AUTOWELD Series

Inverter DC Submerged
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 /73/14. Fax:91-22-82542275.

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

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 Thank you for selecting WARPP brand inverter welding machine. In order to keep you safe away from
unexpected accidents, and enjoy full benefits offered by our quality products during welding, please read the
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…………….……………………………………………(7)

6. Operating Instruction………………………………….……………….…(7)

7. Repair& Maintenance.………………………….………….…………….(19)

8. Main Technical Parameters ………………………... …………………..(20)

9. Main Machine & Accessories……………………………………………(25)

Appendix A: Ordinary failures, probable cause & countermeasures

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 Usage & features
AUTOWELD Series DC Inverter Submerged Arc Welding Machines are manufactured to

comply with the following standards: GB15579, 1-2004 “Arc Welding Machines·Chapter

One·Power Source”.
This Series DC Inverter submerged arc welding machines are newly designed,
high-efficient and energy-saving equipments, which include
AUTOWELD-630/800/1000/1250, etc., used for carbon, stainless, heat-resistant and alloy
steel welding and extensively applied in ship, boiler, chemical container, bridge, crane and
metallurgy facility building industries.
Because of its ideal static and dynamic characteristic as well as comprehensive
controlling functions, this series arc welding machines have the following features:
(1)Welding current remains steady even when fluctuation of input primary power occurs and
arc length changes due to IGBT inverter technology.
(2)Adjustment of welding current according to welding parameters is available result in high
success rate of arc-starting.
(3)Adjustment of arc force current is available result in pretty weld formation, accurate
penetration control and flexible adaptability to context change.
(4)Carbon arc gouging and SMAW in one machine
(5)Wider range of welding current, the minimum current is 60A
(6)Light, small and easy to move.
(7)High power factor, high-efficiency and energy-saving

Safety Precautions

General security rules

z Please strictly comply with rules defined in this manual to avoid unexpected
accidents
z How to connect to power supply, select working area and use pressure gas, please
comply with proper rules
z Not allow non-operator to enter working area
z Welder’s installation, inspection, maintenance, and manipulation must be
completed by authorized person.
z Don’t use welding machine for unrelated purpose (Such as recharging, heating or
pipeline thaw, etc.)
z Must take safe precaution in case welder falling when it is put on the uneven
ground

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 Avoid being electric shock and burnt
z Never touch on the hot electrical units.
z Please instruct the authorized electrician to ground the welder frame by using
proper-sized copper wire.
z Please instruct the authorized electrician to connect the welder to power supply by
using proper- sized, well-insulated copper wire.
z When operating in the damp, space limited area, must ensure well-insulated
between body and work piece
z When operating in the high-rising location, must ensure safety by using safe net.
z Please power off the machine when no longer welding.

Avoid breathing in hazardous welding fume or gas

z Please use specified ventilation to prevent being gas poisoned and asphyxiated,
especially in the container where oxygen is depleted easily.

Avoid being harmed by arc flash, hot spatter and slag

z Arc rays can injure your eyes, make your eyes feel uncomfortable. Hot spatter and
slag can burn your skin.
z Please wear proper welding helmet, leather gloves, long- sleeved suit, cap, apron
and boots before welding.

Preventing from fire, explosion, container break accidents

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 explosion.
z Don’t weld encapsulated container, otherwise it can cause break.
z Ensuring fire extinguisher at hand in case a fire breaks out

Avoid being hurt by moving parts.

z Never let the finger, hair, and cloth near the rotary cooling fan and wire feeder
rollers.
z When feeding wire, don’t let the bottom of gun near your eyes, face and body, to
prevent being harmed by wire.

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 Avoid being hurt by welding machine while in transport

z When moving the welding machine by fork-lift truck or crane, nobody can be
allowed for standing downright the route of the moving welder, in case being hurt
by the falling welding machine.
z The ropes or wires which used for hanging up the welding machine must be strong
enough to withstand corresponding tension strength. The rope or wire inclination
hanging on the tackle must be no more than 30°

Installation
1. Installing situation
(1) Must place welding machine in the room where is no straight sunlight, no rain, less

dust, low humidity ,and temperature range of -10℃～+40℃

(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 value 380V±10%, frequency
50Hz/60Hz.
(2)Unbalance degree of 3- phase volt must be no more than 5%.

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 3. Power supply
Product type AUTOWELD- AUTOWELD AUTOWEL AUTOWELD
630 -800 D-1000 -1250
Input primary power 3 phase AC380V

Min Power 53KVA 66KVA 83KVA 120KVA

capacity network
generator 70KVA 88KVA 110KVA 158KVA
Input volt Fuse 60A 70A 90A 130A
protection Breaker 100A 100A 120A 160A
Input 10mm2 16mm2 25mm2 35mm2
Cable size Output 95mm2×1 50mm2×2 70mm2×2 95mm2×2
(cross-section)
Ground 10mm2 16mm2 16mm2 16mm2
lead
Tip: The size of fuse and breaker in the above table are only for reference.
4. Installation

4.1 AUTOWELD series welders wire diagram. See picture 1.

4.2 Operators should have appropriate switchboard or switch box. Connect the input
primary power cable to the switchboard or switch box, while grounds the lead safely.

Picture 1: Wire diagram

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 4.3 Wire welding machine terminal (+) to tractor by welding cable.
4.4 Wire welding machine (-) to workpiece by work lead.
4.5 Wire welding machine to tractor by control cable.

Definition of Product Model Number

AUTOWELD Series DC Inverter Submerged Arc Welding Machine codification of product

model number illustrate by picture 2:

AUTOWELD - ×××

Rated welding current

Automatic welding
SAW
Picture 2: Definition of Product Model Number

Principle in Brief

Block diagram of principle:

Rectifier HF Inverter HFTransform Rectifier

Control circuit

Picture 3 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 dynamical responsive speed has been greatly increased, so the welder
size and weight are reduced noticeably. Power source enjoy sound anti-fluctuating ability
and high-quality performance.

MZ Series DC Inverter SAW welding machine output characteristic

90–

U=20+0.04I

20
– 7 I(A)

Imin Imax
 Picture 4

Operating Instruction

1. Function introduction
1.1 Front panel illustration and parts number reference
AUTOWELD Series DC Inverter Submerged Arc welding machine front panel (take
AUTOWELD-1000 for example) illustrates in picture 5.

Picture 5 Front panel

(1) Amp meter (A): Display preset value of current while in open load, and display
practical value while in welding.
(2) Voltage meter (V): Display preset value of volt while in open load, and display
practical value while in welding.
(3) Power indication lamp: Lamp indicating whether power source is effectively connected
to power supply

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(4) Working indication lamp: the welding machine is started when it lights on.
(5) “Protection” indicator lamp
Welding machine will automatically stop working when it is overheat, and the lamp will be
light on.
(6) working switch: the welding machine starts working when it is on”1”, while the welding
machine stops working when it is on “0”.
(7) Welding current adjustment knob: it is used for adjust welding current.
(8) Arc force current/ down-slope time knob: it is used for adjusting arc force current to
control penetration and improve the weld formation.
(9) Arc starting current adjustment knob: it is used for adjusting arc start current adapting to
power change.
(10) Remote/ panel control switch: when it is on “Panel”, you can adjust welding current
through knobs on the panel; when it is on “Remote’, you can adjust welding current through
knobs on the control box.
(11) Working mode switch: when it is on “SMAW”, you can use it as a SMAW; when it is
on “SAW”, you can use it as a submerged arc welding machine.
(12) Control box protector (5A): it is to protect control box power source 120V.
(13) Terminal socket (+)
(14) Control cable socket : it is used for connect the control box to welding machine,
providing power source for controlling box and transport control signals between the
welding machine and control box.
(15) Terminal socket (-)

1.2 The rear panel and parts number reference

AUTOWELD Series DC Inverter Submerged Arc welding machine rear panel (take
AUTOWELD-1000 I for example) illustrates in picture 6.

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 Picture 8. AUTOWELD Rear panel
(1) Input power cable connector: it is used to connect to input 3 phase AC 380 V power
cable
(2) Name tag: notes the parameters of the welding machine.
(3) Cooling fan: Cool down the heat components in the welding machine.
(4) Ground bolt : To ensure operators not to be harmed and welding machine to be
working normally, make sure the ground bolt grounded firmly by ground lead specified
in the table 1, or ground wire(mixed-colored) of the input power cord grounded firmly.
2. Routine checkup prior to operation:
2.1 Checkup the welding machine with no power on.
(1) Check if input power cable is well-connected or not.
(2) Check if the working mode switch on front panel and the control mode switch are on
the right selection or not.
(3) Check if welding cable is well-connected or not.
(4) Check if control cable is well-connected or not.
(5) Check if ground bolt is well-connected or not.
2.2 Checkup on open load

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 After your doing the above examination, please exam the machine according to the
following procedure:
(1) Turn on the power of switchboard or switch box, plug input primary power cable
into the socket; power indication lamp will light on.
(2) Shift the working switch to “On”, working indication lamp will light on and
cooling fan will rotate. When working mode is on “SMAW”, there is a voltage
indication on voltage meter; when working mode is on “SAW”, it would be 0 on
voltage meter.
(3) Tuning the knob of welding current, the display would be changed.
(4) Shift working switch to “Off”, working indication lamp will turn off and cooling
fan will stop.
After all the above-mentioned examination passed, you can come into normal
welding.
3. Normal welding
3.1 On SMAW
(1) Well connect the input power cable;
(2) Well connect the ground lead;
(3) Shift working mode switch to “SMAW”;
(4) Connect the welding cable to the terminal socket “+”;
(5) Connect the work piece to the terminal socket “-” by work lead;
(6) Connect control box to the welder by control cable when needed;
(7) Select proper control mode, “Panel” or ”Remote” when needed
(8) Regulating current of the crater filler and arc force
(9) Wire input 3-phase power cable to switchboard or switchbox and turn on the air
switch.
(10) Tuning the knob of welding current, setting up the parameters for welding.
Tip: When working on SMAW, there is no current output if working mode switch is
on “SAW”. Operators can refer to table 1 when working on SMAW.
Table 1

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Thickness（mm） ＜1 2 3 4～5 6～12 ≥13

Diameter（mm） 1.5 2 3.2 3.2～4 4～5 5～6

Welding current(A) 40 40～50 90～120 90～120 160～250 250～400

3.2 On SAW
(1) Well-connect the input primary power cable;
(2) Well-connect the ground lead;
(3) Shift working mode switch to “SAW”;
(4) Connect tractor to welder’s the terminal socket “+”by welding cable;
(5) Connect the work piece to the terminal socket “-” by work lead;
(6) Connect control box to the welder by control cable;
(7) Select proper control mode, “Panel” or ”Remote” when needed
(8)Regulating current of the crater filler and arc force
(9)Wire input 3-phase power cable to switchboard or switchbox and turn on the air
switch.
(10)Tuning the knob of welding current, setting up the parameters for welding
Tip: Power off the welder when you change the welding cable or the contact tip.
3.3 Relationship between parameters setting and welding condition
Output static characteristic curve of inverter DC SAW shows as picture 7.

Picture 7 Output characteristic curve of inverter DC SAW

Line M-A-B-C: output static character curve

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 Line N-B: load curve

(1) Regulate welding current by tuning the current knob, the same as to adjust the distance
between line AB and vertical axial. The line AB which is the constant current output
characteristic curve of SAW, ranges from minimum welding current to rated welding
current.
(2) Regulate arc force current by tuning the arc force knob, corresponding to line DC of the
curve, the same as to adjust the slope of the line DC. On SMAW, regulation range from 0
to 150A; on SAW, range from 0 to 450A.
(3) Regulate instantaneous additional current of arc-start by tuning arc-start knob. The
reasonable arc-start current can anti sticking effectively and increase success rate of
arc-start substantially. Regulation range from 80+10A to 80+I/4(I refer to as SAW rated
welding current)
(4) Weld formation& parameters regulation
Weld formation has the close relationship to parameters regulation, usually present in
following rules:
When parameters are selected in the range of flatting area (arc force current is 0), the
penetration becomes shallow, the reinforcement becomes high and the weld becomes
narrow.
When parameters are selected in the range of drooping area (arc force current is 0), the
penetration becomes deep, the reinforcement becomes low and the weld becomes wide.
Increasing welding current, the penetration becomes deep and the weld becomes wide.
Increasing arc force current, the penetration becomes shallow and the weld becomes narrow.
Increasing welding volt of SAW, the penetration becomes shallow, the reinforcement
becomes low and the weld becomes wide.
Decreasing the speed of welding torch walking, the penetration becomes deep and the weld
becomes wide.
Operators should regulate parameters above-mentioned comprehensively to obtain pretty
weld formation or refer to welding parameters in tables from 2 to 8. When weld defects
occurs, please take remedies described in table 9.

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 Table 2：Range of welding current for different wire diameter

Wire diameter
2 3 4 5 6
(mm)

Current density
63～125 50～85 40～63 35～50 28～42
(A/mm2)

Welding current
200～400 350～600 500～800 700～1000 820～1200
(A)

Table 3： Parameters of Automatic grooved double-side welding with flux bed

Work piece Groove form wire Welding Dimensions of Arc Welding Weldin

thickness diamet direction groove voltage current g speed

（mm） er α（°） ι/κ(mm) （V） （A） （m/h）

（mm）

14 φ5 Forward 80 6 36～38 830～850 25

backward — — 45
36～38 600～620

16 φ5 Forward 70 7 36～38 830～850 20

backward — — 45
36～38 600～620

18 φ5 Forward 60 8 36～38 830～860 20

backward — — 600～620 45
36～38

22 φ6 Forward 55 13 38～40 1050～ 18

φ5 backward — — 45
36～38 1150

600～620

24 φ6 Forward 40 14 38～40 1100 24

φ5 backward 40 14 800 28
36～38

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 30 φ6 Forward 80 10 36～40 1000～ 18

backward 60 10 20
36～38 1100

900～1000

Table 4：Parameters of Automatic double-side-formation single-side welding with flux bed

Work Assembling wire Welding Arc Welding Pressure of flux

piece gap diameter voltage speed bed
current（A）
Thickness (mm) MPa
（mm） （V） （m/h）
(mm)

2 0～1.0 φ1.6 120 24～28 43.5 0.08

3 0～1.5 φ3 400～425 25～28 70 0.08

4 0～1.5 φ4 525～550 28～30 50 0.10～0.15

5 0～2.5 φ4 575～625 28～30 46 0.10～0.15

6 0～3.0 φ4 600～650 28～32 40.5 0.10～0.15

7 0～3.0 φ4 650～700 30～34 37 0.10～0.15

8 0～3.5 φ4 725～775 30～36 34 0.10～0.15

Table 5：Parameters of fillet welding in flat position

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 Work piece Arc
thickness Welding current
Wire diameter (mm) voltage Welding speed (m/h)
(A)
（mm）
(V)

Ф5

6 Ф5 450~475 34~36 40

8 550~600 34~36 30
Ф5
8 575~625 36~36 30

10 Ф5 600~650 34~36 23

10 Ф5 650~700 34~36 23

12 600~650 34~36 15
Ф5
12 725~775 36~38 20

12 Ф5 775~825 36~38 18

Ф5

Table 6：Parameters of Automatic double-side-formation single-side welding with pressing

gantry & copper backing

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 work piece Assembling Wire Welding current Arc voltage Welding speed

thickness gap diameter (A) (V) (m/h)

（mm） (mm) (mm)

3 2 Ф3 380~420 27~29 47

4 2~3 450~500 29~31 40.5

Ф4
5 2~3 520~580 31~33 37.5

6 3 Ф4 550~600 33~35 37.5

7 3 Ф4 640~680 35~37 34.5

8 3~4 680~720 35~37 32

Ф4
9 3~4 720~780 36~38 27.5

10 4 Ф4 780~820 38~40 27.5

12 5 Ф4 850~900 39~41 23

14 5 880~920 39~41 21.5

Ф4

Ф4

Ф4

Table 7：Parameters of Automatic double-side welding with preset gap flux bed

work piece Assembling wire Welding Arc voltage Welding

thickness gap diameter current (V) speed

(mm) (mm) (A) (m/h)

（mm）

14 3~4 Ф5 700~750 34~36 30

16 3~4 700~750 34~36 27

Ф5
18 4~5 750~800 36~40 27

20 4~5 Ф5 850~900 36~40 27

24 4~5 Ф5 900~950 38~42 25

28 5~6 900~950 38~42 20

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 30 6~7 Ф5 950~1000 40~44 16

Ф5

Ф5

Table 8：Parameters of Automatic suspended double-side welding

Wire work piece Welding current Arc voltage Welding speed

processing
diameter thickness (A) m/h)
order （V）
(mm) (mm)

P 380~420 30 34.6
Ф4 6
N 430~470 30 32.7

P 440~480 30 30
Ф4 8
N 480~530 31 30

P 530~570 31 27.7
Ф4 10
N 590~640 33 27.7

P 620~660 35 25
Ф4 12
N 680~720 35 24.8

P 680~720 37 24.6
Ф4 14
N 730~770 40 22.5

P 800~850 34~36 38
Ф4 15
N 850~900 36~38 26

P 850~900 35~37 36
Ф4 17
N 900~950 37~39 26

P 850~900 36~38 36
Ф4 18
N 900~950 38~40 24

P 850~900 36~38 35
Ф4 20
N 900~1000 38~40 24

P 900~950 37~39 32
Ф4 22
N 1000~1050 38~40 24

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 Table 9 Weld defects and troubleshooting in SAW
Weld defects Typical shape of weld cause Possible solution

Inconsistent (1) Inconstant welding (1) Check circuit

Different width or depth speed (2) Adjust driving
weld (2) Instable wire feeding roller
of each pass
(3) Replace contact tip
(3) Contact tip worn out
(1) Too high welding (1) Reduce welding
speed speed or apply
(2) Too big welding double-arc or
current multiple-arc
(3) Too big welding welding
voltage (2) Reduce welding
Undercut
(4) Incorrect wire end current
alignment (3) Reduce welding
voltage
(4) Adjust wire
position

Too big flux backing Adjust flux backing

Convex
pressure
(1) Too long of wire (1) Reduce wire
extension extension
(2) Bevel at small angle (2) Enlarge bevel
(3) Too low welding angle
Metal spillage
voltage (3)Increase welding
(4) Incorrect wire end voltage
alignment (3) Adjust wire
position
(1) Too big welding (1)Reduce welding
current current
Burn-through and (2) Too slow welding (2)Haste welding
thick back weld speed (3)Improve fit-up
(3) Large groove gap (4)Improve fixture
(4) Loose flux backing apparatus

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 (1) Too low welding (1) Increase welding
current current
(2) Too high welding accordingly
speed (2) Reduce welding
(3) Too large welding speed
voltage (3) Reduce welding
Poor fusion (4) Incorrect wire end voltage
alignment (4) Straighten wire
(5) Fluctuation of input and adjusting
voltage welding head
position
(5) Avoid peak of
power utility
(1) Cylindrical ditch (1) Oil stained base (1) Clean up wire
(2) Center around weld metal,
(3) Sporadic or swarm (2) Incomplete rust or (2) Drying flux
distribution oil clean-up on the (3) Replace flux
Pore
wire or damp wire
(3) Incorrect flux
composition or poor
quality
(1) Growing along the (1) Over-segregation of (1) Select low carbon,
line of longitude or low melt point low sulphur, high
latitude crystal sulphide manganese wire
boundary of the (2)Insufficient binding and low silicon,
weld force of weld high manganese
Thermal crack (2) At beginning or crystallization at begin or flux
ending of Automatic end of weld (2) Extend run-on tab
double-formation and intensify weld
single-side cohesiveness.
welding Apply grooved
run-on tab
(1) Slag remains in (1) Clean up slag
multi-pass bead between passes
Slag-entrapment (2) Incorrect wire end (2) Adjusting welding
alignment in next head position
pass welding

Repair & Maintenance

20
 In principle welders maintenance will be completed by us. Clients will be instructed by
us to solve the problems which they come across in using.
Warning: Should not open up case freely, the max volt inside machine will be 600V.
Customer must take safe precautions preventing from being electric shock while in
maintenance.
1. Apparently misunderstood failures
Normal phenomenon occurs in welding
(1)Welder doesn’t work while in pretty low input volt.
(2)When welder has worked for a long time in high temperature or in high welding
current context , the thermal-sensitive circuit breaker will tripped to stop welder working,
protection lamp will light on and LED will show “804” protection code. Welder will
automatically reinstate after merely running up for several minutes in open load (not
necessarily shut down welder).

When welder has worked for a long time in high temperature or in high welding current
context, the circuit breaker on the rear panel will tripped to power off. When this
situation occurs, please switch off the disconnected switchboard, and then halt the
welder lasting at least five minutes to restart. When restarting the welder, please reset
the circuit breaker firstly, then turn on the disconnect switchboard or switch box to
power on welder, finally use for welding after running up for several minutes in open
load.
2．Attentions:
2.1 Welding machine should be located on which are dry and smooth ventilation, not
overheat or damp.
2.2 The input volt should range from 340 to 420V, and no phase missing.
2.3 Check if the ground lead is connected correctly and firmly or not.
2.4 Must check up connection of cables periodically, be sure that wiring welding cable
to terminal plug socket firmly in case burning out the terminal which lead to welding
process instability.
2.5 Shut down welding machine when welding finished.
3.1 Checking procedure prior to maintenance
(1)Check if the input volt lose phase, and range are between 340-420V.
(2)Check if input primary power cable is connected correctly and firmly.
(3)Check if the ground lead is connected correctly and firmly.
(4)Check if the cables are connected correctly and firmly
2. Periodical checkup and maintenance
(1)Removes dust from power resource with pressure air by authorized maintainer every
3-6 months. Check if the jointers are loosened.
(2)Check frequently if cables are worn out, knobs are loosening, and components of
panel are damaged.

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 Technical Data

1、Main technical parameters

AUTOWELD- AUTOWELD- AUTOWELD AUTOWELD-

Item
630 I 800 I 1000 I 1250 I

Input voltage/
Three phase 380V±10%/50HZ
frequency

Rated output
27KW 35KW 44KW 55KW
power

Rated input current 52A 66A 83A 120A

Duty cycle 100%

Range of welding
60-630A 60-800A 60-1000A 60-1250A
current

Output open load SAW：90V MMA：67V

Full-load 92%

Full-load power
0.88
factor

Wire diameter 1.6-4mm 3-5mm 3-6mm 3-6mm

weight(kg) 55 80 95 100

dimension(mm3 ) 530×320×600 767×352×757 767×352×802

Main transformer H
Insulated degree
Power source transformer, output
B
reactor ,etc.

2. Main circuit diagram

Note: The main circuits of AUTOWELD-800/1000 and AUTOWELD-1250 include the
frame of dot lines, but AUTOWELD-630’s not includes.

22
 D3 +
R5
G1 N1 G3 N3
C1 C2 C3 R3
C7 T2
K1 L1 E1 C11 C13 C15 C17
E3
A L7
D1
R1 L3
B
C9
L5
C
C12 C16 C18
G2 N2 C14 G4 N4 C27
D4
C29
E2 E4
L11 C32
D5

C30

R6
M1
G5 N5 G7 N7 T3
C4 C5 C6 R4
C8
L2 L8
E5 C19 C21 C23 C25E7

D2
R2 L4 L6
T1 C10
M2

23
1 12 C28
19V C20 C22 C24 C26 _
G6 N6 G8 N8 D6 FL
380V 11
F1 19V
2
10
E6 L9
L10 C31
E8
3 9
120V 19V
4 8
P1(1) E1 G1 E2 G2 E3 G3 E4 G4 P2(2) A5(1)
19V P2(3) A4(2) A5(2)
6 7 P2(4)
A4(3) A5(3)
36V 13 P1(2) A5(4)
A4(5) A5(5)
5 10V A4(6) AC 1 2 0 V
14 P1(3) A1(1)
Driving Board A1(2) AC 1 2 0 V
A7(1) A1(3)
A7(2) A1(4) Re mo t e / Pa n e l

1
2
A7(3) A1(5)
P1(1) P2(2) A7(4) A1(6) P32 14 Gr ou nd
P2(3) A7(5) A1(7) 1 2
P2(4) A1(8) AC 2 0 V

P32
P32
P1(2) A7(6)
A1(9)
P1(3) E5 G5 E6 G6 E7 G7 E8 G8 3 4 5 SAW
A6(1)
Main Board A6(2) Tr act or Cont r ol r el ay
A6(3) 6 7 8 9
A6(4) Amp Di s pl a y
A2(1)
A2(2)
A2(3)
A2(4)
A2(5)

A3(1)
A3(2)

10 11 12 P/ X Shi f t
Amp of Re mot e Con t r ol
13 14
S1 S2 S3
Vol t of We l di ng

KG5

KG6
KG7 I l l u s t r a t i on of Pi ns of P3 2 Av i a t i on Pl ug Soc k e t

Mai n Ci r cui t Di agr am Front Panel Board

 3、main parts/components
z AUTOWELD-630

No. Mark Item Qty Memo.

1 K1 circuit breaker 1

2 D1 three phase rectifier module 1

Input anti-common mode

3 L1 1
inductor
4 L3 Capacitor filtering inductor 1
5 L11 Resonance inductor 1
6 C7 polypropylene capacitor 4
7 C9 polypropylene capacitor 2

8 N1～4 IGBT module 2

9 R1 Volt- sensitive resistance 1

10 C11～18 Ceramic dielectric capacitance 12

11 C32 polypropylene capacitor 1

12 T2 Main transformer 2

13 D3～4 Fast recovery diode module 4

14 T1 Power source transformer 1

15 L7 Output reactance 1
16 F1 Fuse 1
17 fuse 1
18 M1 axial airflow fan 1
19 toggle switch 1
20 Digital displayer 2

21 S1～2 thermal relay 2

22 potentiometer 3
23 ZKB Main control board 1
24 QDB Driving board 1

24
AUTOWELD-1000 I
No. Mark Item Qua. Memo.
1 K1 circuit breaker 1
2 three phase rectifier 2
D1～2
module
3 Input anti-common 2
L1～2
mode inductor
4 Capacitor filtering 2
L3～4
inductor
5 L10-11 Resonance inductor 2
6 polypropylene 8
C7～8
capacitor
7 polypropylene 4
C9～10
capacitor
8 IGBT module 4
N1～8

9 Volt- sensitive 2
R1～2
resistance
10 Ceramic dielectric 24
C11～26
capacitance
11 polypropylene 2
C31～32
capacitor
12 Main transformer 1
T2、T3

13 Fast recovery diode 6

D3～6
module
14 T1 Power source 1
transformer
15 Output 1
L7～8
reactance
16 F1 fuse 1
17 fuse 1
18 axial airflow fan 2
M1～2

19 toggle switch 1
20 toggle switch 1
21 Digital displayer 2
22 Thermal relay 2
S1～3

23 potentiometer 3
24 ZKB Main control board 1
QDB Driving board 2

25
 z AUTOWELD-1250 I
No. Mark Item Qua. Memo.
1 K1 circuit breaker 2
2 three phase rectifier module 2
D1～2

3 Input anti-common mode 2

L1～2
inductor
4 Capacitor filtering inductor 2
L3～4

5 Resonance inductor 2
L10～11

6 polypropylene capacitor 8
C7～8

7 polypropylene capacitor 4
C9～10

8 IGBT module 4
N1～8

9 Volt- sensitive resistance 2

R1～2

10 Ceramic dielectric capacitance 26

C11～26

11 C3-32 polypropylene capacitor 2

12 Main transformer 2
T2、T3

13 Fast recovery diode module 8

D3～6

14 T1 Power source transformer 1

15 Output reactance 2
L7～8

16 F1 fuse 1
17 fuse 1
18 axial airflow fan 2
M1～2

19 toggle switch 1
20 toggle switch 1
21 S1-3 Digital displayer 2
22 thermal relay 2
23 potentiometer 3
24 ZKB Main control board 1
25 QDB Driving board 2

26
Parts or components depicted above are standard outfits for AUTOWELD series inverter DC
SAW welders. Customers’ special needs can be stipulated in the contract according to the
real situation. Actual parts or components included will be in accordance with the packing
list.

Appendix A: Ordinary failures, probable cause & countermeasures

№ Trouble probable cause Remedies

Indicator
① Phase missing ① Check up power supply
lamp does not
light on,
② Fuse （5A）broken down ② Check up fan, power source transformer,
welder
doesn’t work main control board
③ Input cable break down
and axial
flow fan does ③ Check up cable
1 ④ Air switch tripped
not rotate
when Following components or ④ Consult to authorized maintainers
machine
switches on. parts may be damaged: When IGBT module is damaged, the

IGBT module, 3-phase components on the output part of driving board

rectifier module, output diode may be also damaged, thus need replacement.

module or others.

Instable Check up power supply

① Phase missing
welding
② Following parts may be
current Inspection and replacement
damaged: potentiometers
2
on the front panel.

③ Main control board

damaged

Welding Inspection and replacement

① Conductive wire broken
current is not
② Main control board
3 adjustable.
damaged

③ Control cable broken

27
28
 List For the spares of AUTOWELD-I Series Machines
AUTOWELD-630 I AUTOWELD-1000 I AUTOWELD-1250 I
DESCRIPTION Part Code Part Code Part Code
MAIN PCB PCB-AUTO-630I PCB-AUTO-1000I PCB-AUTO-1250I
DRIVE CARD PCB-DRV-01L PCB-DRV-01L PCB-DRV-01L
IGBT IGBT15012 IGBT10012 IGBT15012
INPUT BRIDGE MODULE IBDG004 IBDG004 IBDG004
OUTPUT RECTIFIER MODULE FRM001 FRM001 FRM001
FAN FAN006 FAN005 FAN006
DC CAPACITOR CAP001 CAP001 CAP001
AC CAPACITOR CAP004 CAP003 CAP004
SNUBBER CARD PCB-SNB-03 PCB-SNB-02 PCB-SNB-03
MCB MCB003 MCB004 MCB004
DIGITAL DISPLAY METER DSP001 DSP001 DSP001
INPUT SURGE SUPPRESSOR ISS001 ISS001 ISS001
SNUBBER CAPACITOR SCAP001 SCAP001 SCAP001
CONTROL TRANSFORMER CTRAX005 CTRAX005 CTRAX005
CONTROL TRANSFORMER FOR
CTRAX006 CTRAX006 CTRAX006
WIRE FEED MOTOR (BIG)
MOV MOV001 MOV001 MOV001
SNUBBER PCB FOR OUTPUT FRM PCB-SNB-OUT-01 PCB-SNB-OUT-01 PCB-SNB-OUT-01
OVERCURRENT PROTECTION PCB PCB-OC-630 PCB-OC-500 PCB-OC-630
MAIN TRANSFORMER MTRX009 MTRX010 MTRX011
FAN CAPACITOR CAP05 CAP05 CAP05
OUT PUT CONNECTOR OUTCON001 OUTCON002 OUTCON002
14 PIN CONNECTOR MALE CON14PNM CON14PNM CON14PNM
SHUNT SHUNT002 SHUNT004 SHUNT004
14 PIN CONNECTOR CABLE SIDE CON-14-CM-01 CON-14-CM-01 CON-14-CM-01
PANEL ON-OFF SWITCH SW-ON-OFF SW-ON-OFF SW-ON-OFF
TOGGLE SWITCH FOR SMAW/SAW
TSW01 TSW01 TSW01
(3P2W)
TOGGLE SWITCH FOR
TSW02 TSW02 TSW02
REMOTE/PANEL (2P2W)
RESET SWITCH RSW01 RSW01 RSW01
POTENTIOMETER FOR
CURRENT/STRIKING, POT001 POT001 POT001
CURRENT/ARC FORCE
KNOB FOR THE POT KNOB001 KNOB001 SW-ON-OFF
 TROLLEY
MAIN PCB FOR TROLLEY PCB-AUTO-TROLLEY-630I PCB-TROLLEY-AUTO-1000I PCB-AUTO-TROLLEY-1250I
DRIVE PCB FOR TROLLEY PCB-DRV-TROLLEY-01 PCB-DRV-TROLLEY-01 PCB-DRV-TROLLEY-01
CONTROL TRANSFORMER IN
CTRAX006A CTRAX006A CTRAX006A
TROLLEY
WELD ON PUSH SWITH WITH
SW-PUSH-01G SW-PUSH-01G SW-PUSH-01G
ELEMENT
WELD OFF PUSH SWITH WITH
SW-PUSH-01R SW-PUSH-01R SW-PUSH-01R
ELEMENT
ON-OFF SWITCH ON THE TROLLEY
TSW02 TSW02 TSW02
(2P2W)
TOGGLE SWITCH FOR FORWARD /
TSW02 TSW02 TSW02
REVERSE (2P2W)
TOGGLE SWITCH FOR WIRE
TSW05 TSW05 TSW05
INCHING (2P3W With Spring Return)
TOGGLE SWITCH FOR TEST /
TSW06 TSW06 TSW06
NORMAL / WELD (2P3W)
CURRENT SETTING POTENTIO
POT001 POT001 POT001
METER

VOLTAGE SETTING
POT001 POT001 POT001
POTENTIOMETER
TROLLEY SPPED SETTING
POT001 POT001 POT001
POTENTIOMETER
KNOB FOR THE POT KNOB001 KNOB001 KNOB001
WIRE FEED MOTOR WFDMTR-SAW-01 WFDMTR-SAW-02 WFDMTR-SAW-02
TROLLEY MOTOR TRMTR-01 TRMTR-01 TRMTR-01
7 PIN CONNECTOR (F) ON THE
CON-7-PM-F-01 CON-7-PM-F-01 CON-7-PM-F-01
TROLLEY CONTROL BOX
7 PIN CONNECTOR (M) FOR THE
CON-7-CM-M-01 CON-7-CM-M-01 CON-7-CM-M-01
WIRE FEED MOTOR CABLE
4 PIN CONNECTOR (F) ON THE
CON-4-PM-F-01 CON-4-PM-F-01 CON-4-PM-F-01
TROLLEY CONTROL BOX
4 PIN CONNECTOR (M) FOR THE
CON-4-CM-01 CON-4-CM-01 CON-4-CM-01
TROLLEY MOTOR CABLE
FLUX DISPENSER FLDS01 FLDS01 FLDS01
WIRE FEED ROLLER 1.6mm SAW-RLR-04 SAW-RLR-04 SAW-RLR-04
WIRE FEED ROLLER 2 to 2.8mm SAW-RLR-01 SAW-RLR-01 SAW-RLR-01
WIRE FEED ROLLER 3 to 4mm SAW-RLR-02 SAW-RLR-02 SAW-RLR-02

WIRE FEED ROLLER 4 to 5mm SAW-RLR-03 SAW-RLR-03 SAW-RLR-03

SAW-TIP 2.5mm TIP-SAW-2.5 TIP-SAW-2.5 TIP-SAW-2.5
SAW-TIP 3.15mm TIP-SAW-3.15 TIP-SAW-3.15 TIP-SAW-3.15
SAW-TIP 4mm TIP-SAW-4.0 TIP-SAW-4.0 TIP-SAW-4.0
SAW-TIP 5mm TIP-SAW-5.0 TIP-SAW-5.0 TIP-SAW-5.0
WIRE GUIDE BAR (TORCH) BRASS SAW-TRCH-01 SAW-TRCH-01 SAW-TRCH-01
TROLLEY WHEEL SAW-WHL-01 SAW-WHL-01 SAW-WHL-01
FRONT CAP SAW-FC-01 SAW-FC-01 SAW-FC-01
ROLLER ASSEMBLY AUTO-WF-RLRASB AUTO-WF-RLRASB AUTO-WF-RLRASB
EXTENSION ROD SAW-EXTN-200 SAW-EXTN-200 SAW-EXTN-200
14 PIN CONTROL CABLE CTR-CBLE-SAW-14 CTR-CBLE-SAW-14 CTR-CBLE-SAW-14