ESAB EASY-WELD SSR 400 Owner's manual

EASY-WELD SSR 400/600
Fully Thyristorised Welding Rectifier (MMA)

EASYWELD SSR 400, SSR 600
FULLY THYRISTORISED MMA WELDING POWER SOURCE
Instruction manual
For
Installation, Operation & maintenance

Contents
Page No.
SAFETY 1-2
RATING & ASSEMBLING 3
ACCESSORIES LIST 4
INSTALLATION 4-5
WELDING OPERATIONS 6
MAINTENANCE & INSPECTION 7
FAULT FINDINGS 8-9
ELECTRICAL WIRING DIAGRAM 10-11
PCB CHECK POINTS 12-13
WELD DEFECTS AND POSSIBLE CAUSES
SPARES LIST
14
15

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.
All work must be carried out by trained personnel well acquainted with the operation of
the welding equipment. 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.
• Work on high voltage equipment may only be carried out by a qualified electrician.
• 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

RATING OF EASYWELD SSR 400, SSR 600
EASY WELD
SSR-400
EASY WELD SSR-
600
CHARACTERISTICS
INPUT:
SUPPLY VOLTAGE, PHASE &
FREQUENCY 415 V ±10%, 3 Phase, 50 Hz, AC
MAXIMUM INPUT CURRENT 30 Amps 55 Amps
MAXIMUM RATING 21.6 KVA 40 KVA
OUTPUT:
OUTPUT CURRENT RANGE DC 10-400 A
(Single Range)
DC-10A – 600A
(Single Range)
MAXIMUM CURRENT AT 60% DUTY
CYCLE 400 Amps DC 600 Amps DC
MAXIMUM CONTINUOUS CURRENT AT
100% DUTY CYCLE 310 Amps DC 470 Amps DC
OPEN CIRCUTI VOLTAGE (MAXIMUM) 100 Volts DC
TYPE OF WELDING CURRENT
CONTROL STEPLESS
CLASS OF INSULATION ‘H’
COOLING FORCED AIR COOLED
APPROX DIMENSION
(L x W x H) IN mm 675 x 350 x 690 615 x 455 x 850
WEIGHT (APPROX) 130 Kgs. 160 Kgs.
ASSEMBLING
The complete installation should consists the following instruments:
Sl
No. Description Type Quantity
1.
WELDING
POWER
SOURCE
EASYWELD SSR – 400
OR
EASYWELD SSR – 600
ONE
2.
REMOTE
CONTROLLER
RCU SSR 400
or
RCU SSR-600
ONE
3

ACCESSORY LIST
FUSE ELEMENT 3A 1 Piece
FUSE ELEMENT 1A 1 Piece
INSTALLATION
a) Capacity of equipment
EASY WELD
SSR-400
EASY WELD
SSR-600
INPUT VOLTAGE 415 V ±10% AC
FREQUENCY & PHASE 50 Hz, 3 PHASE
MAXIMUM RATING OF EQUIPMENT 21.6 KVA 40 KVA
CAPACITY OF FUSE (B CLASS) 32 Amps HRC 60 Amps HRC
INPUT CABLE 8mm2or more 22m2or more
OUTPUT CABLE 50mm2(Cu)
Minimum
70mm2(Cu)
Minimum
− 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.
− Use a shield to protect the welding arc in case of excessive air draft.
4

c) Ventilation
Adequate ventilation is recommended at the place of installation. For example the
following guideline should be followed:
− 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.
− 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.
d) Installation Items
No. Items No. Items
1. Remote control Unit RCU-SSR
400 / RCU SSR 600
7. Control Cable for RCU SSR-400 /
Control Cable for SSR 600
2. Work Piece 8. Welding Cable
3. Switch Box (Input) 9. Welding Cable
4. Connector for Remote Control Unit 10. Input Cable
5. Negative terminal 11. Electrode Holder
6. Positive Terminal 12. Electrode
13. Terminal Block input
REMARKS:
While performing a ground work, it is recommended that a skilled electrician do the work.
5

WELDING OPERATION
Once the installation of the equipment is completed, connect the work Cable to the
negative output terminal and the cable end of the electrode holder to the Positive output
terminal. These cable connections should be tightened properly to avoid electrical heating
due to loose connections. Put the Main Switch box in ‘ON’ position and turn on power
ON/OFF switch. The green lamp on the panel of the Power Source will now glow and the
fan will start rotating. Now the equipment is ready. Connect an Electrode with the
Electrode Holder. The welding current can be controlled by the current control
potentiometer mounted on the front panel of the Power Source or through Remote
Controller as explained below.
a) WELDING CURRENT ADJUSTMENT
Put the local/remote switch to ‘Local’ mode. Now set the DC output current as required
with the help of the current control potentiometer and ignite an experimental Arc. For the
fine tuning of the required current, set the parameters using the Ammeter mounted on the
front panel of the power source.
b) LOAD VOLTAGE/OPEN CIRCUIT VOLTAGE
Press and set Amps/Volts switch to volts position, the meter on the front panel will now
indicate the output DC voltage. On releasing this switch, it will automatically come back to
Amps position and the meter will read the output DC Welding current.
c) REMOTE CONTROLLER
The output Welding current can be increased and decreased as desired from the
operation point with the help of the Remote Controller unit as per the following guideline,
even on load condition.
Set the Local/Remote switch to remote position and connect the remote controller to the
socket provided in the power source. Now set the Welding current by turning current
control potentiometer. Graduation of the current value mentioned on the Remote
Controller Unit should be followed as guideline. However, for accurate output current,
adjust the potentiometer to a proper value from the METER mounted on the Front panel
of the power source after generating as experimental arc.
6

MAINTENANCE & INSPECTION
The maintenance and inspection should be carried out only after the main fuse box in the
3-phase AC line is turned OFF or disconnected properly.
Maintain and inspect the set regularly as per following guidelines:
a) Regular Inspection (Every 3-6 months, depending on operation frequency):
Inspection Inspection Point Maintenance Method
Loose connection / damageFuse Box
Confirmation of proper use
Repair if necessary, refer to
Power Equipment Capacity
Proper tightening of connectionsInput and Output
Terminals Confirmation of insulation
Tighten first and then insulate
with tape
Line Contactor Confirmation of abrasion at Contact
points
Replace with new one
Sedimentation of Dust Blow out the dust using dry
compressed air.
Inside the power
source
Trace of overheating and damage
to cables / wiring
Repair the damaged section
and insulate properly. Replace
with new wire / cable if
damage is severe.
b) Cautions to H.V. Test & Insulation Resistance Measurement Test
Careless execution of these tests will cause damage to the power source since thyristors
and other semiconductor parts are in this unit. While conducting these tests according to
the by-laws of your company, the following steps should be performed first:
o Take off the cables from the switch box that are connected to the three input
terminals and short-circuit the three input terminals.
o Take off the cable that is connected to two output terminals and short-circuit the
two output terminals.
o Short circuit between anode and cathodes of thyristors SCR1-6.
o Remove the two ground conductors. (Take off the left side panel. Remove one
conductor near the contactor on the upper panel and also the other conductor near
to the leg of the reactor at lower front of the power source).
o Use 500 V DC Megger only.
o Go back to original conditions by removing short-circuit etc. once the test is over.
7

FAULT FINDING
Abnormal Condition Cause Remedy
Control fuse on the front
panel blown
Replace with rated fuse
In case of the equipment is
being operated under duty
cycle higher than that of
specified and /or higher
output current, the bottom
WARN LAMP will glow. In
such case, wait and keep
the power switch ‘ON’ to
keep the fan running at on
load condition. After 5 to 10
minutes, the WARN LAMP
will turn off and then adjust
the welding current and /or
duty cycle and restart
welding.
A. Welding / automatically
stops and the bottom
WARN LAMP glows The equipment is over
loaded
Avoid the Welding
operation while Indicator
lamp “WARN” is repeatedly
‘ON’
Loose Connection Fasten the plug & socket
firmly.
Faulty VR1 variable
potentiometer of current
control on the front panel of
the power source or remote
controller unit.
Check with a multimeter,
replace, if found defective.
Remote / Local Switch not
in proper position.
Check the position of the
Remote / Local switch and
position properly.
Fault in control PCB
(ZMAT/D-70 OR ZMAT/D-
720)
Replace control PCB
Fault in Firing PCB ZMAT D
110
Replace Firing PCB
One phase is missing Check and rectify input
supply voltage
B. The current adjustment
does not work
Main SCR damaged Replace SCR
8

Abnormal Condition Cause Remedy
C. FAN does not rotate
while the Power Switch
is ON
Fault in AC input supply. Check the three-phase input
AC supply and current.
Fault in 3 phase AC input
supply
Check the input line and
rectify.
D. Open circuit voltage is
less than 60 Volts DC
while the main power
switch is ON.
Fault in Control PCB Replace the PCB
E. The available welding
current is maximum and
cannot be controlled
Fault in Control PCB Replace the Control PCB
Fault in VR, control
potentiometer
Check and replace
F. Unstable arc Supply voltage fluctuations
(greater than + / - 10%)
Check and rectify
Wrong polarity used for the
electrode
Check and rectify
Damaged main SCR Replace the SCR
One phase missing Check and rectify
Fault in control PCB or Firing
PCB (ZMAT D110)
Check and replace
Damaged main SCR Check & replace
G. Erratic Welding Current
Output
One phase missing Check & rectify
9

WIRING DIAGRAM SSR 400
10

WIRING DIAGRAM SSR 600
11

CHECK POINTS OF EASYWELD SSR – 400
In case of any fault observed which are not listed above, a guideline is provided to detect
the fault within the equipment. Please ensure that the equipment is in ‘NO LOAD’
condition and the supply voltage is 415 Volts, 3- Phase 50 Hz, AC.
Test Point Value (in DC)
(Measured by a Digital
Multimeter)
Position of Current
Control potentiometer
A. Control PCB (ZMAT/D-70M) TP1is 0 Volt
TP2~ TP1+ 15.0 V ±0.2 V Any position
TP3~ TP1- 15.0 V ±0.2 V Any position
TP11 ~ TP1+ 8.30 V ±0.05 V Fully anticlockwise
TP9~ TP1- 1.08 V ±0.05 V Fully anticlockwise
TP9~ TP1+ 6.16 V ±0.05 V Fully clockwise
TP10 ~ TP1+ 5.36 V ±0.05 V Fully anticlockwise
TP10 ~ TP1+ 10.3 V ±0.05 V Fully clockwise
B. Firing PCB (ZMAT/D-110) (TP1is 0 Volt)
TP3~ TP16.0 V + 0.1 V
-0 V
Fully anticlockwise
Please note that the absolute values may vary with ±10% and once this testing is over
refit the top cover and tighten the top screws properly. In case of abnormalities, please
refer to the nearest Area Sales Manager of ESAB INDIA LIMITED with the Serial No. of
the equipment & date of purchase.
12

CHECK POINTS OF EASY WELD SSR-600
In case of any fault observed which are not listed above, a guideline is provided to detect
the fault within the equipment. Phase ensure that equipment is in ‘NO LOAD’ condition
and the supply voltage is 415 volts, 3 phase 50 Hz. AC.
Test Point Value (in DC)
(Measured by a Digital
Multimeter)
Position of Current
Control potentiometer
A. Control PCB (ZMAT/D-720) (TP1is 0 Volt)
TP2~ TP1+ 15.0 V ±0.2 V Any position
TP3~ TP1- 15.0 V ±0.2 V Any position
TP11 ~ TP1+ 8.30 V ±0.05 V Fully anticlockwise
TP4~ TP1- 1.04 V ±0.2 V Fully anticlockwise
TP4~ TP1+ 6.90 V ±0.2 V Fully clockwise
B. Firing PCB (ZMAT/D-110) (TP1is 0 Volt)
TP3~ TP16.0 V + 0.1 V
-0 V
Fully anticlockwise
Please note that the absolute values may vary with ±10% and once this testing is over,
refit the front cover and tighten the screws properly. In case of abnormalities please refer
to the nearest Area Sales Manager of ESAB INDIA LIMITED with the Serial No. of the
equipment & date of purchase.
13

WELD DEFECTS AND POSSIBLE CAUSES
WELD DEFECT POSSIBLE CAUSES
Slow travel speed that allows weld metal to build upExcessive
Convexity Welding currents too low
A combination of Travel speed to fast and current too highInsufficient Throat
Improper placement of weld beads when multiple pass welding
Amperage too high
Arc length too long increasing the force of the arc so that it cuts into corners
Improper weld technique causing the corners to be left unfilled or cut into
Undercut
Groove joint not completely filled and overlapped
Using the wrong electrode angle causing the weld to be deposited too heavily on
one side
Insufficient Leg
Size
Using the wrong angle on multiple pas welds Causing the welds to overlap
incorrectly
Amperage too low
Travel speeds too fast
Using too large an electrode for the root of the joint
Improper electrode angle at the root of the joint
Improper weave technique
Poor Penetration
Using the wrong electrode for the desired joint penetration: (using E-6013 instead of
E-6010)
Amperage too low
Travel speeds too fast
Improper electrode angle at the sides of the joint
Improper weave technique that does not allow enough time at the sides of the joint
Poor Fusion
Using the wrong electrode for the application
Amperage too low and /or travel speed too slowOverlap
Electrode too large with low currents
Dirty base metal painted or galvanized surfaces
Arc length too long especially with E-7018 Electrodes
Moisture in low hydrogen electrodes
Porosity
Wind or fans strong enough to break down the shielding gas
Improper manipulation of the electrode especially with E-6013Slag Inclusions
Improper cleaning and slag removal between multiple pass welds
Using the wrong Electrode for the applicationCracks
Using Excessively high amperage on some metals
Amperage too high
Electrode angle too extreme
Excessive Spatter
Arc length too long
14

RECOMMENDED LIST OF SPARES FOR SSR-400/ SSR 600
Item Code Description Recommended
1 to 5 5 and above
1611642635 FIRING PCB 1 2
1611642005 SSR 400 CONTROL PCB (Z MAT D 70) 1 2
1611642602 SSR 600 CONTROL PCB (Z MAT D 720) 1 2
1611642018 FUSE ELEMENT 3A 5 10
1611642019 FUSE ELEMENT 1A 5 10
1611642020 AMP / VOLT SELECTOR SWITCH 1 2
1611642021 AMP/ VOLT METER SSR 400 1 2
1611642623 AMP/ VOLT METER SSR 600 1 2
1611642024 BLEEDER RESISTER 10OHM 10W 1 2
1611642026 POWER RESISTOR 50E 200W 1 2
1611642050 BLEEDER RESISTANCE 10K 20W 1 2
1611642101 CONTROL TRANSFORMER 1 2
1611642102 CONTROL TRANSFORMER 1 2
1651685149 CONTROL TRANSFORMER 1 2
1651684041 FAN COOLING 1 2
4651685317 SCR MODULE WITH HEATSINK- SSR 600 1 2
4651685316 SCR MODULE WITH HEATSINK - SSR 400 1 2
1651685051 DIODE EMITTING LIGHT GREEN 5 10
1651685052 DIODE EMITTING LIGHT RED 5 10
1651685078 SHUNT 400 AMP- SSR 400 1 2
1651684050 SHUNT 600 AMP- SSR 600 1 2
1651685117 LOCAL / REMOTE SELECTOR SWITCH 1 2
1651685125 TERMINAL OUTPUT- SSR 400 1 2
1651684083 TERMINAL OUTPUT- SSR 600 1 2
1651685205 POTENTIOMETER 5K- REMOTE UNIT 1 2
1651685206 POTENTIOMETER 5K- MACHINE 1 2
1651685236 INPUT TERMINAL ASSEMBLY 1 2
1651685271 CONTROL SWITCH 1 2
4611642001 MAIN TRANSFORMER SSR400 - 1
4611642002 DCL/IPL SSR-400 - 1
4611642603 MAIN TRANSFORMER-SSR-600 - 1
4611642604 DCL/IPL -SSR-600 - 1
4651684122 INPUT ZNR ASSY. SSR 600 1 2
4651685040 INPUT ZNR ASSY. SSR 400 1 2
4651685033 OUTPUT ZNR ASSY. SSR 400, SSR 600 1 2
15

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