WARPP KT-2 User manual

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
USER’S MANUAL
FOR TANK
ROTATOR

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
PREFACE
Thanks for purchasing our product & looking forward to your
precious advice for improvement of our product. We will
dedicate to produce the best products and offer the best
services.
The machine has been carefully inspected both mechanically
and electrically before it left the factory. The machine should
be initially inspected upon receipt, if any damage which may
have occurred in transit inform “WARPP ENGINEERS PVT.LTD.
OR It’s Dealer immediately. Check for the accessories supplied
against those listed in packing slip.
Caution: Before attempting to connect the equipment to any
Power source, read instructions carefully.
In case any defect or deficiency, contact “WARPP ENGINEERS
PVT.LTD.” or its authorized Agent. Make sure to quote model
number and serial number of the equipment in all
correspondence.
THE DESIGN OF THIS EQUIPMENT IS SUBJECT TO CONTINUOS
DEVELOPMENT AND IMPROVEMENTS, CONSEQUENTLY
“WARPP ENGINEERS PVT.LTD.” RESERVES THE RIGHT TO
INCORPORATE MINOR CHANGES FROM THE INFORMATION
CONTAINED IN THIS MANUAL.
************

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
INDEX
1. SAFETY
2. PRODUCT DESCRIPTION & FEATURES
3. WORKING CONDITION & ENVIRONMENT
REQUIRED
4. TECHNICAL SPECIFICATION
5. WORKING PRINCIPLE
6. INSTALLATION
7. CONTROLS
8. PARAMETER AND ITS OPERATIONAL MEANING
9. HOW TO OPERATE THE MACHINE
10. Do’s & Don’ts
11. WIRING DIAGRAM
12. MAINTENANCE
13. SPARE PART LIST

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
1. SAFETY
Our machines are designed and built with ample safety
considerations. However, proper installation & operation of the
machine will increase your safety.
DO NOT INSTALL, OPEARTE OR REPAIR THIS EQIPMENT
WITHOUT READING THIS MANUAL
Following points to be taken care while installing the machine
 Ensure that children or animal do not have access to the
machinery
 Ensure that the machine is placed properly so that it has
enough ventilation and also stability so that it does not
fall
 Any safety items fitted, must not be bypassed, or
removed. if they have to be removed then the equipment
must be put out of operation, until a repair is completed
 Always keep the workplace clean & free from obstacles
 Make sure that the work area is well lit.
 Ensure that the machine is regularly maintained to ensure
that it remains safe.
 Electric shock can kill. Please make sure that you follow
the below guidelines
 All electrical supply terminals shall be well covered and
insulated
 Do not touch both the output terminals with bare hand as
it may lead to electric shock
 Always use proper hand gloves and other safety
equipment while operating the machine

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
 Use proper shaded welding screen as the arc has ultra
violet rays which can damage the eye sight
 Do not obstruct any moving parts as it may cause harm
 Ensure that the clothing is fire resistant to protect your
skin from burns and arc rays
 When compressed gas to be used, then special
precautions to be taken to prevent explosion
 Please make sure that no inflammable items are there in
the weld area
 Spatters can cause burns ensure that you use all
personnel protective equipment
 Newly supplied machines, which is packed in either
corrugated box or wooden box shall be shifted using
forklift
 Proper care shall be taken while shifting or relocating the
machines. Use lifting hooks / mechanism provided on the
machine

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
2. PRODUCT DESCRIPTION & FEATURE
The Conventional Rotator is designed to aid the welding of
cylindrical vessels.
A Conventional Welding Rotator consists of two (2) parts:
• A Motorized drive (power) unit; and
• An Idler supporting unit.
The power unit is driven by a heavy duty geared AC motor
which is designed according to internationally proven
specifications to ensure constant speed.
The heavy-duty Wheels are Coated with Poly urethane coating
with a shore hardness of 90. These coatings not only absorb
shock during placement of shells but also provide required
friction for proper rotation of the job. These coating are also
required when SS jobs are welded as contact of these metal
with CS wheel result in carbon inclusion.
By using independent drive & idler units, vessels of varying
lengths can be placed on the Rotators supported on the
Rotator wheels. The wheel can be adjusted on the base frame
to accommodate different vessel diameter.
Tank Rotators are usually arranged in sets including a pair of
identical rolls, one of the which is rotated by an electric motor
through a reduction gearbox, known as powered unit or drive
unit while the other is idler, so arranged that the distance
between the rolls can be adjusted to accommodate vessels of
different diameters.

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
The idler unit basically consist of a base frame with two-wheel
bracket bolted on to the top of it. there are holes drilled
through the top of the base frame so that the wheel brackets
can be positioned at different distances apart, to suit the vessel
diameter.
The drive unit again has two-wheel brackets and similar to the
idler unit these can be positioned to suit the vessel diameter.
Both wheel brackets are motorized.
Note
Self-Centered Rotators will have a lead screw and a hand
wheel .the distance between the two rollers can be adjusted by
turning the hand wheel provided on drive/idler unit.

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
3.Working condition & Environment
Required
Please make sure that there is enough space around the drive
& idler unit of tank Rotator so that servicing can be carried out.
1) Please note that this equipment to be installed in a clean
place free from dirt, moisture
2) Avoid direct exposure to sunlight
3) Care should be taken to see that it is not exposed to rain
4) Whenever the machine to be used at a site make sure
proper shade is provided for the machine
5) Do not keep the machine near oven, furnace where
temperature may be higher and it can affect the
performance of the machine
6) Always keep the machines at lease with a gap of 300 mm
around the machine as it is required for free circulation of
air
7) Keep the machine in a flat position
8) Use cables with proper cross section based on the input
power requirement of the machine (Please refer to
technical specification page for input power of the
machine)

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
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9) When long cables are used you need to select higher
cross-sectional area of conductors to avoid voltage drop
during the usage.
Selection guide for type of MCB
MCB
Type
Tripping Current
Application
B Type 3 to 5 times the rated
current
Purely resistive load like lighting
and general-purpose outlets
C Type 5 to 10 times the rated
current
Moderate inductive load like air
conditioners, residential /
commercial pumps
D Type 10 to 20 times the rated
current
Heavy inductive loads like heavy
induction motor and welding
machines
Selection of cable size for input supply
Please note that the cable size required for input supply
depends on following
1) Whether the machine is single phase or three phases
2) Input KVA of the machine
3) Distance from electrical supply point
First calculate the current the machine will draw based on the
input KVA given (refer to technical specification page for this)

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
If the machine is a single-phase machine then each KVA would
require around 4.6 Amps of current. That means if input KVA of
the machine is 5 KVA, then it would draw 23 Amps at full load
If the machine is a three-phase machine then each KVA would
require around 1.4 Amps of current. That means if the input
KVA of the machine is 5 KVA, then it would draw around 7
amps of current at full load
Cable capacity for copper cable can be taken as 5 Amps / Sq
mm when cable length is less than 10 meters. That means 1 sq
mm cable can carry a current of 6 Amps of current
Now you have
input current of the machine based on its input KVA
You can calculate the conductor size by this formula
Input current / capacity of conductor
Example
From the above for a single-phase machine of 5 KVA you would
need 23/6=3.8 Sq mm cable. (You can choose 4 sq mm cable)
From the above for a three-phase machine of 5 KVA you would
need 7/6=1.16 Sq mm cable. (You can choose 1.5 sq mm core
cable for each phase)

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
Note:
When the length of the cable is short the required cross
section for input cable will come down
Below table will help you in selecting the right size of welding
cable based on the length and current to be used.
Weld
ing Cable selection chart
Welding
Current in
Amps
Recommended Cable size (Sq mm) based on
length (in Mtrs)
1 ~ 15
Mtrs
15 ~ 30
Mtrs
30 ~ 45
Mtrs
45 ~ 60
Mtrs
60 ~ 75
Mtrs
100
16
25
25
35
50
150
16
25
35
50
50
200
35
35
50
50
70
300
50
50
70
70
95
400 70 70 70 95 120
600 95 95 95
800 140 140
1000 140 190
1200 190 240
1500 240 285
Note:
Table given is just for reference and the actual result may vary
depending on the quality of conductor
Multiple cables can be used where every single cable of
that capacity is not available

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
4.TECHNICAL SPECIFICATION
MODEL LOAD
CAPACIT
Y
WHEEL
DIA(MM)
WORK
PEICE
DIA(MM)
WHEEL
WIDTH
(MM)
KT-2 2 200 200-1200 100
KT-5 5 250 250-2300 100
KT-10 10 300 300-2800 120
KT-20 20 300 500-3500 120
KT-30 30 400 600-4200 150
KT-40 40 400 700-4600 150
KT-50 50 500 750-4800 150
KT-60 60 500 800-5000 150
 NO. OF WHEELS - 4
 WHEEL SPEED - 0.8 TO 0.16 MTRS/MIN
 INPUT POWER- 3 PHASE 380-440 VOLT 50 HZ
SUPPLY
 WHEEL MATERIAL - RUBBER/POLYURATHANE
+C.I. STEEL

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
5. WORKING PRINCIPLE
Tank Rotators are usually arranged in sets including a pair of
identical rolls, one of the which is rotated by an electric motor
through a reduction gearbox, known as powered unit or drive
unit while the other is idler, so arranged that the distance
between the rolls can be adjusted to accommodate vessels of
different diameters.
The idler unit basically consist of a base frame with two-wheel
bracket bolted on to the top of it. there are holes drilled
through the top of the base frame so that the wheel brackets
can be positioned at different distances apart, to suit the vessel
diameter.
The drive unit again has two-wheel brackets and similar to the
idler unit these can be positioned to suit the vessel diameter.
Both wheel brackets are motorized.
MOTOR &
GEARBOX
BASE FRAME
IDLER UNIT

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
GEARBOX

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
6. INSTALLATION
Once the Rotators are received at your end inspect for proper
condition of the equipment then choose the proper place for
Rotator installation.
Make sure that enough space is there around the machine.
Please note that the vessels will stretch out of the Rotators and
you need to allow space for that as well.
Vessels are loaded on to the Rotators by crane and hence make
sure that position of the Rotator in under the crane.
Lifting by Crane
The Rotator can be lifted by using the two hooks provided at
the end of the chassis. it is desirable that the angle between
the chain & the lifting crane should be 60. (as shown in figure)

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
Note
It is important to balance the loading equally between the drive
and idler section. Failure to do so may result in overloading one
of the sections which will cause problems when trying to rotate
the vessel. It can also result in back driving where the vessel
can continue to rotate after stopping the Rotators.
ADJUSTING THE WHEEL BRACKET
The operator will need to adjust the position of the two-wheel
bracket on the base frame, so that vessels of different diameter
can be loaded.
To do this operator needs to;
 Unbolt the wheel bracket from the base frame
 Use a crane (Can be pushed in case of lower capacity
rotators) to lift the wheel bracket using the hooks
 Move the wheel bracket to the required position for the
diameter of the vessel
 Bolt the wheel bracket back on to the base frame using all
the bolts, and tighten properly
INCLUDED ANGLE
The included angle is the angle between two lines from the
center of the rotation axis of the vessel to the center of each
wheel on the drive or idler section.
The distance between the wheel bracket on both the drive and
idler unit depends on the diameter of the vessel. the included
angle should be between 45 to 60.

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
Note - in case of self-centering Rotators the wheel distance can
be adjusted by turning the hand wheel. Do not turn the hand
wheel with job loaded on the Rotators.
It is important, as the angle increases so does the resulting load
on each wheel, and consequently the load on the bearings.
Increased inclusive angle also demands more torque, and
therefore more power is required to rotate the vessel.

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
7.CONTROLS
REMOTE
DISPLAY
W/SPEED
REVERSE
/FOWARD
SWITCH
(SPRING
LOADED)
REVERSE/
FORWARD
SPEED
EMERGENCY
SWITCH

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
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8 . PARAMETER & ITS OPERATIONAL
MEANING
W/SPEED This indicator will show the speed
of the wheel in RPM or Linear
Speed of the wheel. This speed OR
RPM is the speed/RPM of the job
also
E STOP This is an emergency STOP button
SPEED This knob is used for step-less
regulation of the speed of the
wheels of drive unit
FORWARD / REVERSE SWITCH
(Left)
This Switch is used to set the
direction of ration for the wheel
FORWARD / REVERSE SWITCH
(Right)
This is a spring return switch used
as inch Switch for momentary
rotation of the wheel.
9. HOW TO OPEARTE THE MACHINE
 First complete the installation as explained in chapter 6
 Set the wheel housing on scale as per your job diameter.
 Load the job on the Rotator wheels with the help of crane.
 Turn on the main supply and also the MCB provided on the
machine.
 Set the required current as per electrode size and job
thickness (As per WPS)
 Set the speed of job with the help of speed knob provided
on remote box.
 Start the welding process
 Start the Rotator.

WARPP ENGINEERS PVT LTD
36/15,UNIQUE INDL ESTATE ,DHUMAL NAGAR ,WALIV PHATA ,VASAI(EAST)
C NO -8080808734
EMAIL - [email protected]
10. DO’S & DON’TS
 Don’ts -Welded or extended Parts of vessel may come into
contact with the Rotator frame, Wheel OR the floor
Resulting in damage to Rotator or toppling of the job. This
may also result in over load of the Rotator.
Do’s -Care should be taken while loading a job on Rotator.
Please make sure extended parts of job do not touch the
ground or Rotator frame base. If there are extended parts on
job; keep the Rotator on height so that it will not touch the
ground.
 Don’ts - If distance between the wheel bracket is too large,
thus demanding more torque for the vessel of same weight.
Do’s - Always maintain the proper distance between the wheel
bracket as per the job diameter.
 Don’ts - If Wheel brackets are too close together. this is
very unsafe position. During rotation the vessel could roll of
the Rotator causing very serious injury to anyone in the
vicinity of the Rotators.it can also happen if there is an out
of balance load I.e., the center of gravity of the vessel is
offset from the axis of rotation. The Rotators should never
be operated at an angle less than 45
Do’s - when you load the job on rotator wheels; please make
sure you maintain angle between 45 to 70 between the wheel
center
 Don’ts - If the drive unit & idler unit are not parallel to
each other than the vessel can creep lengthways and even
fall off the Rotators. This can cause wear and damage to the