WARPP INTIG 402 PULSE

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Summary

Safety Precautions

Personal Safety Equipment

Guidelines for wearing recommended safety gear like glasses, flame-proof clothing, and gloves, and avoiding loose items.

General Safety Precautions

Ensuring secure connections, qualified personnel for high voltage work, fire equipment readiness, and avoiding maintenance during operation.

Health and Environmental Hazards

Fumes and Gases Safety

Advises on ventilation and extraction to manage dangerous fumes and gases during welding.

Arc Rays Protection

Highlights risks of arc rays to eyes and skin, recommending protective screens, filter lenses, and clothing.

Fire Hazard Prevention

Warns about sparks (spatter) causing fire and emphasizes keeping flammable materials away.

Noise Protection

Advises on protecting ears from excessive noise and warning bystanders of the risk.

Installation Requirements

Installation Environment

Specifies requirements for the welding machine's location, considering sunlight, rain, dust, humidity, and wind.

Input Voltage Specifications

Details required input voltage (380-440V, 50Hz) and acceptable 3-phase voltage unbalance.

Grounding Requirements

Ensures personal safety, proper operation, and reduced EMI through proper grounding and 4-wire service.

Front Panel Description and Operation

Process and Mode Switches

Explains how to select welding modes (ARC, TIG, PULSE TIG) and operation modes (2T, 4T).

Parameter Select;Adjust Knob

Details the function of the knob for selecting and adjusting parameters like pre-flow, current, and post-flow.

Parameter Range Overview

Lists parameters with their minimum and maximum adjustable ranges, such as current, frequency, and time settings.

Maintenance and Troubleshooting

General Maintenance and Caution

Covers cautions for industrial use, maintenance by authorized personnel, and the impact of unauthorized repairs on the guarantee.

Inspection and Cleaning Procedures

Guides on checking and cleaning the power source and welding torch to ensure trouble-free operation and prevent overheating.

Fault Tracing and Error Codes

Provides a table for diagnosing common faults like 'no arc' or 'poor welding performance' and lists specific error codes (Err 001, Err 002).

The WARPP INTIG 402 PULSE is a welding machine designed for industrial use, offering reliable welding and cutting capabilities. This manual provides detailed instructions for its safe and effective operation, emphasizing adherence to safety procedures and regular maintenance.

Function Description

The INTIG 402 PULSE is a versatile welding machine capable of performing three main welding modes: ARC Welding, TIG Welding, and Pulse TIG Welding. It features a front panel with various controls for precise parameter adjustment, allowing users to tailor the welding process to specific requirements. The machine supports both 2T and 4T trigger modes, providing flexibility in how the welding arc is initiated and maintained.

Important Technical Specifications

Input Voltage: Standard sine wave, effective value 380-440V, frequency 50Hz.
Three-Phase Volt Unbalance: Must be no more than 5%.
Parameter Ranges:
- Pre Flow: 0.0 to 5.0 seconds
- Start Current: 0.0 to 400 Amperes
- Up Slope: 0.0 to 10.0 seconds
- Welding Current: 5 to 400 Amperes
- Pulse Frequency: 0.1 to 99.9 Hz
- Duty Cycle: 25% to 50%
- Base Current: 5 to 400 Amperes
- Down Slope: 0.0 to 10.0 seconds
- Stop Current: 5 to 400 Amperes
- Post Flow: 0.0 to 60 seconds

Usage Features

The INTIG 402 PULSE offers a user-friendly interface with clear displays and intuitive controls.

Process Switch: Allows selection between ARC Welding, TIG Welding, and Pulse TIG Welding modes.
Mode Switch: Enables selection of 2T or 4T trigger modes.
- 2T Mode: Requires continuous pressing of the trigger switch to maintain the welding process.
- 4T Mode: Involves pressing and releasing the trigger to start welding, and pressing it again to stop.
Parameter Select/Adjust Knob: This multi-function knob is used to select specific welding parameters (Pre Flow, Start Current, Up Slope, Welding Current, Pulse Frequency, Duty Cycle, Base Current, Down Slope, Stop Current, Post Flow) by pressing it, and then adjusting their values by rotating it clockwise (increment) or anti-clockwise (decrement).
Display: Features a Volt Meter Display for welding voltages and a Current Meter Display for welding current, providing real-time feedback during operation.
Grounding: Proper grounding is crucial for personal safety, optimal operation, and reducing electromagnetic interference (EMI). The power supply must be grounded through the power cord according to national and local electrical codes, utilizing a 4-wire type three-phase service with a green or green/yellow wire for protective earth ground.

Safety Features and Precautions

The manual strongly emphasizes safety, outlining several critical precautions:

General Safety: Users must be familiar with the machine's operation, emergency stops, and relevant safety precautions. Unauthorized persons should not be in the working area during startup, and no one should be unprotected when the arc is struck.
Workplace Suitability: The workplace must be suitable for welding, free from drafts, and equipped with appropriate fire extinguishing equipment.
Personal Protective Equipment (PPE): Always wear recommended PPE, including safety glasses, flame-proof clothing, and safety gloves. Avoid loose-fitting items that could get trapped or cause burns.
Electrical Safety: Install and earth the unit according to applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet clothing. Only qualified electricians should work on high voltage equipment.
Fumes and Gases: Keep your head out of fumes. Use ventilation or extraction at the arc to remove fumes and gases from the breathing zone.
Arc Rays: Protect eyes and body with the correct welding screen, filter lens, and protective clothing. Protect bystanders with screens or curtains.
Fire Hazard: Sparks can cause fire; ensure no flammable materials are nearby.
Noise: Excessive noise can damage hearing. Use earmuffs or other hearing protection and warn bystanders.
Malfunction: Call for expert assistance in case of malfunction.
Installation Environment: The welding machine should be placed in a room free from direct sunlight, rain, dust, and low humidity. Ensure no wind at the welding position. Maintain a minimum distance of 20 cm between the welder and walls, and 10 cm between welders for adequate heat radiation.

Maintenance Features

Regular maintenance is essential for safe and reliable operation.

Professional Installation: Installation must be carried out by a professional.
Power Source Location: Position the welding power source to ensure cooling air inlets and outlets are not obstructed.
Mains Power Supply: Verify correct mains power supply voltage and fuse size. Ensure a protective earth connection is made.
Regular Maintenance: Only authorized personnel with appropriate electrical knowledge should remove safety plates for service, maintenance, or repair.
Warranty: The warranty is void if the customer attempts to rectify faults during the guarantee period.
Inspection and Cleaning:
- Power Source: Regularly check for dirt. Clean the power source with dry compressed air (reduced pressure) at least once a year, depending on usage and environment. Clogged inlets/outlets can lead to overheating.
- Welding Torch: Clean and replace wear parts of the welding torch at regular intervals to ensure trouble-free welding.

Fault-Tracing and Error Codes

The manual provides guidance for troubleshooting common issues:

No Arc: Check mains power supply switch, welding current supply and return cables, and current value settings.
Interrupted Welding Current: Check mains power supply, thermal cut-outs, and mains power supply fuses.
Frequent Thermal Cut-Out Trips: Ensure the unit is not being overloaded beyond its rated data.
Poor Welding Performance: Check welding current supply and return cables, current value settings, electrode type, and gas flow.
Error Codes:
- ERROR 001: Indicates the water circulation pump is off or water is not passing through the torch.
- ERROR 002: Indicates the welding machine is overheated.

Dismantling and Scrapping

Welding equipment, primarily composed of steel, plastic, and non-ferrous metals, must be handled and disposed of according to local environmental regulations.

This comprehensive guide ensures that users can operate and maintain the WARPP INTIG 402 PULSE welding machine safely and efficiently, maximizing its lifespan and performance.