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.

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

A. ASSEMBLING

The complete Installation should consist of the following items:

Description

Type

Quantity

1. Welding Power

Source

AK 400

AK 600

2. Wire Feeder &

Remote Control

Unit

SERVO WIREFEEDER- I WITH

ACCESSORIES & REMOTE CONTROL

UNIT – RC AK 400

SERVO WIREFEEDER- II WITH

ACCESSORIES & REMOTE CONTROL

UNIT – RC AK 600

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

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.

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.

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

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

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.

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