WARPP WTR-600 User manual

OPERATION MANUAL FOR
ARC WELDING RECTIFIER
Model WTR-600
WARPP ENGINEERS PVT. LTD.
B-1005, Western Edge II, Near Metro Mall, Off. Western Express
Highway, Borivali (E), Mumbai-400 066.
Tel: [phone]/14. Fax: [phone].
E-mail: [email protected] Web Site: www.warpp.co.in

INDEX
Sr. No. Description Page No.
1 Introduction 1
2 Installation 2
3 Operation 3
4 Maintenance 3
5 Safety 4
6 Trouble shooting 5
7 Spare part List 8
ILLUSTRATIONS
1) Control Circuit Wiring Diagram 9
2) Power Circuit Wiring Diagram 10
3) Installation Diagram 11

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 FROM 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.
2

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.
3) Put the ON-OFF Switch on front panel of the equipment in ON position this will
a) Start the cooling FAN
b) Energies the main transformer
c) Puts on the MAINS indicator.
4) Set the current regulator to the required output current.
5) Connect the JOB EARTH cable firmly to the job.
6) Hold the required electrode in the holder.
7) Strike an arc by scratching the electrode to the job.
3

MAINTENANCE.
1) Switch OFF the mains supply.
2) Open the top cover
3) Clean the equipment by removing dust by a blower.
4) Lubricate the fan bearings in regular intervals.
CAUTION: SWITCH OFF THE SUPPLY BEFORE OPENING THE EQUIPMENT.
SAFETY PRECAUTION:
1) Welding light is dangerous to the eyes as it has ultraviolet rays. Always use
welding screen with proper glass while welding.
2) Wear leather gloves, Apron and leather shoes while welding.
3) Keep the welding area relatively clean and free from inflammable materials
4) Use fully insulated holder.
5) Do not touch the electrode with the bare skin.
4

TROUBLE SHOOTING.
TROUBLE CAUSE REMEDY
Mains supply is
switched ON and ON-
OFF switch is put to
ON position but
welder does not come
ON.
I) Three phase supply is not
proper
ii) Mains Switch is not proper.
iii) Control fuse is blown off
I)Wait till the three phase
power is available
ii) Check for the proper
electrical contacts in the
mains switch.
iii) Replace the control fuse.
(This fuse is mounted on the
control transformer.
Equipment comes on
but the welding
current varies.
I) The mains connection is not
proper.(Loose connection)
ii) Current regulator is not
working properly. (Either the
carbon brush is weared out
OR it is not making the proper
contact.
I) Check the mains for proper
and firm connection.
ii) Replace the carbon brush.
The equipment comes
ON but the
control fuse blows.
Welding arc is not smooth and
spatter is more
I) Current setting is too high.
ii) DC polarity used for that
particular electrode is not
right.
iii) Diodes have failed.
Welding arc is sluggish. I) Welding current is low.
ii) Loose connection
iii) Input supply is less.
the equipment give minimum
current but the current doesn’t
increases
i) Current regulator burnt OR
not working.
ii) Control transformer is
dead.
iii) Control rectifier is failed.
iv) Control fuse is blown.

i) Reduce the current.
ii) Use proper polarity
(Interchange the polarity and
check).
iii) Replace the diode OR
Diodes.
I) Increase the current.
ii) Make firm connection.
iii) Check the input
supply.
and use proper tapping
(380/415/440) by changing the
jumper on the main
transformer
I) Replace.
ii) Replace.
III) Replace.
iv) Replace.
Mains fuse blows i) Short circuit in the
primary of the main
transformer.
ii) Short circuit in main
diodes
i) Remove the short circuit.
ii) Replace the diodes.

Description PART NO
Control Transformer C140401
Control Rectifier C244801
Auto transformer C140101
Fan C160302
Primary coil Top C1104
Primary Coil Bottom C1103
Secondary Coil C1113
DC Coil C1123
Load Coil Without Tappings C1126
Load Coil With Tappings C1124
Diode C150502
Out Put Terminal C180202
High-Low out put terminal C180502
Indicator Red 220V 20MA 20MM C240701
Toggle Switch C221801
Power plug backalite Male C240901
Power plug backalite Female C241001
Rotary Switch C221402
SPARE PART LIST FOR WTR-600