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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. 

 

 

 

 

 

Summary of Contents for WTR-400

Page 1: ...NG 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 91 22 28542272 73 74 Fax 28542275 E mail sales warpp co in Web Site www warpp co in ...

Page 2: ...e 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 ...

Page 3: ...ying 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 aut...

Page 4: ...ssible 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...

Page 5: ...TENANCE 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 leath...

Page 6: ...ot 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 i Control Transformer Damaged ii Fan Damaged iii Current Regulator Damaged iv Control Rectifier Damage i Check Replace ii Ch...

Page 7: ...ace iv Check Replace 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 i Reduce the current ii Use proper polarity Interchange the polarity and check iii Replace the diode OR Diodes Mains fuse blows i Short circuit in the primary of the main transformer ii Short circuit in main diodes i ...

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Page 11: ...ndary Coil C1112 2600 DC Coil C1122 1500 Load Coil Without Tappings C1121 800 Load Coil With Tappings C1119 850 Diode C150401 600 Out Put Terminal C180101 400 High Low out put terminal C180401 750 Indicator Red 220V 20MA 20MM C240701 100 Toggle Switch C221801 100 Power plug backalite Male C240901 75 Power plug backalite Female C241001 75 Rotary Switch C220401 500 SPARE PART LIST FOR WTR 400 WTR 40...

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