ESAB RS 400x User manual

RS 400x
Instruction manual
Welding Power Source

RS 400x
Instruction manual
For
Installation, Operation & General maintenance

SAFETY
Precautions for installation
Beware of electric shock!
Install grounding device according to application standard.
Do not touch live parts with naked skin, wet gloves or wet clothes.
Be sure you are insulated from ground and work piece.
Cover the cover plate of the machine before power on to avoid an
electric shock.
Confirm the safety of your working position.
Beware of fire hazard!
Please install the machine on non-combustible materials to avoid
a fire.
Make ensure there are no inflammables near the welding position
to avoid a fire.
Beware of explosion!
Do not install the machine in an environment with explosive gas
to avoid an explosion.
Replacing the components can be dangerous.
Only professionals can replace the components of the machine.
Make sure the connecting wires inside the machine are correctly connected after replacing the
PCBs, and then the machine can be run. Otherwise, there is a risk of damage to property.
Make sure there are no foreign bodies such as wire leads, screws, gaskets and metal bars
falling into the machine inside when replacing the components.
Carrying or moving the machine can be dangerous.
Cut the input power off via the switching box before moving the welding machine.
The handle can only be used for moving the welding machine by hand in short distance, and
it cannot be used for lifting. Otherwise, personal injury or property damage may be caused by
a drop.
Make sure that the flying rings are tightened, and that the machine enclosure and cover are
fixed when moving the welding machine with a crane,
Two lifting belts should be used when lifting the welding machine, and the angle formed by the

lifting belt and the vertical should be smaller than 15°.
Do not apply any stress on the operation panel and cover when moving the welding machine.
Otherwise, personal injury or property damage may be caused by a drop.
Do not install and run the welding machine when the machine is damaged or lacks any
components. Otherwise, fire hazard or personal injury may be caused.
Precautions for operation
Smoke-may be harmful to your health!
Keep your head away from the smoke to avoid inhalation of waste
gas in welding.
Keep the working environment well ventilated with exhaust or
ventilation equipment when welding.
Arc radiation-may hurt your eyes and burn your skin!
Use proper welding mask and wear protective clothing to protect
your eyes and body.
Use proper mask or curtain to protect onlooker from being injured.
Magnetic field can make cardiac pacemaker a bit wonky.
People with cardiac pacemaker should consult the doctor before
carrying out welding.
Stay away from the welding source to reduce the effect of magnetic
field.
Improper use and operation may result in a fire or an explosion.
Welding spark may result in a fire, so please make ensure there are
no inflammables near the welding position, and pay attention to fire
safety.
Ensure there is fire extinguisher nearby, and make sure someone
has been trained to operate the fire extinguisher.
Do not weld closed container.
Do not use this machine for pipe thawing.
Hot work piece can cause severe scald.
Do not touch hot work piece with bare hands.
Cool the welding torch for a while after continuously working.
Excessive noise does great harm to people’s hearing.
Wear ear covers or other hearing protectors when welding.
Give warning to onlooker that noise may be potentially hazardous to
hearing.

Moving parts may injure your body.
Please keep away from moving parts (like fan).
Each door, panel, cover, baffle plate, and protective device the like
should be closed and located correctly.
Seek professional support when trouble strikes.
When trouble strikes in installation and operation, please inspect
according to related contents in this manual.
If you still cannot understand fully, or you still cannot solve the
problem, please contact the service center to obtain professional
support.

TABLE OF CONTENTS
1. GENERAL DESCRIPTION..........................................................................7
Technical parameters ................................................................................
2. INSTALLATION AND CONNECTION ..........................................................8
Installation requirements............................................................................
Electrical connection..................................................................................
3. OPERATION...........................................................................................9-10
Panel functions of RS 400x ......................................................................
Rear Panel.................................................................................................
Output Terminals .......................................................................................
Work after welding.....................................................................................
4. MAINTENANCE ...................................................................................11-13
Daily maintenance.....................................................................................
Periodic check...........................................................................................
5. TROUBLESHOOTING...............................................................................14
6. WIRING DIAGRAM....................................................................................15
7. SPARES LISTAND EXPLODED DIAGRAM ........................................16-18

7 | P a g e
Specifications / Technical Data RS 400x
General Description
The RS 400X is thyristor based MMA welding machine. This unit uses 3~Phase
415V, 50 Hz AC power input supply. This machine is suitable for rutile and basic
electrodes. It can weld carbon steel, stainless steel.
It's main parts include: main transformer, three phase thyristor rectifier, control
PCB and inductance.
Description
Specification
Model
RS 400x
Input power V
415
Frequency Hz
50
Rated input current A
47
Rated input capacitance KVA
19.5
No-load voltage V
70
Rated working voltage V
36
MMA welding current A
50-400
Welding current（10min）A
60%@400
100% duty cycle A
310
Insulation class
H
Enclosure protection IP
21S
Cooling type
Fan cooled
Dimension L×W×H mm
705*420*790
Weight kg
130

8 | P a g e
INSTALLATION AND CONNECTION
Installation Requirements
1) Environment requirements
a) Do not install the machine at places with excessive dusts and metal powders.
b) Do not install the machine at places with corrosive or explosive gas.
c) The temperature of the working environment should be between -10℃and 40℃.
d) Do not carry out welding with the welding machine placed on a platform with a pitch
greater than 15°.
e) The machine should be installed in a well-ventilated place with humidity of 90% or less
and without water condense.
f) Pay attention to the wind at the welding site, and use wind deflector if necessary.
Otherwise, the welding process will be affected.
2) Installation space requirements
The welding machine should be at least 20cm away from the walls, and there should
be at least 30cm between them when two machines are installed side by side. Please refer
to the table below to determine the installation position of the welding machine.
Table 2-1: Reserved space when installing the welding machine
Machine part
Front
Top
Left
Right
Rear
Reserved space
≥20cm
≥10cm
≥20cm
≥20cm
≥20cm
Electrical connection
•High voltage danger from power source! Consult a qualified electrician for
proper installation of receptacle. This welder must be grounded while in use to
protect the operator from electrical shock.
• Do not remove grounding prong or alter the plug in any way. Do not use any
adapters between the welder’s power cord and the power source receptacle.
Make sure the POWER switch is OFF when connecting your welder’s power
cord to a properly grounded 3 phase 415 VAC, 50Hz, power supply.

9 | P a g e
OPERATION
Panel functions of RS 400x
1. Arc force adjusting knob
2. Digital display for output Amp
3. Output Current adjusting knob
4. Digital display for output Volt
5. Thermal protection indicator
6. Power input indicator
7. Output current range selecting switch
8. Main Power Switch
9. Remote control selecting switch
10. Remote control connector socket

10 | P a g e
Rear panel
Connect input cable with size >=10mm2.
Output Terminals
Work after welding
1) Cut off the power of the welding machine 3~5min after the welding work is
finished, so as to cool the internal part of the machine.
2) Turn off the air switch on the welding machine first and then switch off the
power in the switching box when shutting off the power.