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

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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

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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.

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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

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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.

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MAINTENANCE
Daily maintenance
WARNING
The power of the switching box and the welding machine should be shut down
before daily checking (except appearance checking without contacting the
conductive body) to avoid personal injury accidents such as electric shock and
burns.
Tips:
1) Daily checking is very important in keeping the high performance and safe operation
of this welding machine.
2) Do daily checking according to the table below, and clean or replace components when
necessary.
3) In order to ensure the high performance of the machine, please choose components
provided when replacing components.
Table 4-1: Daily checking of the welding machine
Items
Checking requirements
Remarks
Front panel
Whether any of the components are damaged or
loosely connected;
Whether the cables at the bottom are tightly
connected;
Whether the abnormity indicator illuminates after
starting the machine.
If not proper, check the interior of the
machine, and tighten or replace the
components.
Back panel
Whether the input power cable is in good condition;
Whether the air intake is unobstructed.
Cover
Whether the bolts are loosely connected.
If not proper, tighten or replace the
components.
Chassis
Whether the rubber feet are damaged or loosely
connected.
Side plates
Whether the side plate is distorted, damaged or
loosely connected.
Fan
Whether the fan or fan guard is distorted or damaged.
Whether the fan works or sounds normal when the
If not proper, eliminate the failures or
replace the fan.

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machine is running;
Table 4-2: Daily checking of accessories
Items
Checking requirements
Remarks
Earth cable
Whether the grounding wires (including work piece
GND wire and welding machine GND wire) break off.
If not proper, tighten or replace the
components.
Welding cable
Whether the insulating layer of the cable is worn, or
the conductive part of the cable is exposed;
Whether the cable is drawn by an external force;
Whether the cable connected to the work piece is
well connected.
Use appropriate methods according to
the work site situation to ensure safety
and normal welding.
Periodic check
WARNING
Periodic check should be carried out by qualified professionals to ensure safety.
The power of the switching box and the welding machine should be shut down
before periodic check to avoid personal injury accidents such as electric shock and
burns. Due to the discharge of capacitors, checking should be carried out 5 minutes
after the machine is powered off.
Tips
Safety
All maintenance and checking should be carry out after the power is completely cut off.
Make sure the power plug of the machine is pulled out before uncovering the welding
machine.
When the machine is powered on, keep hands, hair and tools away from the moving
parts such as the fan to avoid personal injury or machine damage.
Periodic check
Check periodically whether inner circuit connection is in good condition (esp. plugs).
Tighten the loose connection. If there is oxidization, remove it with sandpaper and then
reconnect.
Check periodically whether the insulating layer of all cables is in good condition. If there
is any dilapidation, rewrap it or replace it.

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Beware of static
In order to protect the semiconductor components and PCBs from the static damage,
please wear antistatic device or touch the metal part of the enclosure to remove static
in advance before contacting the conductors and PCBs of the machine internal wiring.
Keep it dry
Avoid rain, water and vapor infiltrating the machine. If there is, dry it and check the
insulation of the welding machine (including that between the connections and that
between the connection and the enclosure) with an ohmmeter. Only when there are no
abnormal phenomena anymore, can the machine be used.
Put the machine into the original packing in dry location if it is not to be used for a long
time.
Pay attention to maintenance
Periodic check should be carried out to ensurethe long-term normal use of the machine.
Be careful when doing the periodic check, including the inspection and cleaning of the
machine interior.
Generally, periodic check should be carried out every 6 months, and it should be carried
out every 3 months if the welding environment is dusty or with heavy oily smoke.
Beware of corrosion
Please clean the plastic parts with neutral detergent.

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TROUBLESHOOTING
No
Fault
Cause
Solutions
1
Power indicator light is
OFF.
No power.
LED / Circuit
Faulty.
Check main supply.
Check LED / Circuit.
2
Cooling Fan is not
working or turning
slowly.
Fan faulty.
Connection
problem.
Replace Fan.
Check the connection.
3
Unstable Welding
current.
Earth Cable
faulty.
Work Piece is not
clean.
Fix Earth cable
problem.
Clean the work piece.
4
Amp / Arc Force is not
changing.
Potentiometer
faulty.
Control PCB
faulty.
Change
Potentiometer.
Change Control PCB
5
Others
Contact ESAB
Service.

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Wiring Diagram

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SPARES LIST AND EXPLODED VIEW
No
Code No
Item Description
1
020060040002
LIFTING RING RS 400x
2
011010010603
TOP PANEL RS 400x
3
020070890060
COOLING FAN RS 400x
4
020050060018
INSULATION SLEEVE RS 400x
5
012020140079
MIDDLE PANEL RS 400x
6
020070380045
THYRISTOR RS 400x
7
011010031562
BACK PANEL RS 400x
8
020050050046
THREE PHASE JUNCTION BOX RS
400x
9
020050050032
THREE PHASE CABLE
CONNECTOR RS 400x
10
020050050037
CABLE BRACKET RS 400x
11
011020013495
BRACKET FOR HEAT SINK RS 400x
12
011040011242
CONTROL TRANSFORMER RS
400x
13
011020013497
AIR CHANNEL RS 400x
14
011010040246
BOTTOM FRAME RS 400x
15
020010310023
WHEEL RS 400x
16
020060240012
LOCKING PIN RS 400x
17
011010020744
RIGHT SIDE PANEL RS 400x
18
011020013498
BRACKET FOR MAIN CONTROL
PCB RS 400x
19
020070910010
SUPPORTING FRAME RS 400x
20
020070070016
CEMENT RESISTOR RS 400x

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21
011050020265
MAIN CONTROL PCB RS 400x
22
011020013127
BRACKET FOR SWITCH RS 400x
23
011010032316
FRONT TOP PANEL RS 400x
24
020070800285
MAIN SWITCH RS 400x
25
011010060834
RIGHT SIDE SUPPORTING FRAME
RS 400x
26
011020013992
BRACKET FOR OUTPUT
TERMINALS RS 400x
27
020050030018
BINDING POST RS 400x
28
011010032317
FRONT MIDDLE PANEL RS 400x
29
011020013494
FRONT BOTTOME PANEL RS 400x
30
011010060835
LEFT SIDE SUPPORTING FRAME
RS 400x
31
020070540063
AVIATION CONNECTOR WITH
3PINS RS 400x
32
020070800148
SELECTING SWITCH RS 400x
33
020070110007
POTENTIOMETER KNOB RS 400x
020070100025
POTENTIOMETER RS 400x
34
020070110008
POTENTIOMETER KNOB RS 400x
020070100026
POTENTIOMETER RS 400x
35
020070460006
VOLTAGE METER RS 400x
36
020070460023
CURRENT METER RS 400x
37
011010020743
LEFT SIDE PANEL RS 400x
38
011020013496
AIR CHANNEL RS 400x
39
012010050183
INDUCTANCE RS 400x
40
020070280054
LED RED RS 400x
41
020070280055
LED YELLOW RS 400x

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ESAB INDIA LIMITED
Registered and Head Office:
13, Industrial Estate, III Main Road,
Ambattur, Chennai - 600058.
Telephone: + 91 44 42281100
Fax: + 91 44 4228 1107
Web: www.esabindia.com