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INTIG- PULSE
Digital Inverter
MMA/TIG / Pulse TIG
Welding Machines
Operating manual
WARPP ENGINEERS PVT. LTD
.
TH
B-1005, 10
FLOOR, WESTERN EDGE II, NEAR METRO MALL,
OFF.WESTERN EXPRESS HIGHWAY, BORIVALI (E,)
MUMBAI-400 063.
TEL: 91-22-28542272 /73/74 / 32404434 Fax91-22-28542275.
E-mail:sales@warpp.co.in Web Site: www.warpp.co.in
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Summary of Contents for WARPP INTIG-PULSE series
- Page 1 INTIG- PULSE Digital Inverter MMA/TIG / Pulse TIG Welding Machines Operating manual WARPP ENGINEERS PVT. LTD B-1005, 10 FLOOR, WESTERN EDGE II, NEAR METRO MALL, OFF.WESTERN EXPRESS HIGHWAY, BORIVALI (E,) MUMBAI-400 063. TEL: 91-22-28542272 /73/74 / 32404434 Fax91-22-28542275. E-mail:sales@warpp.co.in Web Site: www.warpp.co.in...
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Page 2: Table Of Contents
Thank you for selecting WARPP brand inverter welding machine. In order to keep THE operator 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. -
Page 3: Usage& Features
Usage & Features IN TIG series pulse TIG welders include 315 A, and 400A types, can Perform DC TIG, Pulse TIG, and DC MMA, used for mild steel, alloy steel, stainless steel, Copper, Silver, and Titanium welding. This series welder enjoy reasonable static characteristic and sound dynamic characteristic as well as comprehensive functions: Soft switch Inverter, high efficiency and reliability, small size, light weight and portable... - Page 4 Avoid being electric shocked and burnt Never touch on the hot electrical units. Please instruct the authorized electrician to ground the welder case by using proper sized copper wire. Please instruct the authorized electrician to connect the welder to power supply by using proper- sized, well-insulated copper wire. When operating in the damp, space-limited area, must ensure well-insulated between body and work piece When operating at the high-rising location, must ensure safety by...
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Page 5: Installation
Avoid being hurt by moving parts Never let the finger, hair, and cloth near the rotary cooling fan and wire feeder rollers. When feeding wire, don’t let the bottom of gun near your eyes, face and body, to prevent being harmed by wire. Avoid gas bottle falling or gas regulator breaking Gas bottle must be firmly fixed on the ground, else if injure will exerts on. - Page 6 (4) The distance between welder and wall must be more than 20cm, between welders more than 10cm to ensure enough heat radiation. When using water cooled gun, must be care of not being frozen. 2． Requirement of input supply: (1) Input volt must be standard sine wave, effective value 350 ~ 465V,frequency 50Hz/60Hz Unbalance degree of three phase volt must be no more than 5% Power supply:...
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Page 7: Principle In Brief
4.1 For MMA welding: (1) Connect welding cable to welding machine tightly. (2) Reset the circuit beaker on the rear panel of the machine (3) Connect the input power cable to the disconnected switchboard, then power on. 4.2 For TIG welding: (1) Well-connect welding cable with welder (+), and well-connect TIG torch with welder (-). -
Page 8: Operating Instruction
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 result in energy saving. - Page 9 1.2 Rear panel illustration and parts number reference Fig.5: Rear panel 1.3 Control panel The machine’s control panel drawing for mode selection and parameters preset shows as figure (6). Control panel includes LED alphanumeric display, tuning knob, diode indicator lamps. Fig.6: Control panel 1.3.1 Mode selection and parameters preset “TIG /MMA”...
- Page 10 Switch between “2- Step” (Non-Autolock) and “4-Step” (Autolock) on TIG “2-step” refers to start welding while push torch trigger, stop welding while releasing “4-step” refers to starting-arc current while firstly pushing torch trigger, then current slopes up to where can welding normally while releasing it. When welding finished, current slopes down to where stops arc and stands while pushing it again, then stops output current while releasing it.
- Page 11 8、Pulse ratio: time ratio between length of peak value current and length of whole single pulse, can be used for controlling penetration in all-position or thin sheet welding. 9、Pulse frequency: frequency of pulse output. 10、Base current: current of arc-stand in pulse output. 11、Down –slope: time of welding current slopes down 12、Crater filling: current of crater filling 13、Post-gas flow: time of gas flow after ending welding...
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Page 12: Welding Parameters
Display 806: water insufficient protection 1.3.4 Power on/off lamp: display red when power on 2. Procedures of TIG welding 2.1”2-step” push torch trigger pre-gas flow arc-start arc-starting current constant current TIG arc welding up-slope normal welding pulse TIG arc welding release torch trigger down-slope stop arc... - Page 13 3.1 TIG welding parameters Tungsten Sheet wire Welding Gas flow electrode Clearance thickness diameter current rate diameter （mm） （mm） （mm） （A） （L/min） （mm） 1.0-1.6 0-1.0 5-30 1.0-1.6 0-1.6 10-30 1.0-1.6 0-1.6 50-70 1.6-2.4 1.6-2.4 70-90 1.6-2.4 1.6-2.4 90-120 7-10 1.6-2.4 120-150 10-15 2.4-3.2...
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Page 14: Repair& Maintenance
Repair & Maintenance Warning: Should not open up case freely, the max volt inside machine will be 600V. Must take safe precautions to prevent from being electric shocked while in maintenance. 1. Apparently misunderstand failures Normal phenomenon occurs in welding (1) Welder doesn’t work while in pretty low input volt. - Page 15 3. Troubleshooting 3.1 Routine checking procedure prior to maintenance 1. Check if the input volt has the phase to be lost, and range are between 340-420V. 2. Check if the power input cables are correctly and firmly. 3. Check if the ground leads are connected correctly and firmly. 4.
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Page 16: Technical Data
Technical Data 1. Main technical parameters Item IN TIG-315 P IN TIG-400 P Rated output volt 3 phase 350 ~ 465 V/50Hz Rated input volt 13.8KVA 18.4KVA Rated input current Duty cycle 60％ Pre-flow gas 0.1-15s Striking arc current 10－160A Slope up time 0.1-10s Arc-starting current... -
Page 18: Appendix A: Ordinary Failures, Probable Cause
Appendix A: Ordinary failures, probable cause & countermeasures № Trouble Probable cause Remedies ① inspect power ① Phase missing source Indicator lamp does not ② Fuse size（2A） ② Inspect fan, power light on and doesn’t work source transformer and breaks when machine switches on. -
Page 19: Front Panel
Front Panel Encoder for Parameter Encoder for Selection (ENC01) (ENC01) Parameter Setting (ENC01) MCB (MCB001) Output Connector Output Connector EURO Type (OCN- 2 Pin Connector EURO-S) Male (CON2PNM) - Page 20 Rear Panel Rear Panel Fan (FAN002)
- Page 21 Top View Drive Card Display PCB (PCB- (PCB-DRV- DSP-TIGPLS-01) 01U) Main PCB (PCB- Control TIGPLS-315I) Transformer (CTRAX004)
- Page 22 Right View Over Current Protection t P t SNUBBER CARD SNUBBER CARD PCB (PCB33) (PCB-SNB-04) Capacitor Capacitor (CAP002) IGBT (IGBT50R12) Input Bridge Module (IBDG003) HF PCB (PCB-HF-01) Water Flow Switch (WFS-50W) DC Capacitor DC Capacitor HF T HF Transformer Fan Capacitor Solonaid Valve (CAP001) (MOV001)
- Page 23 Left View Insulation Transformer Secondary (INSTRX001) Thrust Coil (S-THCL) (S THCL) Main Snubber Transformer PCB for (MTRAX006-P) Output FRM (PCB-SNB- (PCB-SNB- OUT-01) Output Rectifier Isolation PCB M d l Module (PCB-ISO-02) (FRM001) Output Choke Current Sensor (CHK001) (CS001)
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Page 24: Spare Part List
List for the spares of INTIG-PULSE Series Machines INTIG-315 PULSE INTIG-400 PULSE DESCRIPTION Part/Code SPEC. Part/Code SPEC. MAIN PCB PCB-TIGPLS-315I PCB-TIGPLS-400I DRIVE CARD PCB-DRV-01U PCB-DRV-01U PCB-DSP-TIGPLS- PCB-DSP-TIGPLS- DISPLAY PCB IGBT IGBT50R12 IGBT50R12 SNUBBER CARD PCB-SNB-04 PCB-SNB-04 50R12SNB ( 50 50R12SNB ( 50...
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