ABB RPB 520 User manual

Instruction manual
505 890-102
2003-05
RPB 320/420/520 Power source

The information in this document can be subject to change without prior notice and should not be
regarded as an undertaking from ABB. ABB assumes no responsibility for errors that can appear in
this document.
ABB is not responsible for damage incurred by the use of this document or software or hardware
described in this document.
The document, or parts there of, may not be reproduced or copied without prior permission from ABB.
It may neither be imparted to a third party nor otherwise used without authorisation. Infringement here
of will be subject to action in accordance with applicable laws.
Further copies of this document can be obtained from ABB at current prices.
ABB Automation Technology Products AB
Article number: 505 890-102
Date: 2003-05
ABB Automation Technology Products AB
Arc Welding & Application Equipment
S-695 82 Laxå
Sweden

RPB 320/420/520
LIST OF CONTENTS Page
505 890-102 3
1 Introduction................................................................................................................. 5
1.1 Safety ................................................................................................................. 5
1.2 Description......................................................................................................... 6
2 Start-up ........................................................................................................................ 7
2.1 Placing ............................................................................................................... 7
2.2 Connection to the mains .................................................................................... 8
3 Controls and utilization.............................................................................................. 9
3.1 Main switch ON/OFF (I/O) ............................................................................... 9
3.2 Indicating lamps................................................................................................. 9
3.3 The function of the fan....................................................................................... 9
4 Maintenance/Service................................................................................................... 11
4.1 Cables................................................................................................................. 11
4.2 Power source...................................................................................................... 11
4.3 Functional trouble.............................................................................................. 12
5 Technical Data ............................................................................................................. 15
6 Diagram........................................................................................................................17
6.1 RPB 320............................................................................................................. 17
6.2 RPB 420............................................................................................................. 18
6.3 RPB 520............................................................................................................. 19
7 Reservdelsförteckning/Spare Parts List..................................................................... 21
7.1 RPB 320............................................................................................................. 22
7.2 RPB 420............................................................................................................. 26
7.3 RPB 520............................................................................................................. 30

RPB 320/420/520
4505 890-102

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This manual is intended for use by technicians with appropriate electrical training
for fault-tracing and repair.
The product complies with the demands for CE marking.
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• Install and earth the welding equipment in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare hands, wet gloves
or wet protecting clothing.
• Insulate yourself from earth and from the workpiece.
• Ensure your working stance is safe.
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• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from
your breathing zone and the general area.
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• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protecting clothing.
• Protect bystanders with suitable welding helmets or curtains.
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• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
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S11 Main switch I/O
02 Mounting opening for
control panel
H11 Indicating lamp I/O
H12 Indicating lamp for ther-
mal protection
5Welding dynamics control
01 Mains cable grommet
F11 Fuse for control panel 6.3 A, Slow
F12 Fuse for mains terminal 1,0 A Slow
X11 Welding and return cable
connection Parallel
X12 Welding and return cable
connection Parallel
X13 Welding and return cable
connection
X14
X15 Control cable connection Parallel
X16 By productive earhed outlet isolated safety transformer,
RPB 420/520
1~”230V/
250VA”
02
H11H12
S11
5
01
F11
F12
X16
X11, X12
X14
X15
X13

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• Preferably place the machine above floor level.
• Make sure there is DWOHDVW 20 cm free space behind and in front of the
power source for the cooling air to circulate.
• Protect the power source from heavy rain and under hot conditions also
from direct sunlight.
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See to that the machine is positioned away from line of particle spray, created by
grinding tools etc.
max. 15°
rain water
60°

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The power source is supplied with 5 m mains cable without plug.
1RWHMounting or replacing the mains connection cable and plug shall only be exe-
cuted by an expert.
1RWHFor the mounting of the cable, first remove the right-hand side panel.
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Pass the cable through the hole on the rear of the power source and lock it by way
of the cable retainer (05). Connect the phase conductor of the cable to the connec-
tions L1, L2 and L3. Connect the yellow/green earth conductor to the connection.
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*S-type cables include a yellow/green conductor for protective earthing.
RPB 320 RPB 420 RPB 520
Nominal voltage
Mains voltage range 400V 3~ 360V ......440V 400V 3~ 360V ......440V 400V 3~ 360V ......440V
Fuses 25A 25A 35A
Connection cable *mm24 x 2,5 S 4 x 6,0 S 4 x 6,0 S
05
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When the switch is set to position ,the indicating lamp (+ on the front goes on
to indicate that the power source is ready for use.
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There are two indicating lamps (H11, H12) on the power source, se Figure 6.:
The green lamp (H11) for stand-by mode is always on when the power source is
connected to the mains and the main switch is in position I.
The yellow lamp (H12) for thermal cut-out goes on when the thermostat has tripped
as a result of overheating. The fans cool the power source and when the lamp goes
out the power source is ready for use again (resetting takes place automatically).
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RPB 320 has one fan and RPB 420/520 has two fans running simultaneously.
• The fans run for a while when the main switch is turned to position I.
• The fans go on when the power source after a period of welding is heated
and stops 1-10 minutes after the welding is terminated.
• At idle running the fans enter into function for about 60 sec. every 30 min.
H11
H12

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The degree of utilization as well as exterior conditions influence the demand for
service of the power source to a high extent. Sensible use and preventive mainte-
nance will guarantee problem-free operation.
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Check the condition of the welding and return cable every day.
1RWHNever use damaged cables!
Make sure the connection cables conform to the regulations valid.
1RWHRepair and mounting of mains connection cables shall only be executed by
an authorized electrician.
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1RWHUnplug the cable from the wall socket and wait about 2 min. (due to capacitor
discharge) before removing the cover plate.
Check the following points at least once every six months:
• The electrical connections of the machine - clean oxidized components and
tighten loose parts.
1RWHBefore the connection work is started, inform yourself about the right tight-
ening torques.
• Clean the inner parts of the power source from dust and filth, using a soft
brush and a vacuum cleaner.
1RWHDo not use compressed air as there is a risk that filth hereby can get packed
even harder in the apertures of the cooling profiles!
1RWHDo not use high-pressure washing!
1RWHRepair of the power source is only to be executed by an authorized electri-
cian.

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1RWHIn the event of functional trouble, please contact your nearest FAC/ABB
agency.
Check the service points before sending the power source to the workshop.
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Theyellow indicatinglamp forthermaloverload(H12) goes onwhen the thermostat
has tripped as a result of overheating of the power source.
The thermostat trips if the power source is continuously overloaded beyond the nor-
mal values, or if the circulation of the cooling air is blocked.
The fans cool the power source, and when the lamp goes out the power source is
ready for use again (resetting takes place automatically.)
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The fuse (F11, 6.3 A, slow) on the rear of the power source functions as a protection
for the terminal of the remote control cable X14-15.
The supply voltage unit for extra equipment (single-phase, alternating current, 30V/
240 VA) has a separate fuse (F12 1.0 A, slow).
1RWHUse the same type and size of fuse as indicated beside the fuse holder.
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The primary circuits of the machine are protected against sudden, short over-volt-
ages.
The machine is designed for continuously withstanding 3 x 440V, (see Technical
Data: 415V +6%). Check that the voltage remains within the permissible limits, par-
ticularly when the voltage is supplied by for example a generator, driven by an inter-
nal combustion engine.
If there is under-voltage on the mains (below 300 V) the control of the power source
automatically ceases to function.

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505 890-102 13
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Phase dropout leads to considerably worse welding properties compared to normal
conditions, or that it is not possible to start the power source at all.
Phase dropout can be caused by:
 A tripped mains fuse
 A defect mains cable
 Bad connection of the mains cable to the terminal block or to the socket
outlet.
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The MIG and MAG welding dynamics are controlled over the same potentiometer.
Setting the MIG and MAG welding dynamics:
The setting of the MIG/MAG welding dynamics influences the stability of the weld-
ing and the amount of spatter coming up.
The welding result can be optimized for each type of wire and each mixture of
shielding gas by way of the setting.
-9...-1 A soft arc is used to cause less spatter.
0 Recommended basic setting for all types of wire.
1...9 A hard arc is used to maximize the stability of the arc within the short-arc
range, for example, or for steel welding using 100% CO2 shielding gas, (position
7...9).

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RPB 320 RPB 420 RPB 520
Electric connection, 3-phase
a.c.
Connection power
Connection cable and fuses
50/60 Hz
80% duty cycle
100% duty cycle
400 V ±10%
320 A/14,6 kVA
4x6S - 5m/25 A slow
400 V ±10%
420 A/19,7 kVA
400 A/18,6 kVA
400 V ±10%
520 A/26,6 kVA
440 A/20,0 kVA
Permissible load
Max. 40º(rated values)
Setting range
for welding current and
voltage (steppless)
Max. welding voltage
80% duty cycle
100% duty cycle
MIG/MAG
320 A/32,8 V
10 V...36 V
46 V/300 A
420 A/36,8 V
400 A/36 V
10 V...41 V
46 V/400 A
520 A/40.0 V
440 A/37,6 V
10 V...45 V
50 V/500 A
Open-circuit voltage
No-load power
Efficiency at rated values
Power factor at rated values
ca 65 V
< 75 W
ca 85%
ca 0,93
ca 65 V
< 75 W
ca 85%
ca 0,93
ca 65 V
< 75 W
ca 85%
ca 0,93
Storing temperature
Working temperature
Temperature class
Protection class
-40...+60 °C
-20...+40 °C
H (180 °C)/B (130 °C)
IP 23
-40...+60 °C
-20...+40 °C
H (180 °C)/B (130 °C
IP 23
-40...+60 °C
-20...+40 °C
H (180 °C)/B (130 °C
Outer dimensions
without handle
Weight
Length
Width
Height
530 mm
230 mm
520 mm
37 kg
530 mm
230 mm
520 mm
41 kg
530 mm
230 mm
520 mm
48 kg
Terminal 230V
X16 Single fase, alternating current,
230 V/250 VA
slow fuse 1,0 A
Single fase,
alternating current,
230 V/250 VA
slow fuse 1,0 A
Single fase,
alternating current,
230 V/250 VA
slow fuse 1,0 A

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6.1 RPB 320

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6.2 RPB 420

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6.3 RPB 520

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