WARPP INTIG-200IDS User manual

Web Site: www.warpp.co.in
E-mail:[e-mail]·
Survey No. 35/16, Little LacyHouse, Unique Industrial Estate
Dhumal Nagar, Vasai (EL Distt. Palghar Maharashtra (India)
PIN- 401208
WARPP ENGINEERS PVT. LTD.
*Safety *
*Functions *
* Installation *
*Operation *
*Technology *
I · Owner's Manual 1
INTIG Series

spatter and slag burn the skin.
• Please use leather gloves, long-sleeved clothes, hats, spats & apron to avoid welding arc,
eye inflammation and spatter & slap can burn eyes.
• Please wear enough shading degree protection glass. Because the welding arc will cause
& Please avoid the welding are, spatters & slag to harm human body
protect gas gathering in the surrounding.
f) Please pay special attention to ventilation when working at.the bottom of container for
accidents.
G Please use standard exhaust equipment to prevent gas poisoning and suffocation
Please avoid the welding smoke and dust to harm the human body
• Please switch off the power switch when no use.
• Please use safety net when in aerial work.
activities place working.
• Please make sure your body in insulation between base metal when in damp, limited
but the insulation sleeve should notbe damaged.
• Please hire professional electrical person to connect welding machine and power supply,
provisions section of copper wire.
., Please hire professional electrical person to connect the welding machine and ground with
• Please don't touch charged parts.
,
To prevent electric shock or electric burns
e It is forbidden to make the welding power for use of thawing in the pipe.
• If uneven ground, please pay more attention to prevent dumping of welding machine.
• please hire the professional qualifications worker to install, maintenance and use.
• Irrelevant person don't enter the welding working places.
according to relevant standards and regulations.
• Input power supply, installation site, high pressure gas use and so on must be carried out
• Please be sure to comply with rules of specification, otherwise it may have an accident.
General Safety Caution
Security Warning

II
welding machine and sport, to prevent falling welding machine by part
• Using lift forklift or crane handlinq welder, personnel shall not front at the bottom of the
To prevent the movement of the welding machine cu~s
• Please use the company equipped with gas regulator, and used to abide by its rules.
high pressure gas cuts.
• When I open the cylinder valve, face do not close to the gas outlet, in order to avoid the
• Do not use a cylinder at high temperature or sunshine place.
• Cylinders should be reliable fixation, dumping can cause accidents.
To prevent dumping cylinders, gas regulator rupture
avoid the wire cuts.
• When send wire, do not use welding torch end near the eyes, face and body, in order to
rotating parts, etc.
• Do not use your fingers, hair, clothes, etc. Close to the cooling fan, wire feeding wheel
To prevent the rotation movement part cuts
• Please prepare a fire extinguisher
• Do not weld airtight container, otherwise it will break.
container, otherwise it will explode.
• Do not in the combustible gas welding or welding on containing combustible material of
• Cable must be fastened to the parent metal, otherwise it will cause fire.
• Welding place can not put combustible, otherwise weld spatter may cause a fire
• Should be ready for fire extinguisher in case of the fire accidents.
• Please don't weld the airtight container, otherwise it may break.
otherwise it may cause explosion.
• Please don't weld in the combustible gas or on the container with combustible material,
cause fire.
• It must make sure the welding cable and connected base metal is tight, otherwise it may
• It's not allowed to put combustible in the welding sit. The welding spatter may cause a fire.
& To prevent the accidents such as fire, explosion and burst accidents
'. ii

III
1. Public power supply system
Way ' sio reduce emission
k..,.".,,'_:_';'.. :..' ~ ._..:,_-:~,_~. :<" s_,, - ,, ' _ '_ ",,~.:, .. ,':i:-';;;., -,'."._,_:':'_'~"'~'__._._.,.,,'_- ._.J':\' ."";'_;:~:__' ,: .:.._ ...'; '_, ,:,_,,-.:.:.: ,,',_ "_. '''': _ .;_.__'_:') ;:' :' _ ."),_:'·~:'.w;;·",.·).-~':
8. Please arrange proper time for welding and other activities.
ensure the surrounding devices are compatible, it may require extra protective measures.
7. Please pay attention to the class of surrounding noise immunity to their devices. User should
6. Please check it has equipment used for calibration and testing or not.
5. Please consider the health of staff around such as wear hearing AIDS & heart pacemakers.
equipment.
4. Please check whether it has high security level equipment such as industrial protective
3. Please check whether it has computer and other control equipment.
2. Please confirm whether it has transmitting and receiving devices of radio & television.
equipment.
1. It is no other power supply cable, control cable & signal and telephone lines near arc welding
of electromagnetic disturbance in the surrounding area. Please consider the following matters:
Before the installation of welding equipment, the user should response to value potential problem
II Environment assessment advice
ensure the electromagnetic compatibility.
buildings. Because of the conduction & radiation harassment in these places, it is difficult to
4. Warning: Class A equipments can not apply to the public low voltage power supply of residential
except common low voltage power system for residential use).
3. The products described in the manual belong to class A (It can be applicable in all occasions
and correct method of use.
2. It can minimize the electromagnetic interference of arc welding equipmentsby proper installation
1, It has electromagnetic interference when welding.
II Overview
Electromagnetic Compatibility Notes
with the hook Angle should not be greater than 30 0.
'. ,
o when hoisting rope should be able to afford enough tension, shall not be broken.The rope

IV
6. Shielding
It can reduce the electromagnetic interference by shielding to the surrounding equipment &
cables. It can be shielding to the whole welding area for some special industries.
Arc welding equipment shall be in accordance with the -manutacturer's recommended way to
connect public power supply system. If the disturbance occurred, it need take extra precautions
such as adding filter in the public power system. For fixed arc welding equipment, user should
consider power supply cable shielding problem It can use metal pipe or other equal methods to
solve it. But it must keep the electrical continuity. Please make sure that it connected well.
2. Arc welding equipment maintenance
Arc welding equipment shall be in accordance with the manufacturer's recommended way for
routine maintenance. All the entrance, the door &cover should be shut down and tighten when
running. Arc welding equipment should not have any modifications, unless it's allowed in the
instructions. Especially it must follow the advice of manufacturer to adjust the spark gap of the arc
starting and arc stability devices.
3. Welding cable
Welding cable should be short and as close as possible. It's better to put it on the ground.
4. Equipotential connecting
Please pay special attention to the connecting of all metal objects. It's high dangerous when
metal objects connecting with work pieces. It may have electric shocks when operator contacts
these metal objects and electrode. So the operator should keep insulation with all these metal
objects.
5. Work piece grounding
For electric safety or work piece location, size ect. work piece may not be grounding such as ship
body and building steel shelf. It can reduce emission when artifacts connecting ground, but not
same each time. So be sure to prevent the increasing risk of electric shock & equipment damage by
work piece grounding. When necessary, it should connect the ground directly. But it's not allowed to
directly grounding. It can only select the suitable capacitor according to the regulations of the host
countries.

v
Troubleshooting and Maintenance(TIG) 13
Troubleshooting and Maintenance(MMA} ....·..·....·..·....··..·..····....·..·..·..······................ 12
Troubleshooting and Maintenance
Circuit board diagram 11
Technology introduction 10
Technical data 9
Technical data
TIG welding condition for instance 8
'--'
TIG welding operation 6
M1\1Aweldinz condition for instance 7
b
MMA weldinz operation 5
b
Safety protection and connection confirm .4
Operations (functions)
Installation environment and power 3
Installation and connection
Front panel and function _._....................... 2
Products introduction ..
About products
. ,
CONTENTS

Products can be used to welding stainless stee1,non-ferrous metals,key elements such as carbon steel
and alloy welding except aluminum and magnesium products.the products have been ~'(idely used in
piping.pressure vessel bottom welding and aviation.aerospace precision welding.can meet the highquality
requirements.
WS Series IGBT inverter DC tig wclding. machine adopt IGBT (Insulated-gate bipolar transistor) and
fast recovery diode and so on high power switching devices, inverter frequency reach 20KHz.Replacing
traditional transformer welding machine with compact high frequency transformer , high efficiency and
energy saving, with higher comprehensive economic and technical indicators.Products comply with
GB 15579.1-2013 Standard.
uction
.,

2
LCD display: display current 0
MMAfIIG switch: TIG and MMAfunction switch
4T/2T: Choose 4T/2T function
Power indicator: power on indicate the machine connect with power
Abnormal indicator: means welding device inside temperature is quite high, please check fan or stop
working to cool the machine
Post gas adjustment: adjust the time of post gas after welding
Welding current adjust: adjust welding current
IPort connect eart~
Connect with
power network
IOutput j
Gas output. connect with
gas pipe and torch
'IGas butpu~
4T,when press torch switch,
machine start to work, when
release the torch s\\'itch,'
" machine keep on working.
press again.machine stop
working
- . /
/i
. . -: I
Post gasad.ius~
~-
©
IGas inpu~
OFF
ON
Back Panel
•
Tig welding, connect with torch ~
s,vitchconnectio
ITorc~
tvlMA welding.connect
electrode holder TIG
welding, connect
workpiece through cable
TIG
MIlA
il1
l I
L_ Q__j
[Qutput 1
PQWER
ICurrent adjus~
/
I
o
MMA welding, connect •
workpiece through cable,
TIG welding connect
\., ~ I with torch
3-380V ~ -
Ir-P~o\~y~er~i--'nl
IAbnormal indicato~
Po\ver indicato~
mma/tig switchl
• Front panel

3
Warning:
In order to prevent electric arc welding process is not stable and cause damage to the machine,
and in order to ensure the safety of staff, please observe the following provisions:
• The power supply voltage fluctuation range ±10%;
• Capacity for each welding power source should be set rules automatically switch or fuse
circuit breaker (or leakage protector);
In the work place is wet, and in iron, steel shelves, please install the leakage protector.
-
I
INTIG-200IDS INTIG-?50IDS INTIG-315IDS
Input power 3phase AC3 80V
150Hz
Device Suitable power 8kVA 12kVA 15kVA
capacity
Input Fuse A 15A 15A 20A
protection No fuse protection 20A 30A
device 20A
Input ;;; 6mnl ;;; 6mm
2 ;;; 6111m 2
cable Output
I
35mm 2
50mm 2 50m111 2
Earth cla mp ;;; 10m111
2
)
;;; 10111m 2
;;; 10m111 -
7) The ground slope should be no more than 15 00
machine more than 30 ern.
6) Welding machine more than 20 cm away from the walls, the distance between the welding
5) To avoid in the environment of the strong air flow for welding operation;
3) Avoid welding in the sun or rain, don't let the water or rain infiltration into the weldinqrnachine
4) Avoid under the environment of dust area or containing corrosive gas welding work;
2) temperature should be between - 10 °C to 40 °C;
should not exceed 90%;
1) Welding operations shall be carried out in a relatively dry environment, air humidity generally
Installation and connection

4
• please check again whether welding system according to the manual "installation and
connection" unit connection is good.
Installation confirmation
• Avoid arc, spatter, etc to eyes and skin exposed parts of the injury, please wear special
fire overalls, gloves and safety shoes;
• With helmet
• Take the necessary measures for air, avoid inhaling the harmful gas formed during
welding
Safety protection
Operation ( function )
l

5
During welding, need adjust the current
according to welding result
6
Workpiece
Put the switch on the
position ofM~1A
3
Put the switch to the
position "ON"
=
MMAJTIG switch
4 I Adjust current according to the
I thickness of workpiece and
1 \ 1 ~~l;:;~re:f \\\:.~~~;Od :nachine
have current preset function,can
I adjust the current before starting
I welding, LCD display will show
I current
~5-1,-.-\~-e-I-dl-·.:
Welding current adiust switch
2T
MMA
111
! !
U, .J
TIG
o
"~l
o INTIG 250 IDS I
O.C ¥ , IGB(INVERTER' I!
II
,--------------.----,
Open the power distribution box i
1
MMA welding operation process:

6
Remarks: TIC welding, can cooling torch through adjusting post gas time,if the current is
large,contribute to cool torch through extend post gas time.
The above icon instruction and operation as following:
1. Adjust tvlMAJTIG switch to the position ofTIG.
2. Adjust the current according to requirements 0 WS series welding machine which have the function of
preset function,please adjust current through adjust the switch before welding.the LCD display will
show the current. welding.
Connect welding machine, gas pipe,torch, workpiece as above instruction
2
MMA 4T
C]
11
L_Q_j
TIG 2T
O.C
POWER
INTIG 250 lOS
\
,-- --. 1 \
G rJ o !\
, I I
~-- \
(-
\
\
TIG WELDING PROCESS

7b) Multil'ayer m'Lflti-channelwelding
a) multi-channel welding
Welding current:
Welding current manual arc welding is the main process parameters.When the welding
current 'is too big, electrode tail to red, of the coating to failure or avalanche, mechanical
protection effect, can cause porosity.ln addition, can also lead to bite side, weld defects such
as burning through. Excessive use of welding current, still can make joint heat affected zone,
coarse grains, welding joint of plastic.Welding current is too small, can cause lack of
penetration, incomplete fusion, defects such as porosity and slag, and low
productivity.Therefore, select welding current, first of all, should guarantee the welding quality,
second larger electric current, should be adopted in order to improve labor productivity.
Welding current is generally can be preliminary selection according to the electrode
diameter (see chart 2).Also, further consideration of thickness, joint type, welding position,
welding environment factors such as temperature, workpiece material and
electrode.Thickness is larger, T and lap welding environment at low temperature, all because
of the high thermal conductivity, welding current to a bigger one.Flat position welding, in order
to easy to control weld, the welding current is smaller.Stainless steel welding, in order to
reduce the degree of influence of intergranular corrosion, welding current should be
smaller.Some important structure, even heat input range determined by experiment, and then
according to allow heat input welding current range is determined.
Welding current preliminary selected check after welding, weld and defects, and can only
be determined.With the performance requirements such as boilers, pressure vessels and
other important artifacts, passes through after the qualified welding procedure qualification,
and to finally determine the welding technology of the welding electric current and so on.
Thick plate welding, generally want to open groove and USES the multi-layer welding or
multi-layer welding, as shown in figure 1.Multi-layer welding and multi-layer welding head of
microstructure is fine, narrow heat-affected zone.Therefore, the plasticity and toughness of joint
are good.
,---
Rod diameter 1.6 2.0 2.5 3.2 4 5 6
(mm)
current CA) 25-40 40-65 50-80 100-130 160-210 200-270 260-30
.
0
Table 2
Thickness of work ::;4 4-12
~
piece (mm)
Diameter (mm) Not more than work 3.2-4 ;::4
piece
Table 1 Rod chosen
Electrode diameter generally choose according to the thickness of work piece (see chart 1).Th!:!first layer of
the open groove welding and the flat positionwelding smaller electrode diameter should be adopted.For important
structure should beaccordingto the provisionsofthe weldingcurrent range(seetable 2) to determinethe electrode
diameter.
The electrode diameter:

8
~ ~
Tungsten
Thickness electrode Welding cutTent Argon gas flow Welding speed
(mm) diameter (A) (Umin) (cm/min)
(mm)
1.0 2 40 -6 0 8- 10 30-42
1.5 2 60 -80 10 - 12 21 - 40
2.0 2~3 80- 110 1 2- 14 2 3 -3 7
. -
2.5 2~3 11 0-120 12-14 23-37
~
Table V titanium and its alloys thin plate Tiz weldinz condition instances
Tungsten
Thickness electrode Welding current Argon gas flow Welding speed
(mm) diameter (A) (Umin) (ern/min)
(mm)
1. 0 27 - 2 8 3- 4 1 2- 4 7
1.2 2 1 5 3- 4 2 5
1.5 2 5 - 1 9 3-4 8- 32
Table IV Stainless steel sheet Tig welding condition instances
Following table IV and table V list stainless, titanium and its alloys thin plate Tig
w-eldingcondition instances
II DC argon arc welding for instance:
.. Gas flow: Under certain conditions, there is an optimal range of gas flow, at this point, the gas
protection effect is best, effectively reserve is the largest. If gas flow rate is too low, poor sriffness of
the air, eliminate ambient air capacity is weak, reduce the effectiveness of protection. Gas flow is too
large, easily become turbulent flow, make the air in, will also reduce the effectiveness of protection.
Tungsten Current (A)
electrode Tip diameter Tip angle
diameter
Cmm )
(0 )
DC tig welding
(mm)
--
1. 0 0. 1 25 1 2 2~15
1.0 0 . 25 20 5 ~ 30
1. 6 0 .5
I
25 8~50
1.6 0 . 8 30 1 0 - 70
2.4 0 . 8 35 1 2 - 90
2 .4 1 . 1 4 5 15-150
3.2
l.l 60 20 - 20 0
3.2 1.5 90 25 ~ 2 50
.
Welding current: welding current are the main parameters of welding penetration,it is mainly
selected according to workpiece material and thickness,joint type,welding position.
Tungsten electrode diameter and tip shape: Choose tungsten electrode diameter and tip shape
according to tip shape,more details please check following table.
Table III Recommend current according to tungsten electrode diameter and tip shape '.
electrode diameter and tip shape and shielding gas flow,
Tungsten argon arc welding technological parameters mainly include welding current.tungsten
,.- ,

9
• Rated .duty cycle: also called nominal temporary load rate, refers to the percentage of
rated load working time accounts for the selected time.For example, 40% in 10 minutes,
4 minutes to work in the welding current rating, 6 minutes to rest;
• 100% load current: refers to the temporary load rate of 100% (rest), the maximum
current may be used.For example: 100% load current is 200 a, refers to the welding
power source when the welding current, within the use 200 a can work long time (rest).
Note: if more than the rated load, the continuous use may cause performance degradation or
damage to the machine.
I~TIG-200IDS Ii\TIG-2S0IDS Ii\TIG-31SIDS
Input Voltage 3Ph as e 3 80 V± 10 % 50Hz
Rated input capacity (KVA) 7.9
11.2 13.8
Rated duty cycle 40% 40 % 4D %
100'Yoload current (A) 158
199
215
Rated welding current (A) 250 315 340
j
No-load voltage
(V)
68 68 68
c ~ c:· c
Output current (A) 20 -250 20 -315 20 -340
Post gas (S)
11 1
Insulation class F
/
F F
Cooling method Gas-coo led Gas -coole d
Gas-cooled
Dimcnsion (L X \V X H) (mm)
480 x256 x435 480x256x435 480x256 x435
Weight (Kg)
28 30 30

10
Static external characteristic of welding power source output
,.
IH(A)
20(lO)V
UH=20( 10)+0.041
UH .v:
75V
Static External Characteristicofwelding power source
Block schematic diagram
The control circuit controls output cunent through adjusting pulse-width of driving signal.The current
negative feedback signal obtained from current diverter is magnified and then feeds into the inverse input
terminal of error amplifier on the special pulse-width modulation integrated circuit to (;'ontrol the
conducting time of 1GBT.Through this way,the stability o'f output current is maintained and. the dropping
extemal characteristic of inverter is obtained eventually.
• Control circuit:
WS IGBT series inverter DC arc welding machine adopt the full-bridge inverter main circuit.the
3-phase alternating-current supply is rectified via 3-phase power frequency and then transmits to IGBT
inverter where covert them into medium-frequency(20KHZ)AC.after this,the medium-frequency AC goes
through medium-frequency transformation and rectification,and then through filtration and current
negative feedback control,in result, the output continuous adj usting current is obtained to satisfy the
welding needed.
II l\'lain circuit:
===~,
,.:r
,
DC output

IIII
I
~
+

l2
• Note: If any problem can not be fixed, please contact our service department or distributor
prornptly.or arrange the professional person maintenance.please do not repair without
authorization
Reason Troubleshooting
l.
Three-phase rectifier bridge 1. Replace
damaged 2. Replace
2. IGBT broken
3. Replace
).
Filter capacitor is damaged
l.
Lack phase l. Check input power
2. Control transformer broken 2. Replace
" 0 '
3.
Main control board broken 3 .
Replace
4. Air switch broken
4.
Replace
l.
Main board broken'
l. Replace
2. Control board broken 2. Replace
3. IGBT broken
3 . Replace [GBT
4. Diode broken
4.
Replace diode
S . LCD display broken
S . Replace LCD display
.
l. L3 reactor interturn short 1. Replace or clear tum to tum
circuit or insulation short circuit
2. Output current too small 2. Increase output cun'ent
3. Polarity on the wrong side
3.
Replace polarity
4. Control board broken
4.
Replace
.
1.
Cooling fan broken, 1. Replace
temperature of inverter too
2. Keep welding machine
high no-load operation, so that
2. Overload for a long period the internal temperature decreases
of time.relay start to .then you can continue to work
work.achieve thermal
protection
Suddenly there is no
weldingcurrent in the
welding process
After booting, unloaded pro
perly, but ..there was
a broken arc welding or eu
rrent is very small
After booting,without
no-load voltage,and power
indicator is on
After booting.without
no-load voltage,and power
indicator is not on
Welding machine is connec
ted to power, the air switch
tripping
Trouble
TrollbfeshQQting'~and 1\1.aintehance·
.... _ :,..; _.__;;;;.....__-,:.;:.:.;. "_.~,,. ~ ..__~,.,;,,;~,,'.-:c,_- _,, _ " _'__,,"'__ ~_,-",,·vv • ,~.,.. .:" ~

13
• Note: If any problem can not be fixed, please contact our service department or distributor
prornptly.o r arrange the professional person maintenance,please do not repair without
authorization
I , check coil voltage or
replace val ve;
2, Repair or replace;
I, Valves broken;
2, Main control board broken;
No argon gas output
spnng;
1, Repair or replace;
2, Clear valve;
30pen the valve, elongate
of stretch;
3, Valve spring fatigue, lack
1, Main control board broken;
2, Unclear in valve;
completely
Argon gas can not closed
tungsten;
1, Clear workpiece;
2 -, Replace or sharpen
1, Repair or replace;
2, Repair or replace;
1, Connect well;
2, Replace torch switch ,
connect plug well;
tungsten electrode too obtuse;
I, Too dirty on workpiece;
2, Poor quality tungsten or
broken
or high voltage capacitor
2, High frequency transformers
I, Main control board broken;
output and workpiece;
2, Torch switch or plug
broken.not work when press
torch;
I , Not connect well betw een the
ARC starting difficult
No high frequency
No Arc
3, Replace;
work overloaded;
1, Replace fuse;
2, Fix fan and welding
machine can not
1, Replace;
1, Fuse broken;
2, Fan stop work or overload
\\ ork long time.temperature
relay start to work;
3, Temperature replay broken;
damaged;
lThree-phase rectifier bridge
No output c urrent
Welding machine is connected to
power, the air switch tripping
Reason Troubleshooting
Trouble
l
II
::_.:
JI
~