ESAB AK 400 User manual

AK 400
AK 600
Fully Thyristorised MIG/MAG
Welding Power Source
Instruction manual

AK400, AK 600
FULLY THYRISTORISED MIG/MAG WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General maintenance

CONTENTS
Item Page No.
SAFETY 1-2
ASSEMBLING 3
ACCESSORIES LIST 3
RATING 4
CAUTIONS FOR INSTALLATION 5
INSTALLATION 6
WELDING OPERATIONS 7
JIG TERMINALS AND SWITCHING TERMINALS 8-9
IN WELDING POWER SOURCE. OPERATIONS
MAINTENANCE & INSPECTION 10
AFTER SALES SERVICE 11
FAULT FINDINGS 12-14
OVERALL CIRCUIT DIAGRAM 15, 16
RECOMMENDED LIST OF SPARE PARTS 17
WELD DEFECTS AND POSSIBLE CAUSES 18-19

SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety
precautions. Safety precautions must meet the requirements that apply to this type of
welding equipment. The following recommendations should be observed in addition to
the standard regulations that apply to the workplace.
Trained personnel well acquainted with the operation of the welding equipment must
carry out all the work. Incorrect operation of the equipment may lead to hazardous
situations, which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
2. The operator must ensure that:
• no unauthorized person is stationed within the working area of the equipment
when it is started up.
• no one is unprotected when the arc is struck
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment
• Always wear recommended personal safety equipment, such as safety glasses,
flameproof clothing, and safety gloves.
• Do not wear loose—fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. General precautions
• Make sure the return cable is connected securely.
• Only a qualified electrician may carry out work on high voltage equipment.
• Appropriate fire extinguishing equipment must be clearly marked and close at
hand.
• Lubrication and maintenance must not be carried out on the equipment during
operation.
1

Read and understand the instruction manual before installing or operating.
ESAB can provide you with all necessary welding protection and accessories.
WARNING
Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’
hazard data.
ELECTRIC SHOCK – Can kill
• Install and earth the welding unit in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare skin, wet
gloves or wet clothing.
• Insulate yourself from earth and the workpiece.
• Ensure your working stance is safe.
FUMES AND GASES – Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS – Can injure eyes and burn skin.
• Protect your eyes and body. Use the correct welding screen and filter
lens and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE – Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk.
MALFUNCTION – Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding
Do not dispose of electrical equipment together with normal waste!
In accordance with national law, electrical equipment that has
reached the end of its life must be collected separately and returned
to an environmentally compatible recycling facility. As the owner of
the equipment, you should get information on approved collection
systems from the local representative. By applying this Directive you
will improve the environment and human health
2

A. ASSEMBLING
The complete Installation should consist of the following items:
Description Type Quantity
1. Welding Power
Source
AK 400
OR
AK 600
1
2. Wire Feeder &
Remote Control
Unit
SERVO WIREFEEDER- I WITH
ACCESSORIES & REMOTE CONTROL
UNIT – RC AK 400
OR
SERVO WIREFEEDER- II WITH
ACCESSORIES & REMOTE CONTROL
UNIT – RC AK 600
1
B. ACCESSORIES LIST FOR AK 400 / AK 600 THYRISTORISED
MIG/MAG WELDING POWER SOURCES
Fuse, element 5A 1 piece
Fuse, element 8A 1 piece
Instruction Manual 1 piece
3

C. RATING OF AK 400 / AK 600 THYRISTORISED MIG/MAG
WELDING POWER SOURCES
CHARACTERISTICS CONSTANT POTENTIAL TYPE
INPUT:
SUPPLY VOLTAGE, PHASE
& FREQUENCY
415 V ±10%, 3 PHASE, 50 HZ, AC
MAXIMUM INPUT CURRENT 31 Amps 55 Amps
MAXIMUM RATING 20.7 KVA 40 KVA
OUTPUT:
OUTPUT CURRENT RANGE DC 60A-400A DC 60A-600A
Maximum output Current at
60% Duty Cycle
400 Amps 600 Amps
Maximum continuous current
at 100% Duty cycle
310 Amps 470 Amps
Open circuit voltage (Max) 53 Volts DC 63 Volts DC
Type of Welding Voltage &
Current control
Stepless through remote control
Unit RC AUTO K 400 &
RC AUTO K 600
Class of Insulation CLASS H
COOLING FORCED AIR COOLED
Approximate dimension
(LENGTH X WIDTH X
HEIGHT) in mm
675X 350 X 690 617 X 455 X 850
Weight (Approximate) 110 Kgs. 155 Kgs.
4

D. CAUTIONS FOR INSTALLATION
a) Capacity of Equipment
Input Voltage
AC 415 V ±10%
Number of Phase &
Frequency
3 phases, 50 HZ
AK 400 AK 600
Maximum rating of
Equipment
20.7 KVA 40 KVA
Capacity of Fuse (B Class) 32 Amps 63 Amps
Input Cable More than
8 mm2 More than 14 mm2
Output Cable More than
38 mm2
More than
60 mm2
− Provide a Switch Box for every Welding Power Source, and use designated
fuse
− Tolerance of Power Voltage Variation is ±10% of rated input voltage.
− 100 Amps MCB to be used as alternative to SFU.
b) Installation place
− Install in the place where less moisture and dust exist. Avoid direct sunlight and
rain, and maintain ambient temperature within –10o to 45o C as much as
possible.
− Keep the welding power source at least 20 cm. away from the wall (if any).
− In case of installation of more two units side by side, a distance of more than 20
cm. is recommended between the two power sources.
− Keep the Gas Cylinder on a separate stand.
− Use a shield to protect the welding arc in case of excessive air draft.
5

c) Ventilation
Adequate ventilation is recommended at the place of installation. For
example the following guideline should be followed:
a) In case of the area is more than 300 square meters (per unit), no
ventilation is required, provided the room is not completely air tight.
b) In case of the area is less than 300 square meters, the torch is used in
fixed condition and the welding is continuously performed, adequate
ventilation is recommended with the help of vent fan or exhaust duct.
E. INSTALLATION ITEMS OF AK 400 / AK 600
While performing the grounding work, it is recommended that a skilled electrician does
the work.
No. Items No. Items
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Remote Control Unit
RC AUTO K 400 / RC AUTO K 600
Wire Feeder
SERVO WIREFEEDER-I / SERVO
WIREFEEDER-II
Welding Torch PSF 400 / PSF 500
Base Metal
Gas Regulator
Gas Cylinder
Switch Box
Connector for Remote Control
Gas Outlet
Connector for Wire Feed
Terminal for work
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Terminal for Wire feeder (+)
Gas Inlet
Connector for CO2 Heater
Control cable for RC
AK 400 / RC AK 600
Welding Cable
Gas Hose
Welding Cable
Control cable for Wire feeder
Gas Hose
Cable for CO2 Heater
Input Cable
6

F. WELDING OPERATIONS
The welding operation can be adjusted from the front operation panel of the power
source and remote control unit.
Gas Supply:
To check the gas supply before welding, set the SHIELD GAS switch to CHECK
position. The shielding gas will start flowing. After confirmation, release the switch and
it will automatically return to WELD position.
Welding method:
Set the switch at CO2or Ar-CO2depending on the Shielding Gas used for GMA
welding.
Self hold:
When the Self hold / Crater switch is ON, the arc is produced while the torch switch is
ON and then the self hold is maintained even though the torch switch is turned OFF,
and the crater control condition will start functioning if the torch switch is triggered ‘ON’
for the second time.
Crater control function
An Arc Crater normally formed at the end of the welding can be filled without any
defect by adjusting the crater current and crater voltage knobs on the front panel of
the Power Source.
Remote Control unit
Adjust welding voltage and current from the Remote Control Unit as per following
guidelines:
a) Welding Current Adjustment:
Set the welding current by turning the current adjustment knob and adjust at
the proper graduated value of the current. However, for fine-tuning, set the
welding current from the ammeter in the front panel of the Power Source, by
generating an experimental Arc.
7