WARPP INTIG 250 PULSE Manual

OPERATION & MAINTENANCE MANUAL
MODEL - INTIG 250 PULSE
DC Pulse Argon Arc Welding Machine
WARPP ENGINEERS PVT.LTD.
SUERVEY NO. 36/15, UNIQUE INDUSTRIAL COMPLEX ,
DHUMAL NAGAR,VASAI (E) DISTT. PALGHAR
MAHARASHTRA (INDIA) PIN –410208
Contact No. 08551819944, 8551817869, 851817744.
E mail: [e-mail]
Website :www.warpp.co.in

INTIG 250 PULSE DC Pulse Argon WeldingMachine
Safety Depends on You
Our arc welding and cutting equipment are designed and built with ample safety consideration. However, proper
installing and operating the machine can increase your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL
THROUGHOUT.
Special Attention (Very Important):
1. BE SURE TO AVOID THE WELDING MACHINE FALLING DOWN WHEN IT IS PLACED ON
THE GRADIENT GROUND.
2. IT’S FORBIDDEN UNFREEZING THE PIPELINE BYTHE WELDING MACHINE.
3. THE SHIELD RANK OF THIS SERIES OF WELDING MACHINES IS IP23E.
4. The rated duty cycle of this welding machine is 60%, there is protection function when the
machine is overloading used. When it’s protected and no power output, must wait and after
the temperature back to normal, then use again.
5. When welding current is lower than 200A, the argon gas flow is 4-8L/min, when welding
current is higher than 200A, the argon gas flow is8-15L/min.
Purchase Date：
Serial Number：
Machine Type：
Purchase Place：

INTIG 250 PULSE DC Pulse Argon WeldingMachine
1 Electric shock: The welding circuits are not insulated when welding. If you touch the two output
electrodes of the machine with your bare skin at the same time, it will lead to electric shock,
sometimes even fatal dangers. Users need to follow the items below to avoid electric shocks:
 If possible, lay some insulating materials, which are dry and large enough, inyour
working field. Otherwise, use the automatic or semiautomatic welding machine, DC welding
machine as possible as you can.
 Components in the automatic and semiautomatic welding machine such asthe
welding wire reel, feed wheel, contact tip and welding head are all electriferous.
 Always be sure the machine has been connected perfectly to the work piece with the work
cables and should be as close as possible to the workingarea.
 The work piece should be grounded perfectly.
 Make sure that the insulating material of the electrode holder, the grounding clamp, the welding
cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
 Never dip the electrode in water for cooling.
 Never touch electriferous parts of two welding machines at the same time, because this voltage is
supposed to be two times of welding voltage while the grounding mode is not clear.
 While working high above the ground or other places having the risk offalling,
please be sure to wear safety belt to avoid losing balance caused by electric shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks and the rays of the arc,
pay special attention to the filter glass, which must be conformable to the national standard.
 Use clothing made from durable flame-resistant material or sailcloth to protect your
skin from hurting by the arc rays.
 Remind other nearby personnel before working lest arc rays hurt them by accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous to health. Avoid breathing
these fumes and gases. While working in limited room, use enough ventilation and/or exhaust to
keep fumes and gases away from the breathing zone, or use the respirator. Do not weld at the
same time when using of degreasing, cleaning or spraying operations. The heat and rays of the
arc can react with these gases to form phosgene, a highly toxic gas,.
 Some protective gases used in welding might displace the oxygen in the air, and can lead to
hurt or even death.
 Read and understand the manufacturer’s instructions for this equipment,and
validate the health certification of consumptive materials, make sure they are asepsis and
innocuity.
4 Spatter: Spatter can cause fire or explosion.
 Remove fire hazards from the welding area. Remember that spatter from welding can easily go
through small cracks and touch fire hazards. Keep the safety of all kinds of lines going though
welding area, including hydraulic lines in thewild.
 Where compressed gases are to be used in the field, special precautions shouldbe
used to prevent explosion.
 When not welding, make certain that no electriferous part is touching the work piece or the work
stage. Accidental contact can create a fire hazard.
 Do not weld containers or lines, which are not proved to beinnocuity.
 It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until
the proper steps have been taken to insure that there are no flammable or toxic gases there.
 Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers,high
shoes and a cap over your hair to prevent from burning by spatter. Wear the ear shield when
performing sideways or face up welding. Always wear safety glasses with side shields when
being in a welding area.
 The welding cables should be as close to the welding area as possible, andthe
short, the better. Avoid welding cables going through the building framework, lifting chains, AC or
DC cables of other welding machines and appliances. The welding current is strong enough to
damage them while having short circuit with them.

INTIG 250 PULSE DC Pulse Argon WeldingMachine
5 Cylinder: Damage of it might cause explosion.
 Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
 Make sure that the installation of cylinder is by the wall and bundled tightly bya
chain.
 Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
 It is forbidden to touch cylinder with the welding clamp or the workcables.

INTIG 250 PULSE DC Pulse Argon WeldingMachine
CONTENTS
1. Overview
2.Working condition and environment
3. Specification and parameters
4. System description
5. Front Panel description
6. Installation
7. Operation
8. Maintenance
9. Trouble shooting
10.Spare Parts List

INTIG 250 PULSE DC Pulse Argon WeldingMachine
1. Overview :
INTIG 250 PULSE series TIG welding machine adopts the high power IGBT, the invert
frequency reaches 20KHZ. The small mid-frequency transformer replaced the heavy industrial
frequency transformer, which with advantages as: high efficiency, low non-load loss, stable current,
energy saving, material saving and high reliability etc.
INTIG 250 PULSE series TIG arc welding machine has all functions required by welding
technique: high frequency arc striking, gas pre-send (adjustable), initial current (adjustable), current
up-slope (adjustable), current down-slope (adjustable), crater current (adjustable), gas post-off etc.
Except for DC welding mode, the INTIG 250 PULSE series has pulsed welding mode, the advantage
is: welding current high and low interchange working, so it has better arc and stronger weld seam
which is decided by the welding machine parameter.
This series of welding machine can used for almost all metal work pieces except magnesium-
aluminum alloy, such as stainless steel, pipeline, boiler, aerospace equipment etc.
2. Working condition & Environment:
a. Input Power
i. The exact input voltage wave shape should be sine wave, the frequency
fluctuation should be no more than +1% of the rated value；
ii. The fluctuation of input voltage must be within +15% of the ratedvalue;
iii. The unbalance rate of input voltage should be ≦5%.
b. Environment
i. Ambient temperature ranges:Welding temperature range: -10℃~+40℃,
Transportation and Storage temperature range: -25℃~+55℃
ii. Relative humidity: ≤50% @ 40℃
≤90%@20℃
iii. The dust, acid, corrosive gas or material around should not exceed the
normal content, except the one produced during welding;
iv. Operating altitudes: less than 1000m;
v. Wind speed should be no more than 1m/s;
vi. Keep the machine inside and dry all the times, do not locate where the
machine is exposed to direct sunlight and rain.
2. Specification and parameter
Model
Item
INTIG 250 PULSE
Input power
3 ～ 415V±15 ％ 50／60 Hz
Rated Input
Capacity
(KVA)
TIG
7.5
MMA
10
Rated Input
Current(A)
TIG
10
MMA
14
Rated
Output
Voltage (V)
TIG
17.6
MMA
27.6

INTIG 250 PULSE DC Pulse Argon WeldingMachine
Rated
Open
Circuit
Voltage (V)
TIG
75
MMA
75
Power
factor
TIG
0.93
MMA
0.91
Efficiency (η)
TIG
82%
MMA
86%
Rated Duty Cycle
(%)
60%
Hot Start Current
Range (A)
0 ～ 120
Arc Force Current
Rage (A)
0 ～ 120
Gas Pre-flow Time
(S)
0 ～ 5
Arc Striking
Current Range (A)
5 ～ 250
Current Up-slope
Time (S)
0 ～ 10
Welding current
(A)
5 ～ 250
Pulse Peak Current
Range (A)
5～250
PulseBackground
Current Range(A)
5～250
Pulse Frequency
Range (Hz)
0.2～99.9
Pulse Duty Ratio
Range
5%～95％
Current Down-
slope Time Range
(S)
0 ～ 10
Crater Current
Range (A)
5 ～ 250
Gas Post-flow
Time (S)
0 ～ 20
Cooling mode
Air Cooling
Isolation Grade
H

Ingress Protection
IP23
Dimension
(L*W*H)
460X270X390
Net Weight (KG)
24
INTIG 250 PULSE DC Pulse Argon WeldingMachine
4.System description
a. Working principle
INTIG 250 PULSE series welding machine adopts IGBT as the main circuit switch. The three-
phase AC input power inverted to 20KHz mid-frequency current through the rectifier of the full
bridge. Then through the filter and current negative feedback control to get the constant
adjustable weldingcurrent.
The control circuit will control the output current through the adjusting of the pulse width. The
negative feedback signal, which is the real welding current get from the output current sensor,
put into the special PWM circuit after comparedwith the current adjust signal, then output the
driving pulse to control the IGBT, so that the output current will keep stable to get descending
externalcharacteristic.
This machine has functions of gas pre send, gas post cut off, HF arc striking, current up-
slope, current down-slope. All these functions are controlled by the digital signal controller
automatically.
b. Working circuit diagram

INTIG 250 PULSE DC Pulse Argon WeldingMachine
5.Front Panel description
PARAMETER SETTING FOR INTIG 250 PULSE
DESCRIPITON OF INDICATION AND SWITCH :
This LED indicates the welding is in the MMA or SMAW mode .
This LED indicates the welding is in the TIG mode .
This LED indicates the welding is in the PULSE mode .
This LED indicates the welding is in the 2 Trackmode. ( Applicable
only in TIG Mode ).
This LED indicates the welding is in the 4 Track mode .
(Applicable only in TIG Mode )
PREFLOW :This LED indicates the preflow time before the GAS.
START CURRENT : This LED indicates the Start Current or `Hand
3. Arc welding current state output.
UP SLOPE :This LED indicates the time taken for machine to reach

INTIG 250 PULSE DC Pulse Argon WeldingMachine
4. it welding current from its start current.
PEAK CURRENT :This LED indicates the Welding current during
5. welding & arc welding normal output state.
PULSE FREQUENCY :This LED indicates the operating
6. frequency of PULSE output ( applicable in PULSE MODE ).
DUTY CYCLE :This LED indicates the ON / OFF TIME OF pulse
frequency output.
BASE CURRENT :This LED indicates the base current during
7. off time of pulse output ( Applicable in PULSE MODE).
DOWN SLOPE :This LED indicates the time taken for machine to
reach its Arc current from its welding current.
STOP CURRENT : This LED indicated the current value before the are
welding quenching.
POST FLOW :This LED indicates the continues flow timing after
welding.
PROCESS :This SWITCH is used for selection of MMA , TIG Or PULSE
WELDING.
MODE :ThisSWITCH is used for selection of 2 Track Or 4 Track welding.
VOLT/AMP :This is digital display for voltage and current display.

INTIG 250 PULSE DC Pulse Argon WeldingMachine
Item
Model
Sectional area of
power cable (mm2)
Air switch
(A)
Sectional area of
ground cable
(mm2)
INTIG 402 PULSE
≥2.5
40
≥25
6.Installation :
a. The power supply of this machine is 3~ 415V 50/60HZ, user should prepare the switchboard
and install the air switch (breaker) and ground cable. Connect the green-yellow wire of the
three-phase input cable to the grounding wire on the switchboard reliably according to the
below table:
b. - Connect the argon gas to the air inlet through reducing valve (Use Ф6 air hose);
c. - When work as Tig, connect “+” terminal to work-piece firmly; when work as MMA, connect
the “+” terminal according to differentelectrode;
d. -Weldingtorch connection: Air cooling torch: connect the torch gas hose withthe “Gas outlet
“on the welding machine, connect the torch control plug with the “Torch Switch“on the
welding machine, connect the main cable with “-” terminal on the welding machine;
7. Operation :
e. Turn on the power switch, the welding machine start to check by itself, the digital meters
and indicators on panel lights on together for 1.5 seconds and lights off 0.5 seconds, then
display normally;
f. - Press the torch trigger switch & adjust the argon gas flow according to different welding
technology.
g. - Set the “pulse on/off”according to different welding technology, press the “Pulse current”
key to do that. If choose “pulse off”, set the welding current by adjusting the encoder; if
choose “pulse on”, set the “peak current”, “PWM ratio”, “Pulse frequency”and “base
current”, press left/right selection key to choose the parameters need to be set;
h. - Set the “gas pre-flow time”, “arc starting current”, “Up-slope time”, “down- slope
time”,”crater current” and “gas post-flow time” according to different welding technology;
i. Welding operation:
i. Two steps: take the tungsten electrode close to the work-piece about 1~3mm,
press the welding torch switch without loosen, it startB s weld normally after current
up-slope, when finish welding, loosen the welding torch switch, the current down-
slope to crater current. After welding, please don’t take away the welding torch at
once, should wait the gas post-flow time finish, to protect the weld crater and
tungstenelectrode;
ii. Four steps: take the tungsten electrode close to the work-piece about 1~3mm,
press the welding torch switch without loosen, after arc striking, find the welding
position, then loosen the welding torch switch, the welding current will increase to
the set current, it starts weld normally , when finish welding, press the welding
torch switch again, the current down-slope to crater current, loosen the torch
switch, arc stop and the welding finish. After welding, please don’t take away the
welding torch at once, should wait the gas post-flow time finish, to protect the weld
crater and tungsten electrode
j. MMA: connect the work-piece too “+’”-” according to different welding technology; after
connecting the ground cable and electrode holder, set the welding current/arc force
current/hot starting current according to electrode
diameter; before welding, the welding machine output 18V ～20V DC voltage, when the
instant moment that electrode touch the work-piece, the welding
machine output welding current and start the normal welding, after arc stop, the open
circuit voltage will remain 1 second.

INTIG 250 PULSE DC Pulse Argon WeldingMachine
8
Maintenance :
For safety, the welding machine should be maintained and checked regularly, when check the
inner or outside connecting terminals, do cut off the power distribution box( or the breaker).
Daily notes:
Check if there is any abnormal noise, vibration or smell;
Check if there is abnormal heating on the joint of cables;
Check if the cooling fan working well;
Checking items in 3~6 months period:
The electrical connection: check the fastening screws on cables, to find if there is any
loosen, rust or poor connecting and so on;
Grounding cable: check if the welding machine is groundedwell
Clean the dust inside the machine: this work should be done every half a year, with dry
compressed air.
Adjust the high frequency: never touch the spark electrodes (the distance of the spark electrodes
should be 1mm), when the electrode surface is rough or polluted, polish it. Before touching the
electrodes, please discharge them, and then adjust the distance to 1mm.
9. Trouble shooting:
Problem
Possible reasons
Trouble shooting
1. When machine
energized, the circuit
breaker trip
Three phase bridge rectifier
was may damage
Replace the rectifier；
IGBT damage
Replace IGBT
2. No output current
Cooling fan not work, or overload
cause overheat, then temperature
relay protect
Repair the cooling fan and do
not overload
Temperature relay may
damage
Replace the temperature
relay
3. No Arc striking
Machine output terminal not
connect reliably with the work piece
Reliably connect the work piece
and output terminal
Torch trigger or plug wire may
damage
Replace the torch trigger
and well connect the plug
4. There is no output
voltage, but noise
from the machine
FRD may damage
Replace the FRD
5. Difficult to strike
arc
Work piece too dirty
Clean the workpiece
Tungsten quality not good
Replace good tungsten
6. Cannot turn off the
argon gas.
PW03 damage；
Replace PW03；
There are substance in gas
valve；
Clean the air valve
Check gas/auto selection
switch does not set to auto
position；
Put the switch to auto
position；
The spring in the air valve
may have elastic shortage
open the air valve and
extend the spring
7. No argon
The voltage of the air valve
coil is insufficient or the coil was
burnt
Check the coil
voltage（~36V）or replace
the air valve
PW03 damage；
Replace PW03；

INTIG 250 PULSE DC Pulse Argon WeldingMachine
8. There is burnt
smell from
the
machine
Some components was burnet or
there are wires short
circuit.
Replace the damaged
components or deal with the
short circuit parts；
9. Machine not work, but
the overload
indicator on
Machine overload
Stop welding, let the
machine rest for 10min
without load
Cooling fan damage
Replace cooling fan
10. Arc break during
welding or the
machine not work,
but the lack voltage
indicator
on
Water pressure too low or no
water let in
Connect water
The water checking switch
damage
Replace the water checking
switch

10 Spare Parts List :
No
Spare Name
Part No.
1
MCB
SP02488
2
Rectifier bridge
SP01901
3
IGBT
SP01871
4
Filter
Capacitor
SA00033
5
Cooling fan
SP01321
6
Display PCB
SP01928 D
7
Main PCB
SP01928 M
8
Drive PCB
SP01229
9
Control T/F
SP00899
10
Output Diode
SP02703
11
Power T/F
SA00038
12
Choke
SP02650
*******