WARPP INTIG 316 AC/DC Page 1 Operator'S Manual Download

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INTIG 316/501 AC/DC

Inverter AC/DC Pulsed Argon Arc Welding Machine

OPERATOR’S MANUAL

(PLEASE READ CAREFELLY BEFORE OPERATION)

Summary of Contents for INTIG 316 AC/DC

Page 1: ...INTIG 316 501 AC DC Inverter AC DC Pulsed Argon Arc Welding Machine OPERATOR S MANUAL PLEASE READ CAREFELLY BEFORE OPERATION ...

Page 2: ...crease 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 FROM RAIN UNDER PROPER ROOFING READ THE INSTRUCTION MANUAL CAREFULLY BEFORE OPERATE THE MACHINE Purchase Date Serial Number Machine Type Purchase Place ...

Page 3: ...ing 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 Spatte...

Page 4: ...c as well as the welding equipment itself Electromagnetic would affect cardiac pacemaker the cardiac pacemaker users should consult one s doctor first The effect of electromagnetic to one s health is not confirmed so it might 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 w...

Page 5: ...t 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 ...

Page 6: ...AVE 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 high...

Page 7: ...r 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 us...

Page 8: ...INTIG 316 501 AC DC 7 ...

Page 9: ...sed 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 area Storage and allocation area Protection indicator area Operation mode ar...

Page 10: ...requency when there is pulse selected it is pulsed working frequency the inverse of pulse cycle L Base current when there is pulse selected it is the base current of pulse M AC frequency during AC welding adjusting the current frequency N Clean width when it is AC welding adjusting the width ratio of current negative half wave and clean width of negative pole O Down slope time the time of current ...

Page 11: ...st time to press this Pass key voltmeter displays current pass no and ammeter displays current storage welding parameters The left selection key or right selection key can be pressed to display other parameters stored inside the pass The storage key can be pressed to store the current welding parameter into current pass The allocation key can be pressed to allocate the storage parameter inside pas...

Page 12: ...Back panel picture and introduction A Power protection switch it only used for protection of the over load current B Power input cable the three phase input cable is fixed on the machine through the screw connector C Communication interface A it connects the pedal controller INTIG 316 AC DC or the same frequency communication interface of double machine INTIG 501 AC DC D Communication interface B ...

Page 13: ...minals of power source or open the machine cover for interior examination When there is need to check welding torch of exchange spare parts When there is no need to use welding machine M For avoiding electricity shock please make sure if it is earth connected reliably N The damaged cables must be replaced O When operating in the moist field or connecting mother material cables the dry working clot...

Page 14: ...y Have the fast connector of torch cable connected terminal and the gas inlet nut of the torch to the gas outlet of the machine The water inlet pipe of the torch connects with the water outlet connector of the machine the water outlet pipe of the torch connects with the water backward of the machine Warning the fast connector must be connected tightly or else it may produce heat may damage connect...

Page 15: ... carbon steel 4 As per requirement set pulse on pulse off and press the pulse current key to set If pulse off mode selected adjust encoder to set the welding current If pulse on mode selected set the peak current pulse width ratio pulse frequency base current press left selection key or right selection key to select the parameters to set 5 When the AC welding is selected as per requirement set the...

Page 16: ...away immediately until the postponed gas cut off time is ended so that the molten pool and tungsten could be better protected Operation 1 Warning To avoid shock the following items should be complied with The fatal shock or burnt accident can be caused if touching the electrified parts It is prohibited to touch the tungsten electrode when press the switch of torch Before replacing the tungsten ele...

Page 17: ...urrent A Argon flow L min Layer Groove Stainless Steel DC positive 0 6 1 0 1 6 2 4 3 2 4 0 4 8 6 4 1 0 1 6 1 0 1 6 1 6 2 4 1 6 2 4 2 4 3 2 2 4 3 2 2 4 3 2 4 0 3 2 4 0 4 8 1 6 1 6 1 6 1 6 2 4 2 4 3 2 2 4 3 2 2 4 3 2 3 2 4 8 20 40 30 60 60 90 80 120 110 150 130 180 150 220 180 250 4 4 4 4 5 5 5 5 1 1 1 1 1 1 1 1 2 a b a b b b b c d c d a c Desoxy copper DC positive 0 6 1 0 1 6 2 4 3 2 4 0 4 8 6 4 1 ...

Page 18: ...80 280 280 50 50 30 3 2 1 5 50 50 40 80 50 25 75 75 Titanium 0 200 100 1 30 25 0 Shielded gas argon 10 L min Electrode thorium tungsten electrode 3 2 mm Welding wire diameter 1 2 mm Length of arc 2 mm welding for different thermal capacity joint connector Material Shape of joint Seam width mm Pulse Welding speed cm min Wire feed speed cm min Pulse current A Based current A Pulse frequency Hz Pulse...

Page 19: ...blems or not 2 Grounding wires The cover of the machine is connected with ground safely or not c Eliminate the dusts inside the welding machine The dusts deposited on the cooling board of thyristors will cause bad heat dispersal and bring adverse influence The dusts deposited at the windings of the transformer will cause insulation deterioration So the examination should be carried out every half ...

Page 20: ...current value 2 Pure tungsten electrode is used should use the dthorium or cerium tungsten electrode 3 The other shielded gases are used except pure argon 4 The mother material cable is not connected perfectly 5 The gas flux is too large E4 Gas sending is bad or even not 1 Midway of the gas pipe is flexed 2 The torch is blocked by dunghills 3 The gas valve doesn t act E5 Gas flows out of control 1...

Page 21: ... 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 8 There...

Page 22: ...3 INTIG 501 AC DC FZ600R12KE3 600A 1200V 102070100105 5 Filter capacity INTIG 316 AC DC 1000µF 400V 85 102020100041 INTIG 501 AC DC 2200µF 400V 85 102020100058 6 Main transformer INTIG 316 AC DC 2090311 INTIG 501 AC DC 2090411 7 Reactor INTIG 316 AC DC 2090312 INTIG 501 AC DC 2090411 8 Diode INTIG 316 501 AC DC MMF300N060DK6B 300A 600V 102070100110 9 Diode INTIG 316 501 AC DC MMF300N060DA6B 300A 6...

Page 23: ... 0V 36V 110V TC1 C11 C13 C14 V10 V11 R11 R12 V12 V13 23 24 35 36 KT2 voltage feedback 74 73 0 16 1 pi n l i ne 45 2 44 3 42 4 40 5 41 43 6 1 pi n l i ne 52 2 53 3 54 4 55 L6 AP3 PW05 PCB 5V END CS CLK DAT KEY XZ1A XZ1B CS1 EC11 A C B 1 2 3 XZ1 XS2 2 C XS2 4 B XS2 3 A END1 XS2 2 C NC NC END1 XS4A 60 XS4B 61 XS4C 62 XS4D 63 XS4E 64 XS4F 65 XS4G 66 XS4H 67 XS4I 68 XS4J 91 XS4A 64 XS4B 63 XS4C 62 XS4D...

Page 24: ...DGND MISO CLK CS MOSI pedel control connector XS8A 46 XS8H 49 XS8D 54 XS8C 55 XS8E 53 XS8F 52 XS8B 47 XS8G 48 XS3D 37 XS3C 38 XS3B 39 XS3A 0 XS11A 40 XS11B 41 XS11C 42 XS11D 43 XS11E 44 XS11F 45 XS9A 58 XS9B 59 XS4A 56 XS4B 57 5V END CS CLK DAT KEY XZ1A XZ1B CS1 XS2 1 XS2 2 HF control torch switch input 69 70 voltage feedback END1 XS4A 60 XS4B 61 XS4C 62 XS4D 63 XS4E 64 XS4F 65 XS4G 66 XS4H 67 XS4...

Page 25: ...INTIG 316 501 AC DC 24 1 Top View 2 Right side View ...

Page 26: ...INTIG 316 501 AC DC 25 3 Left side View 4 Front View ...

Page 27: ...MALE CONNECTOR FOR CONTROL SIGNAL CABLE SIDE CON7PNM CON7PNM 5 AC CAPACITOR C 4UF 1000VAC C 5UF 1000VAC 6 CONTROL TRANSFORMER CTRXB24 CTRXB24 7 CT COIL CTCOIL 316 CTCOIL 501 8 DC CAPACITOR ELECTROLYTIC C 1000UF 400VDC C 2200UF 400V 9 DC CAPACITOR POLY C 100UF 500VAC C 100UF 500VAC 10 DISPLAY CARD PCB DSP 04 PCB DSP 04 11 DRIVE CARD PCB DRV 05 PCB DRV 05 12 ENCODER SWITCH KNOB KNOB001 KNOB001 13 FA...

Page 28: ...FIER MODULE P TYPE FRM MPKC2CB150U60 FRM MPKC2CB150U60 29 OUTPUT RECTIFIER MODULE N TYPE FRM MPKC2CA150U60 FRM MPKC2CA150U60 30 PRIMARY THRUST COIL ROUND TYPE THCL P 316 THCL P 501 31 ROTATION ENCODER C2373 C2373 32 SECONDARY IGBT IGBT FF400R06KE3 IGBT FZ600R12KE3 33 SECONDARY THRUST COIL THCL S 316 THCL S 501 34 SNUBBER CAPACITOR BOX 1 C 0 027UF 1000V C 47UF 1200V 35 SNUBBER CAPACITOR BOX 2 NA 36...

Page 29: ...INTIG 316 501 AC DC 28 41 THERMAL CUTOUT SENSOR C2373 C2373 42 WATER FLOW SWITCH FS DS01AW131DH FS DS01AW131DH 43 WIRE WOUND RESISTOR R 20E 200W R 20E 200W ...

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