WARPP INTIG-315 AC/DC User manual

-１-
Inverter Series
AC/DC Pulse TIG
Welding Machines
Operating Manual
WARPP ENGINEERS PVT. LTD.
B-1005, 10TH FLOOR, WESTERN EDGE II, NEAR METRO MALL,
BORIVALI (E), MUMBAI-400 063.
Tel:[phone]/74. Fax: [phone].
Email:[email protected]. Website:www.warpp.co.in

-２-
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………………………………………(4)
3. Installation…………….………………………………...(7)
4. Definition of Product Model Number…………………..(9)
5. Principle in Brief…………….………………………….(9)
6. Operating Instruction………………………………….(10)
7. Repair& Maintenance...………………….…………. ..(22)
8. Technical Data…………...…………………………….(24)
9. Structural Diagram…………………………………….(30)
10.Spare Part List…………………………………………(39)

-３-
Usage & Features
IN TIG (AC/DC) series inverter multifunctional welding machines can
be divided into three types (315A、500A and 630A). They can perform
DC constant current TIG welding, DC pulse TIG welding, square wave
AC constant current TIG welding, square wave AC pulse TIG welding,
which are used for carbon steel, copper, titanium, aluminum as well as
aluminum-magnesium alloy welding. Because of reasonable static and
sound dynamic characteristic the welders enjoy, they have
comprehensive operational functions. The features are showed below:
&IGBT HF soft-switch-transfer technology. High frequent ， small ，
light ；
&Notable control and adjust function ， multifunctional ， convenient ；
&Additional foot pedal switch for adjusting welding current;
&Using non-source power factor correction technology ， power
factor is high ；
&Easy to start arc 、 stable arc ， good performance ；
&High success rate of arc-starting while in low welding current ；
&The penetration, melt pool width and pass form which
commensurate with weld can be obtained by adjusting pulse
current, pulse frequency and pulse width as well as prolonging
tungsten electrode lifespan, especially suitable for automatic and
robot welding.

-４-
Safety Precautions
General safety precaution:
zPlease strictly comply with rules defined in this manual to
avoid unexpected accidents
zHow to connect power supply ,select working area and use
pressure gas, please comply with proper rules
zNot allow non-operator to enter working area
zWelder installation, inspection, maintenance, and manipulation
must be completed by authorized person.
zDon’t use welding machine for unrelated purpose (Such as
recharging, heating or pipeline thaw, etc.)
zMust take safe precaution in case welder falling when it is put
on the uneven ground
Avoid being electric shocked or burnt
zNever touch on hot electrical units.
zPlease instruct the authorized electrician to ground the welder
frame by using proper-sized copper wire.
zPlease instruct the authorized electrician to connect the welder
to power supply by using proper-sized, well-insulated copper
wire.
zWhen operating in the damp, space limited area, must ensure
well-insulated between body and work piece
zWhen operating in the high-rising location, must ensure safety
by using safe net.
zPlease power off the machine while no longer welding.
Avoid breathing in hazardous welding fume or gas

-５-
zPlease use specified ventilation to prevent being gas poisoned
and asphyxiated,
zEspecially in the container where oxygen is depleted easily.
Avoid being harmed by arc flash, hot spatter, slag
zArc rays can injure your eyes and make your eyes feel
uncomfortable. Hot spatter and slag can burn your skin.
zPlease wear proper welding helmet, leather gloves, long-
sleeved suit, hat, apron and boots before welding.
Preventing from fire, explosion, container break
accidents
zDon’t put flammable material in the working area. Hot spatter
and hot weld can easily start a fire.
zCable must be connected the work piece firmly to ensure good
conductivity in case causing fire by resistance heat.
zDon’t weld in the flammable gas or weld container which
contains flammable material, otherwise it can cause explode.
zDon’t weld encapsulated container, otherwise it can break.
zEnsure a fire extinguisher at hand in case a fire breaks out.
Avoid being hurt by moving parts
zNever let the finger, hair, and cloth near the rotary cooling fan
and wire feeder rollers.
zWhen feeding wire, don’t let the bottom of gun near your eyes,
face and body, to prevent being harmed by wire.

-６-
Avoid gas bottle falling or gas regulator breaking
zGas bottle must be firmly fixed on the ground, else if injure
will exerts on.
zNever place bottle under high temperature or sun light.
zNever let your face near gas outlet while turning on the gas
valve to prevent from being hurt by pressure gas.
zCustomer should use gas regulator provided by our company,
and comply with the proper instruction.
Avoid being hurt by welding machine while in
transport
zWhen 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.
zThe 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°

-７-
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%
3. Power supply:.

-８-
Table1: The size of fuse and breaker in the table are for reference only
4. Installation
The input power of this series welding machines is three phase
AC 380v/50Hz. Operator must use the properly disconnected
switchboard or switch box(not provided by our company) which
is equipped circuit breaker, and should ground the welder safely
and firmly.
(1) Connect ground lead.
(2) Connect terminal socket (+) to workpiece on DC TIG, to
stick holder cable on SMAW.
(3) Connect terminal socket (∽) to workpiece on AC TIG (IN
TIG 315 AC/DC) still use terminal socket (+) to connect
workpiece).
(4) Connect TIG torch to terminal socket (-) on AC or DC TIG,
connect socket (-) to workpiece on SMAW.
(5) Connect welder’s gas inlet to gas regulator by gas hose.
(6) Connect TIG torch’s gas inlet to welder’s gas outlet.
Product type 315 500 630
Power supply 3 phase AC380V
Min. capacity Power
network 14KVA 27KVA 45KVA
Input volt
protection
Fuse 20A 40A 60A
Circuit
breaker 40A 60A 100A
Cable size
(cross-section)
Input volt 4mm26mm210mm2
Output volt 35mm250mm270mm2
Ground lead 4mm26mm210mm2

-９-
(7) Wire foot pedal switch or torch control cable to control
cable socket.
(8) When use water-cooled torch, connect water circulator to
welder’s water inlet and torch’s water inlet to welder’s
water outlet.
(9) Power on air switch on the welder’s rear panel.
(10)Connect input power cable to switch box and power on.
Definition of Product Model Number
Product model codification of Series is illustrated by Picture 1：
I N T I G -- ×××
Ratedweldingcurrent
AC/DC
Pulse
MMA
TIG
Fig.1: Product model definition of IN TIGAC/DC series
Principle in Brief
Block diagram of principle：
Fig.2: Block diagram of Series principle
3 phases
Rectifier
Hi-frequent
inverter
Hi-frequent
transformer
Rectifier
& filte
r
Control circuit
Hi-frequent
inverter

-１０-
This series welding machines apply IGBT HF inverter technology.
Inputted line frequency 3-phase 380V are rectified by rectifier, inverted
into HF AC, reduced by HF transformer, rectified and filtered by HF
rectifier, then output DC volt or 50Hz AC square wave volt suitable for
welding by second invert. After this process, the welder’s dynamical
responsive speed has been great increasing, the size and weight of
welder’s transformer and reactor are reduced noticeable. Power source
enjoy sound anti-fluctuating ability due to excellent circuit loop control.
Power source can reach their potential as well as easy arc-start,
stable arc, pretty weld formation and continuous regulation of welding
current during external context changes(As to fluctuation in input power
supply and extended welding cables) due to reasonable control circuit
design .
a)TIG b)SMAW
Fig.3: IN TIGAC/DC Series output characteristic
Operating Instruction
1．Function introduction
1.1 Front panel illustration and parts number reference
1.1.1 IN TIG-315 AC/DC Front panel illustration and parts number
reference

-１１-
Fig. 4: IN TIG -315 AC/DC’s front panel

-１２-
Fig.5: IN TIG-500 / 630AC/DC’s front panel
1.2 Foot pedal switch with adjustable welding current
Fig.6: Foot pedal switch
Foot pedal switch can be used for arc start control and welding
current regulation of IN TIG-315 AC/DC. Welder will switch
automatically to foot pedal control after the control plug is
connected to welder’s control cable socket. When the pedal is
stepped on, the welder begins to work at welding current in line
with the degree of the pedal being pressed. The ceiling current is
controlled by regulating current preset potentiometer.
Note: If customers demand foot penal switch for IN TIG-500
AC/DC or IN TIG-630AC/DC, please underline in order(s).
1.3 Rear panel illustration and parts number reference

-１３-
Fig.7: IN TIG-315 AC/DC Rear panel

-１４-
Fig.8: IN TIG-500 / 630 AC/DC rear panel
1.4 Control panel
The control panel is shown as Picture 4, which is used to select
welder functions and to set up parameters. The control panel is
consisting of digital displayer, regulation knobs, and LED
indication lamps.

-１５-

-１６-
1stline. DC TIG/AC square wave TIG
2ndline.2-step (Non-Autolock)/4-step (Autolock)
When the lamp in 5th or 7th line is selected, the digital displayer will
show values of respective parameter setting. They can be adjusted by
pressing and tuning the regulation knob clockwise to increment, counter
clockwise to decrement. Press the knob and tune simultaneously for
quick setting.
“2-step” refers to start welding while push torch trigger, stop welding
while releasing it.
“4-step” refers to output 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 fills
crater and maintains while pushing it again, then stop outputting current
while releasing it.
3th line Constant current TIG/Pulse TIG /SMAW
4th line

-１７-
1.4.1 Glossary:
1. Pre-gas flow: Time elapse of gas flow before welding
2. Arc-start: Min current of start arc
3. Up-slope: Time elapse of welding current slopes up
4. Constant current: welding current on output constant current
5. Oxide clean ratio: time ratio of output clean current
While in AC TIG, regulate clean width and penetration to
obtain optimum welding quality.
6. AC Bias: Ratio of clean current dividing by welding current.
By adjusting the parameter, as to adjusting clean current result
in reasonable oxide clean effect.
Control panel
Consumption of
tungsten electrode
Wave form of
current
Clean effect
More Less
Wide &shallow
Narrow &deep

-１８-
Suggestion: At the same clean effect, reduce clean ratio and
increase AC bias to obtain deeper penetration, higher
productivity and prolong tungsten electrode lifespan.
7. AC frequency: Frequency of output AC
8.Peak: Peak value of output pulse
9. Pulse ratio: Time ratio between length of peak value current and
length of whole single pulse applied in pulse TIG, can be easily
used for controlling penetration in all-position or thin sheet
welding.
10. Pulse frequency: Output pulse frequency
11. Base current: Arc maintenance current of output pulse
12. Down –slope: Time of welding current slopes down
13. Crater filling: Welding current of crater filling.
14. Post-gas flow: Time of gas flow after ending welding
Function selection knob: Used for shifting modes illustrated
previously. Tuning clockwise can select modes orderly from
left to right, while select reversely by tuning
counter-clockwise.
Parameters preset knob: Used for adjusting the values of
parameters. Increase by tuning clockwise, reducing by tuning
counter-clockwise. Press the knob and tune right or left for quick
adjustment.
Welder can automatically save the set-up for next use while
turning off the machine

-１９-
1.4.2 “Protection” indicator lamp: lights on yellow and stops
welding automatically while in overheat, over-current,
over-voltage or water insufficient, but will not light on
while in normal welding. Protection codes are illustrated
below:
1． Display 801: Over-voltage protection. Please turn off welder
immediately and inform authorized reseller to repair.
2． Display 802 or 803: Over-current protection. Please turn off
welder immediately and inform authorized reseller to repair.
3． Display 804: overheat protection. Please turn off welder
immediately to cool it down.
4． Display 805: Pulling torch trigger for a long time with no
current or torch damaged. Repair welding torch or foot pedal
5． Display 806(500,630 types): water insufficient protection.
The default setting is “water cooled”. It does work while using a
water-cooled torch at normal water circulation. When applied
air-cooled torch, the welder’s protection lamp will light on and
display “806” protection code. Press the Function selection and
parameter preset knobs simultaneously for up to 3 seconds to
eliminate water insufficient protection. Redo the same way to
back to previous mode.
1.4.3 Power on/off lamp: It displays red when power on

-２０-
2. Operation procedure：
1). 2-step: push torch trigger pre-gas flow arc start arc start current
DC Constant TIG
up-slope normalwelding DCpulseTIG
ACconstantTIG
ACpulseTIG
release trigger down-slope crater filling post-gas flow
end welding
2). 4-step:
push torch trigger pre-gas flow arc start arc start current
DC Constant TIG
release trigger up-slope normal welding DC pulse TIG
AC constant TIG
AC pulse TIG
push torch trigger down-slope crater filling release trigger
post-gas flow end welding
TIG welding parameters forAl and Al-Mg alloy (Only for reference)