A

ASS~MCUNG

Description
1.

Yv'elding Power Source

RS 400 Power Source

2.

Remote Controller

RCU RS.40Q..

,------- --

(Optional)

...

B. '

ACCESSORIES LIST FOR THYRISTORiSED

WELDING
:,

fuse, elemenl 1A

II plec~

Fuse, elemenf 0.1 A

11

Instruction

C.

...

....

Monut1.1

RECTIFIER

pie:ce

II pf(~ce

'-------,

RATING OF RS 400 THYRISTOR'ISED

MMA WElO:NG

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itS 400

POWEJr~QU~E
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~::;:C-TE--R-I~-!-I~~=--_==-_---~-,
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SUPPLY VOLTAGE,-P-H-A-S-E-&-F-R-E'QUENC;'.nS
RAT~D, INt:'Ur

CURRENT

~-'~-O-%-,-3'-~:~-~?-~:-~-~L.-"""""~~~

127 A':>:!

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RATED RATING
-

......0.- __

Output:
OUTPUT

- --

CURRENT
RANGE
,
...
""'".

..

CURR~NT
.....--...---MAXIMUM

" DC 10-400A {Single)?ange):;:~"

......

AT 60%

270A

DUTY CYCLE

90 V DC

OPEN C!.~CUIT VOLTAGE (1v\AXIMUM)

TYPE OF WELDING

STEPLESS

CURRENT CONTROL

'H'

CLASS OF INSULATION

,,-.'

_______________

COOLING

WEIGHT
(APPROX)
APPRO_X_'_D_'_M_E_N_S_I_O
.-----

.-1-.

FORCED I\IR COOLED

N .__~j(W ,

, 195 _x_6
KG ?,~_:",S~'!_~
"~--~~~-~_/\.i\----I~12'-,'
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.

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D.
..

CAUTiONS
0)

FOR INSTALLATION

Capa~ity of Equipment

..

,-

415. 10% AC

INPUT VOLTAGE
FREQUENCY

50 HZ, 3 PHASE

& PHASE

RATED r.0IA OF

RS 400

19.4 KVA

EQUIPMENT

CAPACITY OF FUSE (B CLASS) TIS

SOA HRC

INPUT CABLE

a ~m2 or more

OUT CABLE

50 mm2 lCu) or

75 mm2 (AL) Minimum

-----'
I

A separate switch box should be designated for ea4h welding

power source and fuses of rated capacities should be 4sed.
I

Tolerence of voltage fluduation is 10% of the rated input voltage.

I

In case of no-fuse breaker is used, use 100 amps. hrcl fuse.

I

b)

Installation

I.

place:

I
I
,

Install in a place where less moisture and dust exist. Avoid direct
rain fall on the equipment. The bmbient temperature! should be
I.
within - 10 to 45C as much as possible.

The power source should be away from the wall

20 em.

(if

any) more than

I
I
I

In case of side by side installation of two or more po~er source a

distance more than 20 em should be always maintained.
c)

Ventilation
'-'

Adequate ventilation is recommended ,at the place of inst~lIation.

example the following guidelines should be followed ::
\

For

In case of the orea is more than '300 square meters (per unit), no
ventilation is required, provided the roorn is not complct'ely air tight.
I

In ease ofis the

area is less perfo~med,
than 300 square
meterlv~ntilation
and if the
welding
continuo~sl'f
adequate
IS
recommended with the' help of venl fan or exhaust dllJcl.
I

2
~

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CO

ibto

INSTALLATION

DIAGRAM

'OF

RS-400
m

FRONT

..

SlOE

Z
CII
I
;

--r/

REAR SlOE:

. --

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J.

~
,..

1~ -

II

400
13

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._.

. 8 ._._. '__

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---------------

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-c

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RS

-o

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Be sure to ground ,with 14 mm 2 cable wire.

The above connedion diagram relates to standard performance parameters (main
source is shown only by the full line) of the Equipment.
!,

While performing a ground work, it is recommended that the work be d6ne' by a

skilled worker.

Items

No.
1.

I Remote control

Unit RS 400

No.

Items

8.

I Welding Cable

I Welding Coble

(Optional)
2.

I Work Piece

9.

3.

I Switch Box (Input)

10. I Input Cable

4.

Connector for Remote Control

11.

Electrode Holder

Unit '
,

T
5.

Negative Terminal

12.

6.

Positive Terminal

13. Termirial Block input

I

Eledrdde

7.

Control Cable for RCU RS400

14.

ON dFF Switch

1
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F.

WELDING OPERATION

I
,
,
I

Once the installation of the equipment is completed, connected +e work

Cable to the negative output terminal & the coble end of the electrod:eholder
to the Positive output terminal. These coble co~nections should be tightened
properly to avoid electricol heoting due to loo~e connections. Put t~e Main
Switch box in 'ON'. Turn on power ON/OFF switch on the rear popel. The
green lamp on the panel of the Power Source will glow and the fan ~ill stan
rotating.
equipment
is ready.
on Electrode
the
Electrode Now
Holder.theThe
welding current
can Conhect
be ,controlled
by curren/ftith
control
potentiometer mounted on the front panel of the Power source or IIthrough
Remote Controller as explained below.
I

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Welding

Current Adjustment

Put the local/remote switch to 'Local' mode. Now sef the DC output current
as required with the help of the current control potentiometer and ignite on
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.

Load Voltage/Open

Circuit Voltage

Press ond 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 bock to Amps position and the meter will read the output
DC welding current.

Remote .Controller
The output Welding current can be increased and decreased as desired from
the operation point with the help of the Remole Controller unit as per the
following guide line, even on load condition.
Set the Local/Remote switch to remote position and connect the remote
cO'1tr,olJer 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
on experimental arc.
I

Welding

with Cellulosi~ ,Electrode

Put NormallCelJulo~k
size
of the electrode.

Switch to Cellulosic

Position depending

on the

o
q.

I(e~p
the main potentiometer around the middle position of the scqle &
..J
1.hi"
e we ding.
\..v

MAINTENANCE

& INSPECTION

The maintenance and inspection should be carried out only after the switches
in the J'.Iloin switch box a:-e certainly turned OFF.
Try to maintain

a)

Regular

and inspeCt. the '..set regularly as per the ..foHowing guide lines .

Inspection

Every 3-6 months, depending on operation

frequerlCY :

,.c-u.~"D.~~1I!~~,1"':'!'If_"'_~.;~

""",..k

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Insp'ection Portion

Inspection

Fuse Box

Point

Maintenance

Fastening & Looseness

at Ihe Connection.
;
Confirmation of proper
fuse

Input and Output

Connedions

Fastening & looseness

at the Connection.
Confirmation of
Insulation

Interior of Welding
Power Source

Sedimentation of Dust.
Trace of Overheat.

b)

Cautions to Insulation Voltage

Resistance Measurement Test:

Method
I

Refer to the Equipment

C
, 0poclty
i
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,
,

l
Fasten first and ~ape

Blow off dust with

Compressed Air. i

_ Proof Test & In$ula~ion

Careless execution of Dielectric Strength test and Insulation Resistance

Measurement will cause doma'ge to the pOwer Source since thyristors,
transistors and other semiconductor ports are used in the un;t. While
conducting
in accordance
with fi the
by-laws af your company,
rst :_
the
following these
stepstests
should
be performed
Take of the cables from the switch box that arc connected to the

three input lerminals and shari circuit the three input terminals.

Toke off the cable that is conneded

to fwo output termin'ols and.

short-circuit

the two output terminals.

I

"I

:.

Short circuit between positive and hegdtive output of RedifiE!r bank

with three AC terminals of redifier bonk.
-

H.

AfTER

. Use I500 V Megger only.

Go bock to original conditions removing
test is Over.
SALES SERVICE

short-circuit

etc. ohce the

i
i

In case of any abnormality observed during usage of the equipment,! which

could not be redified at site, please contact immediately Area Sales M~nager
of the nearest unit of ESAB INDIA LIMITED with the following details
:1

1)

Serial t:.Jumber of the equipment

& type

i
I

2)

Nature ofof Inpul

the complaint
Supply.
details

with the relevant

detoils,

if

possible al'1d the

.
3)

Date of purchase

of the equipm~nt and the date of commissioning.

The qualified and trained service teams of ESAB INDIA L1~ITED, located of
at the zonal bead quarters render the after sales service to the customers o'nd
also assist in intelligent selections af Welding Equipment & consumable for
various application.
I.

FAULT

FINDING

Check points inr case of abnormal operation

A.

I SI.
.r:I

Abnormal

N~.

Welding
automatically
stops and the
WARN

Cause
".

Counter Measure

The equipment over loaded

Wait and keep the

power switch 'ON' to
keep the fan running at
no IOt"'d. 15 min. the
'WARN lamp will off
and then Adjust
Welding Current and/or
duty cycle and restart
Y-(elding

lAMP

glows

t'

Avoid welding operation

while indicator 'WARN'
is repeatedly on
The current
adjus1ment
does not work

Loose Connection

Foulty VR, variable

potentiometer of current
control on the f~~nf panel
of the power source or
remote controller unit.

Fosten the plug &

Socket firmly

Check with a
multimeter replace, if
found defective.

Remote/local switch not In

proper positj9Jl

Fault in PCB

Check the position of

the Remote/Local switch
and position properly .

Replace PCB

One phase is missing.

Check and redify input

supply voltage.

Redifier bank damaged

Replace Rectifier bonk

Abnormal.

Cause,

Counter

Measure
i

Fan does not

rotate when .
Power Switch is

ON

Fault in control transformer

OCV less than

60 V when.
Power Sw. ON

Fault in AC input

Check voltage
3 ph inpu1tAC
supply
,

Check 0-200 V ~inding

,.

Check ~ ph input
I

Welding
Current

maximu'm &'

can not be
controlled

Fault in AC Supply

Fault in PCB

Replace PCB

Repl ace PCB

I.

Fault in PCB
Fault in VR poten'tiometer
on front .panel
'

Check & Replace i

i

II
I

Unstable

arc

Supply voltage f1uduations

(greater than 1 0%) .

Check and redifyl

I
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Wrong polarity used for

the eledrode .

Damaged main Rectifier

bank

One phose.m.issi';1~

Check and rectify:

Replace fhe rect;fj~r
bank

Check and redify

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2.5

I
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~iRCUIT

DIAGRAM

RS400
1
REloIOT(

1
'.

~11
. t.!.

74

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I,

.15

'

TEST POINT VOLTAGES IN RS 40() PCB

K)

..

TP2

wrt.TPl

TP3

wrt TP 1-

TPS

wrl TPl

TP5

wrt TPl

TP10

wrt TPl

" 15 V 0.2 (de)

~ +

TP10

wrt TPl
wrt TP 1

TPll

15 V 0.2 (de)

12 V

0.2 (de) (VRI POlent;ornetermax)

6 V 0.2 de (VR potentiometer

9.5 V (VR Pof min)

10.44 V (VR Pot me::)

8.4 0.05

of 200 A posn.)

(de) (VRI max)

~L

TP12
TP17'

w~. TPl

o -

18 V AC

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I
I

TP22

TP13

III

TP18

TP23

7.5 V (de)

wrl TPI

TP14

TP19'

wrl TPl

7.5 V (de)

rB.24

Across

G" K

910
12-13

0.039
15- 16

V to:O 1 af no load
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RECOMMENDED

LIST OF SPARE

PARTS

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