the arc rays.
4.c. protect other nearby personnel with suitable, non-flammable screening and/or warn them
not to watch the arc nor expose themselves to the arc rays or to hot spatter or material.

FUMES AND GASES can be dangerous

·３·
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding
with electrodes which require special ventilation such as stainless or hard facing or on lead
or cadmium and plated steel and other materials or coatings which produce highly toxic
fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using
local exhaust or mechanical ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precautions are 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 it is within applicable
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use
enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this equipment and the
consumables to be used,
5.f. Also see item 1.b.

WELDING AND CUTTING SPARKS can cause fire or explosion.

6.a. Remove fire hazardous from the welding area. If this is not possible, cover them to prevent
the welding sparks from starting a fire. Remember that welding sparks and hot materials
from welding can easily go through small cracks and openings to adjacent areas. Avoid
welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used

·４·
 to prevent hazardous situations.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or
ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken
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 your hair. Wear ear plugs when
welding out of position or in confined places. Always wear safety glasses with side shields
when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area
increase the possibility of the welding current passing through lifting chains, crane cables
or other alternate circuits. This can create fire hazards or overheat lifting chains or cable
until they fail.
6.h. Also see item 1.c.
6.i. Do not use a welding power source for pipe thawing.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used
and properly operating regulators designed for the gas and pressure used. All hoses,
fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage, A safe
distance from arc welding or cutting operations and any other source of heat, sparks, or
flame.

·５·
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
is in use or connected for use.

FOR ELECTRICALLY powered equipment

8.a. Turn off input power using the disconnect switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the manufacturer’s recommendations.

·６·
 Principle & Technical data

COMBO 500 ID Block diagram of principle

Input Output

3 phase HF HF Rectifier &

Rectifier Inverter Transformer Filter

Control circuit

Figure 1: Block diagram of principle

This series welding machines apply IGBT soft switch inverter technology. 3- phase input volt
are rectified by rectifier, inverted into HF AC, reduced by HF transformer, rectified and filtered
by HF rectifier, then output DC power suitable for welding. After this process, the welder’s
dynamically responsive speed has been greatly increased, so the welder size and weight are
reduced noticeably. Power source enjoys good anti-fluctuating ability and high-quality
performance.
U(V
-
80
- U2=14+0.05I2
60
-
40
-
20
- I(A)
0

Figure 2: CV Volt-Ampere curve

90– U=20+0.04I

20 – I(A)

0
Imin Imax

Figure 3: CC Volt-Ampere curve

·７·
1. Main technical parameters

№ Items COMBO 500 ID

01 Voltage/frequency Three phase 400V/50Hz

02 Rated input power 25KVA

03 Rated input current 37A/27A

04 Rated duty cycle 60%

05 Output current 60～500A

06 Output voltage 15～50V

07 Output open voltage 70V

08 Efficiency 89%

09 Power factor 0.87

10 Wire diameter (mm) 1.0~1.6

11 Electrode diameter (mm) 2～6

12 Carbon rod diameter (mm) 3～8

13 Weight 50Kg

14 Dimensions (mm) 636×322×584

15 CO2 gas flow rate 15-20L/min

16 Insulation class of main transformer H

17 Insulation class of output reactor B

Table 1: Parameter Specification

·８·
2. Main circuit diagram

Figure 4: Main Circuit Diagram

·９·
3. Main components list

No. Item Model

1 Circuit breaker DZ47-D-60A 3P

2 3-phase rectifier module MDS100-16 (large)

3 Polypropylene capacitor MFD-DA01-1400V-20Uf

4 IGBT module SKM100GB128D

5 Polypropylene capacitor MFD-DA01-500V-5Uf

6 Main transformer NBC-500

7 Fast recovery diode module DKR200AB60

8 Transformer for ZKB/QDBⅠ AMIG-500

9 Transformer for ZKB/QDBⅡ AMIG-500

10 Fuse UFE 2A

11 Fan AK2072HB (220V)

12 Thermal switch JUC-079F/70±5 -1D-A

13 IGBT protection board NBC-500

14 Drive board NBC-500

15 Main control board NBC-500Xa

16 Varistor MYL1-625/5

17 Current exchange inductor ZX7-400

18 Quick socket Trak-BE 35-70mm2

19 Current sensor HAS600-S

Table 2: Main Components List

·１０·
 Features & Application

COMBO 500 ID series inverter CO2/MAG welders, which are high-quality performers with CV
(constant volt) and CC (constant current) output characteristic, can be used for semi-automatic
CO2 gas shield welding or SMAW with solid or flux-cored wire(Ф1.0-Ф1.6mm)for welding
mild steel and low alloy steel work pieces. This series welder enjoys reasonable static
characteristic and sound dynamic characteristic.
Features and benefits:
◆ Capable of presetting welding current or wire feeding speed and 10 memory locations for
jobs.
◆ Featured function of wire diameter selection.
◆ Enjoying spot welding function.
◆ Enjoying unified adjustment function.
◆ Self-diagnostic function with error code display.
◆ Equipped with 485 commutation port unit, easily coupled with a cable of automatic welding.
◆ Optional digital remote control box.
◆ Perfect functions of starting arc and reducing melting ball while stopping arc.
◆ Capable of operation with extended 50M long welding cable.
◆ M type can perform SMAW and Carbon Arc Gouging.
Applications:

◆ Suitable for mild steel and alloy steel welding.

◆ Electric power, petrochemical Constructions.

◆ Automobiles.

◆ Metal shop.

◆ Equipment manufacture.

◆ Boiler Pressure container manufacture.

◆ Shipyards.

◆ Steel structure workshops.

◆ Light and heavy industries.

·１１·
 Installation Guide

1． Pre-installation

1.1 Installation Environment

The COMBO 500 ID is designed for use in adverse environments. Examples of

environments with increased adverse conditions are
z In locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts;
z In locations which are fully or partially limited by conductive elements, and in
which there is a high risk of unavoidable or accidental contact by the operator;
z In wet or damp hot locations where humidity or perspiration considerably reduces
the skin resistance of the human body and 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.

1.2. Installation Location

Be sure to locate the welder according to the following guidelines:
z In areas, free from moisture and dust.
z Ambient temperature between 0 degrees C to 40 degrees C.
z In areas, free from oil, steam and corrosive gases.
z In areas, not subjected to abnormal vibration or shock.
z In areas, not exposed to direct sunlight or rain.
z Place at a distance of 12" (304.79mm) or more from walls or similar boundaries
that could restrict natural airflow for cooling.

1.3 Power Source Connections

·１２·
Warning _______
Thermal Arc advises that this equipment be electrically connected by a qualified
electrician.
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after
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 Supplier Requirements

z Input volt must be standard sine wave, effective value 400V, frequency 50Hz.
z Unbalance degree of 3-phase volt must be no more than 5%.
z Power supply

Product type COMBO 500 ID

Power supply 3-phase AC 400V
Power network 38KVA
Min. capacity
Generator 50KVA
Fuse 50A
Input volt protection
Circuit breaker 63A
Input volt ≥6mm2
Cable size Output volt 70mm2
(cross-section)
Ground lead ≥6mm2

Table 3: Power supply connection

Note: The size of fuse and breaker in the table are for reference only.

·１３·
2. Installation:
This series welder is small, light and portable. They will be more convenient if place
them on the trolleys. Ensure the location where to place the welder is even.
COMBO 500 ID connection chart as Figure 5:

Figure 5: Connection Chart for COMBO 500 ID

Procedure for assembling the machine (Refer to Figure 5)
Parts numbers reference:
1) Quick socket for welding torch (+)
2) Water outlet
3) Water inlet
4) Digital controller socket
5) Quick socket (-)
6) CO2 gas regulator
7) Wire feeder control socket
8) Gas inlet of wire feeder

·１４·
 9) Water inlet of wire feeder
10) Water outlet of wire feeder
11) Connecting terminal lug of wire feeder (+)
12) Input power cable of welder
13) Welder control socket
14) Wire hole for water cooler power cable
15) Quick socket (+)
16) Output socket for heating CO2 gas
17) Input power cable of water cooler
18) Water outlet of water cooler
19) Water inlet of water cooler
3. Preparation procedure prior to welding: (refer to figure 5)
(1) Mount the water cooler (optional), welder, wire feeder and gas cylinder to the trolley
fitly.
(2) Connect the socket No.15 to lug No.11 on the rear panel diagram by using wire feeder
welding cable.
(3) Connect the socket No.13 to socket No.7 on the rear panel diagram by using wire
feeding control cable (can be coated by a cover).
(4) Connect the gas inlet No.8 on the rear panel diagram to the gas regulator No.6 by
using gas hose.
(5) Connect the water outlet No.18 to the water inlet No.9 on the rear panel diagram by
using water hose (for water cooled type).
(6) Connect the water inlet No.19 to the water outlet No.10 on the rear panel diagram by
using water hose (for water cooled type).
(7) Connect the socket No.16 to the heating cable of the CO2 gas regulator.
(8) Connect the digital controller (optional) to the socket No.4 on the front panel of
welder (can be coated by a cover).
(9) Connect the workpiece to the socket No.5 on the front panel of welder.
(10) Connect the welding torch to the socket No.1 on the front panel of wire feeder.
(11) Connect the welding torch to the water inlet and water outlet on the front panel of wire

·１５·
 feeder (for water cooled type, the torch is optional).
(12) Connect the power input cable of water cooler to the power supply, and ensure the
earth lead is firmly grounded. When the water cooler is powered by welder, this step
can be neglected.
(13) Connect the input 3-phase power cable to the power supply, and ensure the earth lead
is firmly grounded.
(14) Turn on air switch on the rear panel of the welder.
4. Operating procedure:
Reset the circuit breaker on the switchboard, then the welder’s indicator lamp will turn on,
and the cooling fan will spin. Press on the “Inch feeding” button on the feeder’s controller,
the feeder begin to feed wire. Preset the process parameters by regulating the controller,
tuning the knob, and flipping the switch to proper location on the front panel of the welder.
When the torch trigger is pulled, the feeder start to feed wire, and CO2 will blow out of the
nozzle, therefore it can be used for welding. Operators can select parameters from table
listed below. Be sure to turn off the valve of gas bottle and unplug the power cord while
stop welding.
Welding current (A) Welding voltage (V) Suitable wire (mm)

60~80 17~18 Ф1.0

80~130 18~21 Ф1.0、Ф1.2

130~200 20~24 Ф1.0、Ф1.2

200~250 24~27 Ф1.0、Ф1.2

250~350 26~32 Ф1.2、Ф1.6

350~500 31~39 Ф1.6

500~630 39~44 Ф1.6

Table 4: Recommended welding parameters

·１６·
When on SMAW mode, reset the circuit breaker on the switchboard, adjust the parameters
on the control board, then the welding work can be starting. Customer should refer to
parameters defined in table 5 showing below:

Work piece thickness

＜1 2 3 4～5 6～12 ≥13
（mm）

Electrode diameter
1.5 2 3.2 3.2～4 4～5 5～6
（mm）

Welding current（A） 20～40 40～50 90～110 90～130 160～250 250～400

Table 5: SMAW welding parameters

·１７·
 Operating Instruction

1. Front panel illustration and parts number reference

Figure 6: Front panel

1.1 Quick socket (-)
Connect work piece by work lead
1.2 RD-I digital controller cable socket
1.3 Control panel
The welder’s control panel is used for functional selection and some welding parameters
adjustment. The panel includes nixietubes window, knobs, touch keys and LED
indicators.

·１８·
 Figure 7: Welding machine control panel
1.3.1 Functional selection

Figure 8: Function selection key

1.3.1.1 Wire diameter selection key

Selecting wire diameter betweenΦ1.6、Φ1.2 and Φ1.0mm, and the respective LED

will lights on.

1.3.1.2 “Individual/Synergic” selection key
Select individual/synergic mode. On “Individual” mode, welding current and voltage
can be adjusted individually by regulating controller of wire feeder. On “Synergic”
mode, welding voltage automatically match up to welding current. Fine tunes
welding voltage by regulating “Crater filling” knob.

·１９·
1.3.1.3 “Gas test” key
Gas flows out for about 30 seconds when pressed on. Stop gas flowing when pressed
again in 30 seconds.
1.3.1.4 “Wire test” key
Wire feeding when pressing on the key. Stop feeding when releasing the key. (The
same function as to press the inching button on the wire feeder controller)
1.3.1.5 “FCAW/GMAW” selection key
1.3.1.6 Mode selection key
Selecting 2-step, 4-step or arc spot weld.
(1) 2-step: Perform welding when push torch trigger, stop welding when release the
trigger.
(2) 4-step: After successfully starting arc by push torch trigger, then you can
perform welding by release the trigger, when you pull torch trigger again, torch
will turn into crater-filling condition which was preset by stop- arc knobs on
the front panel. The welder will stop welding when release the trigger. This
mode is suitable for welding long weld.
(3) Arc spot welding: After successfully starting arc by pull torch trigger, the
welder will stop welding automatically at the end of arc spot welding. If release
the trigger during arc spot welding, the welder will stop welding immediately.
1.3.2 Parameters set-up

Figure 9: Parameters setting knob

(1) “Crater filling current/Arc spot welding time” knob
While in “4-step”, be used for adjusting crater filling current.
While in “Arc spot welding time”, adjusts arc spot welding time from 0.5 to 5
seconds.
·２０·
 (2) “Crater filling voltage” knob
While in “4-step”, be used for adjusting crater filling voltage.
(3) “Inductance” knob: Altering welding stability, penetration and spatter volume.
1.3.3 Save/Display

Figure 10: Display area

1.3.3.1 Number Nixietube
Displays number 0 to 9 of the corresponding welding parameter. Operators can
save or load relative welding parameter by welding requirement.
(1) “Num” selection key: Press this key, the number of corresponding welding
parameter will display from 0 to 9 in turn.
(2) Save: Press this key, the number will flash for three seconds. During this time,
press it again to save the preset welding parameters displaying on the windows.
(3) Load: Pressing on the key, the welding parameters which are represented by
present number will display on the windows to be ready for using. While in
loading, the PROG lamp will light on and the represented welding parameters are
not adjustable. Repress the key to quit the parameters loading.
1.3.3.2 Current nixietube
Display wire feeding speed, welding current and arc spot welding time
(1) “M/min” Indicator lamp will light on when displaying preset speed of wire
feeding
(2) “A” indicator lamp will light on when displaying welding current. Displays
preset current while in open load, displays practical value in welding.
(3) “S” indicator lamp will light on when displaying arc spot time.
(4) Pressing on “Crater filling current” and “Crater filling volt” knobs
simultaneously for one second, the Amp nixietube will display values altering

·２１·
 between preset welding current and preset wire feeding.
1.3.3.3 “Volt” nixietube
Display inductance and volt.
(1) When regulating inductance, the nixietube will display value of inductance and

“﹋” lamp will light on. The adjustable range of inductance is from 1 to 50.

(2) When regulating welding current by tuning “crater filling current” knob or “Volt
regulation” knob on the controller, the nixietube will display volt and “V”
indicator lamp will light on.
Displays preset volt while in open load, displays practical value in welding.
1.3.3.4 Welding status indicator lamp
(1) When regulating welding parameters, the “Welding” lamp will light on and the
nixietube will display welding parameters.
(2) When regulating crater filling parameters, the “Crater filling” lamp will light on
and the nixietube will display crater filling parameters. The nixietube resume
displaying welding parameters after stopping regulating for three seconds.
1.3.4 Panel control welding mode

Figure 11: Panel control welding model

When the wire feeder isn’t connected, the welder is in panel control mode. Press this
knob can switch the working mode between MIG/MAG and SAWA gouging.

·２２·
2. The rear panel and parts number reference

Figure 12: Rear panel

(1) Wire hole for water cooler power cable
When the water cooler is powered by the power source, this hole will be closed. When
the water cooler is powered by the welder following the customer’s demand, the power
cable of the cooler will pass this hole from the inside of welder.
(2) Input power cable
The mixed-colored wire must be firmly grounded, the rest wires connect to 3-phase
power (400V/50Hz) respectively.
(3) Circuit breaker
It protects welding machine by automatic trip to turn-off power supply while in
machine overload or failure.
(4) Fuse
(5) Quick socket (+)
Connect to terminal lug of wire feeder (+).
(6) Output socket for heating CO2 gas (AC36V)
Connect to heating winding of the gas regulator.
(7) Window blind
For ventilation and protecting the welder.
(8) Cooling fan
Cool down the heat components in the welding machine.
(9) Control socket
·２３·
 Connect to wire feeder control socket.
(10) Specification plate
(11) Input warning mark
3. Controller
This controller is fixed on the panel of wire feeder. Panel illustration and parts number
reference:

Figure 13: Panel of controller

(1) Current regulation knob
Adjusting welding current
(2) “Inching” button
Used for quick wire feeding
(3) Volt regulation knob
Adjusting welding volt
(4) Working mode selecting switch
When the wire feeder is connected, the welder is in remote control status, and the
working mode selecting switch is no use. Use this switch to select welder working
mode among MIG/MAG, SMAW and SAWA Gauging.

·２４·
4. Water cooler
Water cooler is a kind of light and movable inner circulating water-cooled machine. It can be
used in cooling down the water-cooled torch. The capacity of the cooler is 10 L. Other
technical parameters are shown as the following table.
Item Unit COMBO 500 ID
Rated input voltage V Single phase 400V
Rated input current A 0.9
Rated frequency Hz 50/60
Cooling water capacity L 10
Cooling Style Air-cooled
Cooling water circulating
Inner circulating
style
Circulating water flux L/min 3
Circulating water distance m 18
Cooling ability W 3000
Radiation Area m2 0.6
Pump power W 260
Pump output rpm r/min 2860
Dimension mm 630×342×327
Weight kg 28

Table 6: Water cooler technical parameters

4.1 Instructions
Warning: The case must be well-connected with the earth. It must be maintained and
repaired by qualified people. The case shouldn’t be opened freely.
4.1.1 Environment situation

1) Air temperature scale: 0～40℃

2) Air relative humidity: When it is 40℃, the humidity is ≤50%. When it is 20℃, the

humidity is ≤90%.
3) Dust, acid and corrosive air or substance around the machine is no more than normal
content.

·２５·
 4) Prevent from direct light of the sun and rain.
5) Keep 20-cm-distance from the wall.
4.1.2 Prevent Frostbite
In winter, when the cooler is used in some place where the water may be frozen, please
add glycerol antifreeze (other antifreeze may bring unexpected results to pump and
other machines). Drain out the cooling-water if necessary.
4.1.3 Microorganism anti-grow substance
There’re some microorganisms in the cooling water. They grow and choke the path.
Microorganism anti-grow substance can prevent this phenomenon. Its effect will
depend on the water quality, so you can have a try first.
4.1.4 Please refer to the related welder and torch instructions before you use it.
4.2 Operating instructions
4.2.1 Front panel
1) Water inlet
Put the fresh water in the cooler through the water inlet.
2) Water gauge
Supply the water in time according to the water level.
3) Specification plate

Figure 14: Front panel of water cooler

·２６·
 4) Manometer
Observe the pressure and the flux of water from here.
5) Switch
Turn on the switch, the indictor will light on, and the water cooler will begin to
work.
4.2.2 Rear panel

Figure 15: Rear panel of water cooler

1) Cooling fan
Cool down the heat components in the welding machine.
2) Input powder cable
It is 3-pin cable. The yellow-green wire must be firmly grounded, the rest two wires
connect to corresponding 3-phase power supply (400V/50Hz).
3) Fuse
The fuse will melt down when the water pump or cooling fan has some faults.
4) Water outlet
5) Water inlet
4.2.3 Operating procedure
4.2.3.1 Add water to water tank
Inject fresh water through the water inlet. Impure water may cause faults.
The water level should be proper. Watch the water level meter to make sure the water
not be overflowed.

·２７·
 After connecting the torch and water cooler, the water will start circulating. The water
level will become lower, please add water if needed.
Attention for adding water:
Avoid the water flowing to the welder or other equipments.
The water must be added to the cooler before the machine works, because the pump
may meet some faults if in open load.
4.2.3.2 Operation
1) Turn on the power switch, and the cooling fan and water pump motor will start to
work. The cooling water will cycle in the torch.
2) After the welding work, firstly make sure the torch is completely cooled, then turn off
the power switch of the cooler.
4.3 Repair and maintenance
In order to use the equipment safely, please ask qualified people to repair and maintain it
periodically. Please contact us when the users have unsolvable problems.
Attention: In order to keep you safe you shouldn’t open the case freely. Prevent from
being electric shocked when you repair it.
1) Check and repair the connecting parts.
Please check if there are bad connections or insulation broken.
2) Earth lead
Please check if the case is grounded firmly.
3) Clean out the inside dust
Radiator with dust may reduce the radiating effect. Please clean it every 6 months
using dry compressed air.
4) Replacement of cooling water
Please replace the cooling water every month, the furring will cause water pump motor
can not work and jam cooling water cycle of the torch. If water pump still can not work
after replacing the water, please use screwdriver or other tools to drive the motor
axletree.
How to drain water: Connect another water hose to the water outlet.

·２８·
 4.4 Ordinary failures
z Water pump motor does not work
1) Input powder cable broken or fuse burns out.
2) Capacitor burns out and needs to be replaced.
3) Water freezes in winter.
4) The motor blocks up, repair the motor.
z The cooling water does not cycle
1) The water is insufficient in the water tank.
2) Torch or water hose is jammed (impurities in or water freezes)
3) Impellers abrased seriously, need to be replaced.
5. DR-I digital controller.
This controller is optional. When using, plug the control cable into the socket (Seeing fig.5:
1.2 control socket for RD-I digital controller). For specific using instruction, please refer to
operating manual of RD-I Digital Controller.
Note: When the digital controller is connected, the wire feeder control panel and the
welder control panel will be disabled. All the parameters will be adjusted on RD-I
controller.

·２９·
 Repair & Maintenance

WARNING: Have a qualified electrician do the maintenance and trouble shooting work.
Turn the input power off, using the disconnect switch at the fuse box before working
inside the machine.

1. Cautions:
• Rivet equipment name tag on the specified area of the case, otherwise the inside parts
will possibly be damaged.
• Connect welding cable to terminals firmly, otherwise the terminals will be burn out
which will cause the instability of welding process.
• Avoid welding cable and control cable being broken, and prevent welding machine from
being short circuit.
• Never 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, welder may shut
down automatically due to air switcher trips. Cut off the power supply to the electricity
switchboard on frame, and wait for 5 minutes to turn on the air switcher on the power
source fist then connect the power supply to the electricity switchboard on frame. And
leave the machine runs under open-load condition for a while.
• After welding, cut off gas supply and the power supply.

2. General maintenance

• Remove dust from power resource with pressure air by qualified individuals every 3-6
months. Check if the jointers are loose.
• Check regularly if cables are worn out, knobs are loose, and components of panel are
damaged.
• Check regularly if cables are tightly connected to cable connecting terminals in case of
·３０·
 terminals being burnt out.
• Clean and replace Contact Tip in time.

3. Procedure for regular checking prior to maintenance

• Check if all front panel switches are on the proper positions.

• Check if the input volt has the phase missing, and range are between 360~440V (Input
power 3 phase 400V/50HZ)
• 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: Don’t open up case uninstructed, the max volt inside machine is 600V.
Take safe precautions to prevent from being electric shock while in maintenance.
Shut down power source before changing welding cable or torch.

·３１·
№ TROUBLE CAUSES WHAT TO DO
(1) Phase missing (1) Check power supply
Indicator lamp does not light
01 (2) Circuit breaker is damaged (2) Replace
on when machine switches on.
(3) Fuse is broken (3) Replace (2A)
(1) Circuit breaker is collapsed.
(2) IGBT module is damaged (1) Replace
Circuit breaker trips (3) 3-phase rectifier bridge is (2) Replace
02 immediately after the machine damaged. (3) Replace
is switched on. (4) Varistor is damaged (4) Replace
(5) Welder’s control board is (5) Replace
damaged
(1) Welding machine operates in (1) Operating machine in
Circuit breaker trips while in
03 long term overload rated duty cycle
welding
(2) Circuit breaker is damaged (2) Replace
(1) Wire feeder’s control cable is (1) Replace control cable or
broken or controller is damaged controller
Welding current can not be
04 (2) Control board is damaged (2) Replace
adjusted
(1) Conductive wire connected the (3) Reconnect the broken
rectifier is broken wires

Instable arc welding, more (1) Incorrect welding parameters (1) Fine tune parameters
05
spatter (2) Contact tip is worn out severely (2) Change contact tip

(1) CO2 regulator is damaged

(2) Heater cable is broken or (1) Replace
06 CO2 gas regulator can’t heat shorten (2) Repair heat cable change
(3) Thermal-sensitive resistance in (3) Replace
power source is damaged
Push welding torch trigger,
(1) Control board is damaged (1) Replace
07 wire feeding is normal but
(2) Electromagnet valve damaged (2) Replace
airflow is blocked
Push welding torch trigger, wire (1) Torch trigger is damaged (1) Replace welding torch
08 feeder do not work and there is (2) Feeder’s control cable is broken (2) Repair control cable
no open load volt display (3) Control board is damaged (3) Replace

Table 7: Trouble Shooting Table

·３２·
 Appendix A

1. General
The user is responsible for installing and using the arc welding equipment according to the
manufacturer’s instructions. If electromagnetic disturbances are detected, then it shall be the
responsibility of the user of the arc welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial action may be as simple
as earthling the welding circuit, see note. In other cases it could involve constructing an
electromagnetic screen enclosing the welding power source and the word complete with
associated input filters. In all cases electromagnetic disturbances shall be reduced to the point,
where they are no longer troublesome.
NOTE: The welding circuit may not be earthed for safety reasons. Changing the
earthling arrangements 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, below and
adjacent to the arc welding equipment;
2) Radio and television transmitters and receivers;
3) Computer and other control equipment;
4) Safety critical equipment, for example guarding of industrial equipment;
5) The health of the people around, for example the use of pacemakers and hearing aids;
6) Equipment used for calibration or measurement;
7) The immunity of other equipment in the environment is compatible. The user shall ensure
that other equipment being used in the environment is compatible. This may require
additional protection measures;
8) The time of day that welding or other activities are to be carried out.

·３３·
3. Methods of reducing emissions
1) Public supply system
Arc welding equipment should be connected to the public supply system according to
the manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the public supply system. Consideration
should be given to shielding the supply cable of permanently installed arc welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous
its length. The shielding should be connected to the welding power source so that good
electrical contact is maintained between the conduit and the welding power source
enclosure.
2) Maintenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to the
manufacturer’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 maintained according to the
manufacturer’s recommendations.
3) Welding cables
The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
4) Equipotent bonding
Bonding of all metallic components in the welding installation and adjacent to it should
be considered. However, metallic components bonded to the word piece will increase
the risk that the operator could receive an electric shock by touching these metallic
components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.

·３４·
5) Earthling of the work piece
Where the work piece is nor bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example ships hull or building steelwork, a
connection bonding the work piece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthling of the work piece increasing 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 shielding of other cables and equipment in the surrounding area
may alleviate problems of interference. Screening of the entire welding installation may
be considered for special applications.

·３５·