ESAB ARC400i User manual

ARC400i
INVERTER MMA
Welding Power Source
Instruction manual

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ARC400i
INVERTER MMA WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & General maintenance

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CONTENTS
Item
Page No.
SAFETY
4-5
RATING AND INSTALLATION
6-7
CONNECTIONS
8
WELDING OPERATIONS
8
WIRING DIAGRAM
9
TROUBLESHOOTING
10
PARTS LIST AND EXPLODED VIEW
11-14
ESAB INDIA LOCATIONS AND CONTACT DETAILS
15

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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.
Read and understand the instruction manual before installing or operating.
ESAB can provide you with all necessary welding protection and accessories.

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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

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RATING OF ARC400i INVERTER WELDING POWER SOURCE
Parameters
Unit
ARC400i
Output
No-load
voltage
V
72
Working
voltage
V
22.4-36
Rated welding
current
A
400
Current range
A
60-400
Rated duty
cycle
100%
60%
310A
400A
Input
Phases
phase
3
Frequency
Hz
50
Supply voltage
V
415
Rated input
current
A
26
Maximum
effective input
current
A
20
Rated input
capacity
kVA
24
Efficiency η
≥85%
COSφ
0.93
Insulation class
H
Degrees of protection
provided by enclosure
IP21S
Weight
kg
25
Dimensions (L×W×H)
mm
510×250×483

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INSTALLATION
The complete installation should consist the following items:
Description
Type
Quantity
1.
Welding Power Source
ARC400i
1
2.
Welding Cable with Holder
1
3.
Earth cable with Clamp
1
4.
Remote (Optional)
RT-ARC400i
1
CAUTIONS FOR INSTALLATION
Provide a Switch Box for every Welding Power Source, and use designated fuse
Tolerance of Power Voltage Variation is 10% of rated input voltage.
a) 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.
Use a shield to protect the welding arc in case of excessive air draft.
b) Ventilation
Adequate ventilation is recommended at the place of installation. For example the
following guideline should be followed:
a) In case of the area being more than 300 square meters (per unit), no ventilation is
required, provided the room is not completely airtight.
b) In case of the area being less than 300 square meters and the welding is
continuously performed, adequate ventilation is recommended with the help of vent
fan or exhaust duct.
c) While performing the grounding work, it is recommended that a skilled electrician
does the work.

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CONNECTIONS
a) Input
The specifications of recommended input cable, grounding line and fuse or circuit breaker are
listed below:
Rated
duty
cycle @
400A
Input
voltage
Input
current
Maximum
effective
input
current
60℃cable specifications
Fuse or
circuit
breaker
Three-phase
input cable
Grounding
wire
ARC400i
60%
415V
33A
26A
>6 mm2
>4 mm2
80A
b) Output
The positive and negative terminals of output circuit are at the bottom of the front panel, marked
with “+” and “－”.
Connect and rotate to tightened output cable from the “+” terminal to the positive OKC quick
connector at one end and the electrode holder at the other.
Connect and rotate to tightened output cable from the “－” terminal to the negative OKC quick
connector at one end and the work piece at the other.
Remote control can be connected at the bottom of the front panel depending on the user
selection.
WELDING OPERATIONS
Switch on the power switch at the rear panel of the machine. After switching on the machine, the
power indicator on the front panel will be lighted (red), the current digital meter displays will be ON,
the fan starts running and voltage is available at the output terminal.
The welding current can be set continuously from minimum to maximum value by turning the
welding current knob on the front panel when machine is local mode. When the machine is in
remote mode current can be set by remote potentiometer.
When the power switch at the rear panel is turned off, machine is shut off and power indicator light
is off, digital display will be off, Fan stops rotating.
The droplet transfer property of the welding could be improved through adjusting the ARC FORCE
knob and the arc property of cold electrodes could be regulated through adjusting the HOT
START knob. When the above two knobs are set properly and the welding current is regulated at
right value, the welding will be much easier and more stable.

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TROUBLESHOOTING
All parts of the fan are sealed such that extra maintenance is not required for the fan.
When operated at dusty place, the machine’s air duct may get plugged to cause the machine
overheated, therefore, remove inside of the machine’s dust with dry compressed air regularly.
Overload protection
The thermostat inside the welding machine can effectively protect important power devices with
overload or insufficient cooling, by the thermostat switch. When the machine is continuously
overloaded or the power device IGBT and fast recovery diodes are not cooled adequately, the
over temperature indicator will be lighted and normal output of the machine will be stopped. When
these components are sufficiently cooled, the over temperature indicator will be off and the voltage
output of the machine returns to normal.
Under-voltage protector is equipped in the machine control circuit to stop operation of the machine
when the input voltage is too low. When the input voltage is not within limits, the output of the
machine will stop. If no voltage is available at the output terminals and the power signal is on while
the overheat indicator is off, please check the input supply voltage.

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PARTS LIST AND EXPLODED VIEW
Serial No.
Name of component
Material code
1
Output terminal
0050804024
2
Remote Socket
0012001004
3
Control board
0030101625
4
Arc Force and Hot Start current knob
0010603057
5
Welding current knob
0010603056

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Serial No.
Name of component
Material code
7
Miniature circuit breaker
0011501003
8
Input cable
0030501596
9
Fan
0011702012

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Serial
No.
Name of component
Material
code
10
Driving board
0030101626
11
Control transformer
0060101174
12
IGBT module
0012101029
13
Contra variant board
0030101617
14
Three phase rectifier
module
0012103013
15
Filter capacitor
0010222002
16
AC polypropylene
capacitor
0061301063
17
Power supply
detection board
0030101618
18
Primary inductance
0031001022
19
Current transformer
0011303003
20
Absorption board
0030101384
21
Main transformer
0030801246
22
Auxiliary inductance
0031001012
23
Diode board
0030101102

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Serial No.
Name of component
Material code
24
Handle
0061301073
25
Three phase input inductance
0030501187
The material code of components within the wiring board in the diagram
Model
Driving board
Control
board
Diode board
Absorption
board
ARC400i
0030101626
0030101625
0030101102
0030101384
Circuit
board

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Web: www.esabindia.com