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Summary of Contents for ESAB AK 400
- Page 1 AK 400 AK 600 Fully Thyristorised MIG/MAG Welding Power Source Instruction manual...
- Page 2 AK400, AK 600 FULLY THYRISTORISED MIG/MAG WELDING POWER SOURCE Instruction manual Installation, Operation & General maintenance...
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Page 3: Table Of Contents
CONTENTS Item Page No. SAFETY ASSEMBLING ACCESSORIES LIST RATING CAUTIONS FOR INSTALLATION INSTALLATION WELDING OPERATIONS JIG TERMINALS AND SWITCHING TERMINALS IN WELDING POWER SOURCE. OPERATIONS MAINTENANCE & INSPECTION AFTER SALES SERVICE FAULT FINDINGS 12-14 OVERALL CIRCUIT DIAGRAM 15, 16 RECOMMENDED LIST OF SPARE PARTS WELD DEFECTS AND POSSIBLE CAUSES 18-19... -
Page 4: Safety
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. - Page 5 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’...
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Page 6: Assembling
UNIT – RC AK 400 Unit 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... -
Page 7: Rating
C. RATING OF AK 400 / AK 600 THYRISTORISED MIG/MAG WELDING POWER SOURCES CHARACTERISTICS CONSTANT POTENTIAL TYPE INPUT: SUPPLY VOLTAGE, PHASE 415 V ± 10%, 3 PHASE, 50 HZ, AC & FREQUENCY MAXIMUM INPUT CURRENT 31 Amps 55 Amps MAXIMUM RATING 20.7 KVA... -
Page 8: Cautions For Installation
D. CAUTIONS FOR INSTALLATION a) Capacity of Equipment AC 415 V ±10% Input Voltage Number of Phase & 3 phases, 50 HZ Frequency AK 400 AK 600 Maximum rating of 20.7 KVA 40 KVA Equipment Capacity of Fuse (B Class) 32 Amps... -
Page 9: Installation
E. INSTALLATION ITEMS OF AK 400 / AK 600 While performing the grounding work, it is recommended that a skilled electrician does the work. -
Page 10: Welding Operations
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. -
Page 11: Jig Terminals And Switching Terminals
b) Welding Voltage Adjustment: Adjust the welding voltage by turning the voltage adjustment knob of the Remote Control Unit. Set at a proper graduation of the voltage value. However, the voltage value indicated in the remote Control Unit is indicative only. Therefore, set a proper value from the voltmeter of the front panel by generating experimental arc. - Page 12 Preflow ON and OFF Changeover Terminals • A preflow timer (about 0.6 sec) is built in the control circuit. The Machine comes with the Preflow set at OFF position. • The preflow of the shielding gas can made be either ON or OFF by changeover terminals on Printed Circuit Board.
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Page 13: Maintenance & Inspection
• When the self-hold function is turned off. H. MAINTENANCE & INSPECTION The maintenance and inspection should be carried out only after the switches in the switch box are turned OFF. Try to maintain and inspect the set regularly as per the following guidelines: a) Regular Inspection (Every 3-6 months, depending on operation frequency): Inspection Portion... -
Page 14: After Sales Service
Date of purchase of the equipment and the date of commissioning. The qualified and trained service team of ESAB, located at the ESAB Office, render the after sales service to the customers and also assist in proper selections of Welding... -
Page 15: Fault Findings
J. FAULT FINDING Check points in case of Abnormal Operation Fault Possible Cause Rectification 1. Welding is Control Fuse is blown Replace with the rated fuse automatically stopped, and the “INDICATOR WARN” lamp is ON The Duty Cycle or welding Wait and allow the Cooling Fan current are higher than to rotate. - Page 16 Fault Possible Cause Rectification 3. The wire feeds in Fault of the Torch Switch or Check for continuity using a inching but no feeding disconnection of the control multimeter. Machine has to be when the Torch cables. kept switched OFF during Switch is pressed continuity test “ON”...
- Page 17 Fault Possible Cause Rectification 7. No Gas flow Disconnection of the Fasten the Connector Control Cable in the Remote firmly. Control Unit or improper contact of the connector Damaged Gas Hose. Replace the Gas Hose with new one. Mingled impurities in the Blow off the impurities gas passage.
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Page 18: Overall Circuit Diagram
WIRING DIAGRAM - AK 400... - Page 19 WIRING DIAGRAM - AK 600...
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Page 20: Recommended List Of Spare Parts
Main Transformer Assy. - AK 600 465-1685-003 IPL/DCL Assy.- AK 400 465-1684-006 IPL/DCL Assy.- AK 600 465-1685-040 Input ZNR Assy. - AK 400 465-1684-122 Input ZNR Assy. - AK 600 465-1685-033 Output ZNR Assy. - AK 400 / AK 600... -
Page 21: Weld Defects And Possible Causes
WELDING DEFECTS, POSSIBLE CAUSES AND CORRECTIVE ACTIONS GAS METAL ARC WELDING This welding process produces high quality welds when proper welding procedures are used. The absence of flux coating on Welding Electrode (Wire) eliminates slag inclusions in the weld. Some dross formation may occur when highly deoxidized steel electrodes are used, and it should be removed before the next weld bead or pass is made. - Page 22 Possible Causes Corrective actions Welding Defect Improper joint preparation Joint design must be adequate to Lack of penetration provide access to the bottom of the groove while maintaining proper nozzle- to-work distance and arc characteristics. Reduce root face height. Provide or Increase the root opening in butt joints.
- Page 23 Web: www.esabindia.com...
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Sir remote control wiring diagram k 400 machine please