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

WELDING OPERATIONS

WIRING DIAGRAM

TROUBLESHOOTING

PARTS LIST AND EXPLODED VIEW

11-14

ESAB INDIA LOCATIONS AND CONTACT DETAILS

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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

Working

voltage

22.4-36

Rated welding

current

400

Current range

60-400

Rated duty

cycle

100%

60%

310A

400A

Input

Phases

phase

Frequency

Supply voltage

415

Rated input

current

Maximum

effective input

current

Rated input

capacity

kVA

Efficiency η

≥85%

COSφ

0.93

Insulation class

Degrees of protection

provided by enclosure

IP21S

Weight

Dimensions (L×W×H)

510×250×483

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INSTALLATION

The complete installation should consist the following items:

Description

Type

Quantity

Welding Power Source

ARC400i

Welding Cable with Holder

Earth cable with Clamp

Remote (Optional)

RT-ARC400i

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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