Summary of Contents for WARPP HB-50
- Page 1 Welding Positioner Operator’s Manual WARPP ENGINEERS PVT. LTD. 36/15 Unique Industrial Estate, Dhumal Nagar, Waliv Phata, Vasai (East), Palghar, Maharashtra -401208 Email- service@warpp.co.in Contact- 8080808734 www.warpp.co.in...
- Page 2 Caution: Before attempting to connect the equipment to any Power source, read instructions carefully. In case of 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.
- Page 3 INDEX 1. Safety 2. Product Description and feature 3. Working condition and environment required 4. Technical specification 5. Working principle 6. Installations 7. Controls 8. Parameters and its operational meaning 9. How to operate the machine 10. Do’s & DON’T’s 11.
- Page 4 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 •...
- Page 5 • When compressed gas is to be used, then special precautions are 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.
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Page 6: Description & Feature
2. DESCRIPTION & FEATURE Welding Positioners are devices that provide a comfortable position for a welder to perform welding operations on industrial parts which are tubular or spherical in shape such as flanges and pipelines. A welding Positioner provides options to rotate the tubular equipment through 360 degrees and the welder can set the angle of the flanges or pipeline according to his/her needs and requirements. - Page 8 3. WORKING CONDITIONS & ENVIRONMENT REQUIRED 1) Please note that this equipment to be installed in a clean place free from dirt and 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 an oven or furnace where temperature may...
- Page 9 Selection guide for type of MCB Tripping Current Application Type B Type 3 to 5 times the rated Purely resistive load like lighting current and general-purpose outlets C Type 5 to 10 times the rated Moderate inductive load like air current conditioners, residential / commercial pumps...
- Page 10 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.
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Page 11: Technical Specification
4. TECHNICAL SPECIFICATION Model HB-50 HB-150 HB-300 HB-500 HB-1000 HB-2000 HB-5000 230 VAC 230 VAC 230 VAC 440 VAC 440 VAC 440 VAC 440 VAC Input Single Single Single Three Three Three Three supply Phase Phase Phase Phase Phase Phase... -
Page 12: Working Principle
5. WORKING PRINCIPLE A welding Positioner is a device designed keeping in mind the welder’s comfort. It helps reduce their fatigue as they can stand in one position and do their job. They do not have to move or bend as this welding positioner can rotate up to 360 degrees. -
Page 13: Installation
6. INSTALLATION Installing the Main Unit: Place the main unit on a flat installation location. Secure the unit by inserting suitable anchor bolts into the holes around the base of the unit. Connecting the Foot Switch (Optional): Connect the cable of the foot switch to the mating plug on the main unit. - Page 14 7. CONTROLS Panel Control for HB-50, HB-150 & HB-300 ON/OFF Switch Input Revolution Supply Direction Control Indicator Speed Control Dial Remote Control for HB-500, HB-1000, HB-2000 & HB-5000...
- Page 15 Display Emergency Stop Speed Control Dial Direction Contro Direction Contro 3-way Spring 3-way Selector Switch Return Switch 8. PARAMETERS AND ITS OPERATIONAL MEANING...
- Page 16 Indicates the faceplate rotation DISPAY speed in RPM E STOP This is an emergency STOP button This knob is used for step-less SPEED regulation of the speed of the wheels of drive unit FORWARD / REVERSE SWITCH This Switch is used to set the (Left) direction of ration for the wheel This is a spring return switch used...
- Page 17 9. HOW TO OPERATE A POSITIONER? Here is a step-by-step guide for operating the Positioner: 1. Turn on the Main Power Supply and Power Switch: Activate the main power supply and switch on the Positioner. 2. Prepare the Work Surface: Ensure the table is horizontal.
- Page 18 10.Do’s & Don't s Do’s: 1. Clean the Face Plate Surface: Before loading a job for welding, ensure the face plate surface is clean and free from debris. 2. Proper Earthing: Always use the Positioner with proper earthing to prevent electrical hazards. 3.
- Page 19 Don’ts: 1. Improper Earth Connection: Do not connect the earth conductor to a conduit, gas pipe, or flammable liquid pipe system. 2. Switching On with Remote Switches On: Do not power on the supply when any switch on the remote is in the “on” position.
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Page 20: Troubleshooting
11. TROUBLE SHOOTING Here are troubleshooting steps and solutions for common issues related to the Positioner: 1. Table Does Not Rotate: Possible Causes: 1. Power cord is not properly secured. 2. Blown fuse. 3. Power cord is damaged. 4. Switch or foot switch malfunction. 5. - Page 21 3. Spatter from welding adhered to the gears. 4. Load exceeding the allowable limit on the table. Solutions: Tighten the bearing nut or replace the bearing ▪ assembly. Clean and apply grease to the gears if spatter is ▪ present. Ensure the load on the table is within the allowable ▪...
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Page 22: Wiring Diagram
12. WIRING DIAGRAM WELDING POSITIONER WELDING DIAGRAM REMOTE BOX WIRING DIAGRAM... - Page 23 Note - remote box wiring diagram is same for all the Positioners.
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Page 24: Maintenance
13. MAINTENANCE Proper maintenance is crucial for ensuring the longevity and efficient operation of Positioners. Here are the recommended maintenance checks and guidelines: 1. Oil Change: Regularly check and change the oil in the gearbox. Except for the first oil change, replace the gearbox oil every 2500 hours or 6 months (applicable to tilting gearboxes). -
Page 25: Spare Part List
14. SPARE PART LIST -150 -300 -500 -1000 -5000 MOTOR FOR SP03325 SP03325 SP08358 SP09315 SP00090 SP02782 ROTATION GEARBOX SP08107 SP04961 SP03335 SP03335 SP01534 SP02782 SP09314 SP04627 ROTATION MOTOR FOR SP03326 SP00090 SP03303 TILTING GEARBOX SP03003 SP01225 SP03007 FOR TILTING SLEW RING SP04923 SP03537... - Page 26 PART DESCRIPTION NUMBER LIMIT SWITCH SP02025 SELECTOR SWITCH 3 POSITION ON/OFF/ON SP03438 14 PIN CONNECTOR FEMALE SP00048 14 PIN CONNECTOR MALE SP00047 POWER PLUG METAL TYPE 2 PIN (MALE) SP02858 POWER PLUG METAL TYPE 2 PIN (FEMALE) SP02857 SELECTOR SWITCH 3 POSITION CENTER OFF WITH SP03439 SPRING RETURN BOTH SIDE POTENTIOMETER-10K 10TURN...
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