WARPP WTR-400 Operation Manual

OPERATION MANUAL FOR
ARC WELDING RECTIFIER

Model WTR-400

WARPP ENGINEERS PVT. LTD.

B-1005, Western Edge II, Near Metro Mall, Off. Western
Express Highway, Borivali (E), Mumbai-400 066.
Tel: [phone]/74. Fax: [phone].
E-mail:[e-mail] Web Site:www.warpp.co.in

INDEX

Sr. No. Description Page No.

1 Introduction 1
2 Installation 2
3 Operation 2
4 Maintenance 3
5 Safety 3
6 Trouble shooting 4
7 Spare part List 10

ILLUSTRATIONS

1) Control Circuit Wiring Diagram 6

2) Power Circuit Wiring Diagram 7

3) Installation Diagram 8

INTRODUCTION.

This manual describes the equipment, installation, operation, safety, and
maintenance of WARPP make DC arc welding rectifiers. Tease welding
equipments are designed for manual metal arc and manual TIG welding
application in heavy duty fabrication. Simple design and rugged construction
makes it most ideal for maintenance free operation. This equipment is mounted
on four wheel chassis with two fixed wheels in the front and two revolving wheels
at the back side.
This equipment consists of a three phase step down transformer along with
three phase magnetic amplifier (Transductor) and three phase silicon diode
rectifier. The welding current is varied by varying the current in the DC coils of
the transductor. This current is obtained by a control transformer and an auto
transformer along with a single phase silicon diode rectifier. The transformer
steps down 415 Volts input supply to a voltage around 100 volts which is fed to
the rectifier via the autotransformer. The output of the rectifier is given to the DC
coils of the transductor.By varying the autotransformer setting the current fed to
the DC coils of the transducor varies and hence the actual welding current varies
accordingly. The autotransformer is calibrated for exact output welding current.
Main transformer is provided with primary tapping to work on 380/415/440 volts
input supply. All the components of the equipment is cooled by an single phase
fan. A simple change over of output cables allows the operator to use either
straight OR reverse polarity.

1

INSTALLATION.

1) The machine should be kept in a relatively clean and dry place and a minimum
of 0.3 meters of space should be left around the equipment for easy circulation of
air.

NOTE THAT THE MACHINE DRAWS FRESH AIR FR OM THE FRONT AND

FORCES IT THROUGH THE BACK

2) A separate mains switch should be provided for this equipment. The mains
switch should be of good quality with proper contacts. The switch should be
easily accessible to the operator.

3) Three core 7/20 gauge cables can be used for the input supply connection.
The equipment should be properly earthed and all the electrical connections
should be firm and tight. Power connection point is provided on the back cover of
the equipment.

4) The equipment must be connected to a proper earth point.

.

OPERATION.

1) After installation of the equipment connect the holder to the negative and job
earth cable to the positive output of the equipment. (This connection is termed as
Straight polarity. Reverse polarity can be made by interchanging the job earth
and holder cables).

2) Switch on the mains Supply.

2