WARPP INTIG 316 AC/DC, INTIG 501 AC/DC Operator's Manual

INTIG 316/501 AC/DC
Inverter AC/DC Pulsed Argon Arc Welding Machine
OPERATOR’S MANUAL
(PLEASE READ CAREFELLY BEFORE OPERATION)
INTIG 316/501 AC/DC
-1-
Safety Depends on You
our arc welding and cutting equipment's 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):
PLACE THE MACHINE ON A PROPER PLANE, SO THAT THE MACHINE DOES NOT
SLIP.
PLEASE KEEP THE MACHINE AWAY FRO M RAIN ( UNDER PROPER ROOFING ).
READ THE INSTRUCTION MANUAL CAREFU LLY BEFORE OPERATE THE MACHINE.
Purchase Date
Serial Number
Machine Type
Purchase Place
INTIG 316/501 AC/DC
-2-
Cautions
Arc and arc rays can hurt.
1
Electric shock: The welding circuits are not insulated when welding. If you touch the
two
output
electrodes
of
the
machine
with
your
bare
skinatthe
same
time,itwill
lead
to
electric
shock,
sometimes
even
fatal
dangers.
Users
needtofollow
the
items
below
to
avoid electric shocks:
If
possible,
lay
some
insulating
materials,
which
are
dry
and
large
enough,
in
your
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 as the 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 working area.
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
riskoffalling,
please
be
suretowear
safety
belttoavoid
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
mustbeconformable
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
thembyaccident.
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,oruse
the
respirator.
Do
not
weldatthe
same
time
when
usingofdegreasing,
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
usedinwelding
might
displace
the
oxygen
in
the
air,
and
can
leadtohurtoreven
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
easilygothrough
small
cracks
and
touch
fire
hazards.
Keep
the
safety
of
all
kinds
of
lines
going
though
welding
area,
including
hydraulic
linesinthe
wild.
Where
compressed
gases
aretobe
usedinthe
field,
special
precautions
should
be
usedtoprevent
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
tobeinnocuity.
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
andacap
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, and the 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.
5
Cylinder: Damage of it might cause explosion.
Make
sure
that
the
gasinthe
storage
cylinder
is
qualified
for
welding,
and
the
decompression
flowmeter,
the
adapter
and
the
pipe
are
allingood
condition.
Make
sure
that
the
installation
of
cylinder
isbythe
wall
and
bundled
tightly
byachain.
Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
Itisforbidden
to
touch
cylinder
with
the
welding
clamp
or
the
work
cables.
Avoid
facing
the
cylinder
while
installing
the
decompression
flowmeter
or
the
gasometer.
When
not
working,
please
tighten
the
valve.
INTIG 316/501 AC/DC
-3-
6
Power: (For electrically powered welding and cutting equipment) Turn off input power
before
installation,
maintenances
and
repair,
so
that
avoid
accident.
Huanyuan
welding
equipment
isΙclass
safeguard
equipment;
please
install
the
equipment
by
manufacture
’sprofessional
person
Ground
the
equipment
perfectly
in
accordance
with
the
manufacturer
’srecommendations.
7 Power:(For engine driven welding and cutting equipment)
Workinventilated
placeoroutdoors.
Do not add fuel near to fire or during engine starting or welding. When not working, add
fuel
after
engine
is
cooling
down;
otherwise,
the
evaporation
of
hot
fuel
would
result
in
dangers.
Do
not
splash
fuel
outofthe
fuel
tank,
anddonot
start
the
engine
until
complete
evaporation
of
the
outside
fuel.
Make sure that all the safeguard equipment's, machine cover and devices are all in a good
condition.
Be
sure
that
arms,
clothes
and
all
the
toolsdonot
touch
all
the
moving
and
rotating
components
including
V
belt,
gear
and
fan
etc.
Sometimes
having
to
dismantle
some
partsofthe
device
during
maintenance,
but
must
keep safety awareness strongly every time.
Do
not
put
your
hand
closetofans
anddonot
move
the
brake
handle
while
operating.
Please
remove
the
connection
between
the
engine
and
the
welding
equipment
to
avoid
sudden
starting
during
maintenances.
When
engine
is
hot,itis
forbidden
to
open
the
airtight
coverofthe
radiator
water
tanktoavoid
hurtbythe
hot vapor.
8 Electromagnetic: Welding current going though any area can generate electromagnetic,
as
wellasthe
welding
equipment
itself.
Electromagnetic
would
affect
cardiac
pacemaker,
the
cardiac
pacemaker
users
should
consult
one’s
doctor
first.
The
effectofelectromagnetic
to
one’s
health
is
not
confirmed,
soitmight
have
some
negative
effect
to
one’s health.
Welders
may
use
following
method
to
reduce
the
hazardous
of
electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together. b. Do not enwind partially or entirely your body with the cable. c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding cable
is by your left side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9
Lift equipment: carton or wooden boxes package the welding machines supplied by
Warpp
Engg.Thereisno
lifting
equipment
in
its
wrapper.
Users
can
moveitto
the
prospective
areabya
fork-lift
truck,
then
open
the
box.
If
their
are
rings,
the
machine
canbetransited
using
rings.
While
our
Welding
Machine
Manufacture
reminds
users,
thereispossible
risktodamage
the
welding
machine.
It
is
bettertopush
the
welding
machine
moving
in
useofits
rollers
unless
special
situations.
Be
sure
that
the
appurtenances
are
all
removed
off
when
lifting.
When
lifting,
make
sure
that
thereisno
person
below
the
welding
machine,
and
remind
people
passing
byatany
moment.
Do
not
move
the
hoist
too
fast.
10
Noise: our Welding Machine Manufacture reminds users: Noise beyond the limit (over
80
db)
can
cause
injury
to
vision,
heart
and
audition
depending
on
oneself.
Please
consult
local
medical
institution.
Use
the
equipment
with
doctor
’spermission
would
helptokeeping
healthy.
INTIG 316/501 AC/DC
-4-
1. Features and Usage -------------------------------------------------5
2.
Working
Conditions
and
Environment:
------------------------5
3. Technical specification---------------------------------------------6
4. Product System Introduction-------------------------------------6
5. Product Construction Introduction -----------------------------7
6. Installation ----------------------------------------------------------13
7. Operation Introduction ------------------------------------------14
8. Trouble shooting ---------------------------------------------------18
9. Packing list and appendix ----------------------------------------21
10. INTIG 316 AC/DC electric schematic -------------------------22
11. INTIG 501 AC/DC electric schematic --------------------------23
12. Welding machine Picture’s ---------------------------------------24
13. Spare parts List for INTIG 316, 501 AC/DC -----------------26
INTIG 316/501 AC/DC
-5-
1.
Features
and
Usage:
INTIG AC/DC series pulsed TIG welding machine has the function of DC TIG welding, DC pulsed TIG
welding, AC TIG welding, and AC pulsed TIG welding. It is a kind of tungsten TIG welding machine
incorporated multi-function.
The primary inverter of INTIG AC/DC series pulsed TIG welding machine adopts the latest IGBT and fast
recovery diode etc , the invert frequency is 20KHZ. The small mid-frequency transformer replaced the heavy
industrial frequency transformer, which has the advantages of high efficiency, low no-load loss, stable current,
energy saving, material saving and high reliability etc..
The secondary inverter of INTIG AC/DC series pulsed TIG welding machine adopts the half-bridge inverter
circuit, which has advantages like adjustable frequency and pulse width , good reliability and energy saving etc
INTIG AC/DC series pulsed TIG arc welding machine has all functions required for welding technique. The
functions like high frequency arc striking, gas pre-flow (adjustable), initial current (adjustable), current
upslope (adjustable), current down slope (adjustable), crater current (adjustable), gas post-flow etc are
available in the machine. During the AC TIG welding the cleaning action of welding is adjusted by AC WAVE
BALANCE and also AC frequency is adjustable which is useful to control the bead of the welding. The
machine can be used for ordinary welding as well as pulsed welding. The advantage of the pulsed welding is
variation in the high and low welding current, better arc stiffness due to the electromagnetic pinch effect, the
melting time for the metal is short, so the weld seam is much more fine with higher strength. The form of weld
seam surface could also be changed through changing the four pulse parameters, so it could also decided by
welding machine.
This welding machine can mainly used for all metals like aluminum, magnesium, copper, stainless steel
on pipe, boiler, aviation, etc.
2.
Working
Conditions
and
Environment:
1. Input power
1.1 The exact input voltage wave shape should be sine wave, the frequency fluctuation should be no more than
+1% of the rated value.
1.2 The fluctuation of input voltage must be within 380 to 440 VAC.
1.3 Imbalance between phase should not exceed 5%.
2. Environment:
A. Ambient temperature ranges:
Welding temperature range: -10C ~ +40C
Transportation and Storage temperature range: -25C ~ +55C
B. Operating area must be dust free for better usage of the machine.
C. Operating altitudes: less than 1000m D. Wind speed should be no more than 1m/s
E. Avoid exposing the machine to direct sunlight and rain.
3. Technical Specification:
Model
Parameter
INTIG 316 AC/DC INTIG 501 AC/DC
Input power
380 - 440 vac 50/60 Hz
Rated input capacity(KVA) 11.9 21
INTIG 316/501 AC/DC
-6-
Rated input current(A) 18.2 31.8
Open circuit voltage(V) 82 85
Rated welding current(A) 315 500
Rated welding voltage(V) 22.6 30
Rated duty cycle(%) 60% 60%
Gas pre-flow time(S) 0.0 ~ 5.0
Initial current adj.
range(A)
AC 20 ~ 315 20 ~ 500
DC 10 ~ 315 10 ~ 500
Current upslope time(S
)
0.0 ~ 10.0
Welding current
adj. range(A)
AC 20 ~ 315 20 ~ 500
DC 10 ~ 315 10 ~ 500
Peak current adj.
range(A)
AC 20 ~ 315 20 ~ 500
DC 10 ~ 315 10 ~ 500
Pulse frequency(Hz) 0.2 ~ 99.9
PWM ratio() 10% ~ 90%
Base current adj.
range(A)
AC 20 ~ 315 20 ~ 500
DC 10 ~ 315 10 ~ 500
AC frequency(HZ) 20 ~ 200
Clean width() 10% ~ 50%
Current down-slope time(S) 0.1 ~ 15
Crater current adj.
range(A)
AC 20 ~ 315 20 ~ 500
DC 10 ~ 315 10 ~ 500
Gas post-flow time(S) 0.0 ~ 20.0
Dimension(L×W×H)(mm)
705×350×650 725×385×785
Weight(kg) 52 70
4. Product System Introduction
a) Working principle
INTIG AC/DC series pulsed TIG welding machine adopts AC-DC-AC-DC-AC double inverter circuit. The
primary inverter takes IGBT as the inverter main component. After the three-phase AC input power is rectified
through three phase Bridge rectifier, it is supplied to IGBT inverter, and inverted at 20KHz AC. This is given
as input to main transformer, which steps down the voltage.Output of main transformer given to fast recovery
diode and filter for rectification. Rectified DC is given to secondary inverter section to drive AC output. Which
is used for AC TIG welding operation.
The control circuit controls the output current through pulse width modular. The negative feedback signal
coming from Hallsensor is amplified, then it is fed to negative input end of error amplifier from special PWM
circuit, then it controls the conduction time of IGBT, so that the output current can be kept at required level.
The secondary inverter uses IGBT as the main inverter component, changes the DC current to AC square
wave current, then the square wave required by AC TIG welding is obtained.
This machine has functions of gas preflow, gas postflow , HF arc striking, current upslope, current down
slope. All these functions are controlled by the digital signal programming.
b) Working circuit diagram:
INTIG 316/501 AC/DC
-7-
INTIG 316/501 AC/DC
-8-
5. Product Construction Introduction
1).Front panel description and function:
The front panel is divided into six areas according to the function:
Diagram 2: Front Panel
2).Digital display area:
A.1stdigital display meter: it is used to display welding/preset current, pulse/AC frequency, pulse width
ratio/clean width, pre-gas time etc.
B.Indicates unit of the parameter being selected.
C. Indicates what second display is showing.
3).Selection and adjusting area of parameters:::
Digital display area
Selection and adjusting
area of parameters
Function selection areaStorage and allocation
area
Protection
indicator area
Operation mode area
A DCB
B C D E F G H I J K L M N OA P Q R
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