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Related Manuals for Ronch RONCHWELD Series
Summary of Contents for Ronch RONCHWELD Series
- Page 1 SERIES USER MANUAL Raptor R400ARC E N G L I S H...
- Page 2 CONTENT - KEEP THIS MANUAL • Chapter 1 - SAFETY WARNINGS AND PRECAUTIONS • Chapter 2 - SPECIFIC SAFETY RULES • Chapter 3 - FEATURES & PERFORMANCE • Chapter 4 - WORKING PRINCIPLES • Chapter 5 - SPECIFICATIONS • Chapter 6 - ASSEMBLY •...
- Page 3 KEEP THIS MANUAL Read this material before using this product. Failure to do so can result in serious injury. Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number).
- Page 4 SAFETY WARNINGS AND PRECAUTIONS WARNING: When using the machine, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this equipment. WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.
- Page 5 the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three-wire grounded power cord and the grounded power system. 3.
- Page 6 Equipment Use and Care 1. Use clamps (not included) or other practical means to hold and support the workpiece on a stable platform. Holding the workpiece by hand against your body is unstable and may result in loss of control. 2.
- Page 7 SPECIFIC SAFETY RULES 1. Keep labels and nameplates on the equipment. They contain important information. If they are illegible or missing, contact your dealer for replacements. 2. Always wear approved impact protection goggles and heavy work gloves when operating the equipment. The use of personal safety devices reduces the risk of injury. Maintain a safe working environment.
- Page 8 Remove or secure all combustible materials within 35 feet (10 meters) of the work area. Use fire-resistant material to cover or block all doors, windows, cracks and other openings. - Fence the work area with portable fire-resistant screens. Protect combustible walls, ceilings, floors, etc.
- Page 9 10. Always keep hoses away from the welding area. Examine all hoses and cables for welds, burns or worn areas before each use. If any damaged areas are found, replace hoses or cables immediately. 11. Read and understand all instructions and safety precautions in the manufacturer’s manual for the material to be welded.
- Page 10 12. Proper care of cylinders. Secure cylinders to a cart, wall or post to prevent them from falling. All cylinders should be used and stored in an upright position. Never drop or strike a cylinder. Do not use cylinders that have been dented. Cylinder caps should be used when moving or storing cylinders.
- Page 11 FEATURES & PERFORMANCE The Ronch R400ARC is controlled by an individual MCU and includes the multi-function VRD characteristic of new generation of smart DC arc welding machines, together with high efficiency and energy saving. This series can be applied to a variety of 3PH...
- Page 12 WORKING PRINCIPLES 310V 3-phase Full bridge Main Full bridge Input Output Choppe rectifier inverter transformer rectifier Voltage sample Sample and feedback feedback Control Chopper control Control system The input three-phase AC power is converted into high-voltage DC power by the three- phase rectifier circuit, and maintained at 310 V temporarily by the chopper circuit, converted into MF high-voltage square wave AC power by the full-bridge inverter circuit formed by IGBT, and then into MF low-voltage square wave AC power by reduction by...
- Page 13 SPECIFICATIONS Mode / Item R400ARC Rate input voltage(V) (3P) / AC 220V—440V Frequency (Hz) 50/60 MAX rated input current (A) 30A (440V) 31A (380V) 52A (220V) MAX rated input power (KVA) 24 External breaker (A) No load voltage (V) Welding current (A) 40A-400A Duty cycle (%) Efficiency (Rated condition)
- Page 14 2. Your worktable should allow the work metal to be held firmly in place to prevent it from falling or moving accidentally. 3. The floor and surroundings of the work site should be non-flammable. A clean cement floor is recommended. The welding process will eject molten metal slag onto the floor, and this will spread over 8-10 feet or more in any direction.
- Page 15 ASSEMBLY Grounding the tool 1. Connect a ground wire (not supplied) to the screw at the bottom rear of the machine. Connect the other end of the wire to a suitable ground, such as a steel workbench, a piece of steel push-on or a grounding electrode. ARC torch connector and instructions 1.
- Page 16 1. Digital amps meter. Displays actual welding current or welding voltage (double to point3), which will vary during operation. 2. VRC function: More safety protection, limit the no-load voltage output below 36V to avoid electric shock. 3. A/V selector: This selector decides the digital meter to display the value of Amp or volts.
- Page 17 Installation Connect the welding clamp to the output stud (+) terminal. 2. Connect the ground clamp to the output (-) terminal. 3. Connect the protective grounding cable. 4. Turn on the distribution box (3PH) and connect the power supply to the front panel. 5.
- Page 18 10. If the welder draws too much current, the thermal overload protector will activate, the overload indicator will light, and the welder will shut down until it cools. It will automatically reset. Welding current The welding current level is determined by the electrode size. Normal operating range and current are recommended in the manual.
- Page 19 MAINTENANCE WARNING Make sure the power switch on the welding machine is in the OFF position and the equipment is unplugged from the electrical outlet before performing any inspection, maintenance or cleaning procedures. 1. Before each use, inspect the general condition of the welding machine. Check for loose cable connections, fan misalignment or binding, cracked or broken parts, damaged electrical wiring and any other condition that may affect its safe operation.
- Page 20 them with straps. 6) Environment requirements: Dry and clean indoor place. Do not use it in the rain. Ambient temperature: -10°C 40°C. Relative humidity: ≤50% at 40°C / ≤90% at 20°C. Altitude level < 1000 m Keep the distance between the machine and walls above 20 cm. Keep the distance between two machines above 30 cm.
- Page 21 Shielded metal arc welding (SMAW) Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA), flux-shielded arc welding or, informally, electrode welding, is a manual arc welding process that uses a consumable flux-coated electrode for welding. Electric current, either alternating or direct current from a welding power source, is used to form an electric arc between the electrode and the metals to be joined.
- Page 22 ASSEMBLY DIAGRAM...
- Page 23 PART LIST Code Name Description Unit Qty 302001006 Handle 160MM PCS 2 2050134408 Head cover PCS 1 2020001556 Main control PCB EP10050021-4 PCS 1 303009097 IGBT Model FF100R12RT4 PCS 2 2020001384 Pump power control PCB EP13090158-1 1 301004347 Radiator ...
- Page 24 205016065 Movement stents B EK08231 1 206002184 Tableting 10*36*3 4 2020001425 Diode rectifier PCB EP13070153-1 2 301004353 Radiator ES320-1 1 301004343 Radiator ES311-1 1 205016993 Holder EK08364-1 1 204005042 Reactor EL02092-5 1 Fan capacitor ...
- Page 25 ELECTRICAL PARTS The 3-phase input voltage (220V/380V/440V) is rectified to HV DC power by the 3-phase rectifier (the rectified voltage is 1.414 times the 3-phase input voltage). To guarantee consistent input voltage for the full-bridge inverter circuit (guarantee consistent output voltage), we adopted a step-down chopper circuit, so whatever is the 3-phase input voltage, the input voltage for the full-bridge inverter circuit is 310V (the Min.
- Page 26 CN6 and CN1 on the carrier board relate to the 3-phase input terminal, to sample the input voltage and supply power for the control transformer. For 380V 3-phase input, the output of pin 7# and 3# of CN7 is 380V via the internal control circuit. The pin 7# and 3# of CN7 float.
- Page 27 1. Measurement of the IGBT For inspection, The AVO meter (Fluke-15B) should be set as: When checking the gate pole (G) and emitter (E), the (G) and (E) should be two-way welding-off For checking the collector and emitter: Normal conditions: Collector (C) ( ), emitter (E) (1): Welding off Collector (C) ( ), emitter (E) (1): Break over Connect the positive pole of 9V to the gate terminal and negative pole to the emitter...
- Page 28 AVO Meter Battery (9V) State Red Cable Black Cable G2 E2 ∞ E2 G2 ∞ G1 E1 ∞ E1 G1 ∞ E2 C1 0.606 C2E1 C1 0.314 C1 E2 ...
- Page 29 3. Rectifier circuit The rectifier circuit is mainly composed of a main transformer and rectifier diode. It is the full wave rectifier circuit. Its function is to invert into a high-frequency alternating current of 20 KHz, to transfer the energy through the main transformer and rectifier diode rectifier, to supply the low voltage and high current welding required.
- Page 30 CONTROL SYSTEM 1. The test of Chopped Wave PCB (EP13090158-1) Black Cable Red Cable Test Value Remarks CN6-1 CN6-4 AC380V AC380V input CN6-1 CN6-4 AC220V AC220V input CN7-7 CN7-3 AC380V (power of fan and circuit control) CN7-7 CN7-3 AC380V (power of fan AC220V input ...
- Page 31 2.The test of main control PCB (EP10050021-3) Black Cable Red Cable Test Value Remarks CN13-1 CN13-2 AC8V CN1-3 CN1-4 AC19V CN1-7 CN1-5 AC19V CN1-7 CN1-6 AC19V CN5-4 CN5-5 AC8.5V CN5-1 CN5-2 AC19V CN5-1 CN5-3 AC19V ...
- Page 32 TROUBLESHOOTING PROCEDURES AND NOTICE Troubleshooting 1st step: Inspect what the failure is 2nd step: Check if the machine has obvious signs of burning 3rd step: Check the following: Input power The control cable and output power cable connections The torch connection 4th step: Check the following: The fuse Settings of change-over switch...
- Page 33 Standard Working Conditions 1) According to the manual to install and debug the machine 2) The power switch and the power indicator are normal. 3) The abnormal indicator does not light. 4) The fan works normally, wind direction inward. 5) 80V No-load voltage. 6) Adjust welding current knob, Display range 40-400A.
- Page 34 4) Test input/output voltage of T1. If input is normal, but Output is not, the T1 damaged. 5) Test the main control PCB (EP10050021-3) according to the above-mentioned. If output voltage is abnormal, replace main control PCB. If the above 5 points are normal, replace display PCB. Turn on the power switch, display lights, but fan does not turn on.
- Page 35 The machine is no output (No-load voltage) Possible reasons: 1) The fast recovery diode is damaged. 2) Main control board (EP10050021-3) failure 3) Driver board (EP09100005-2) failure 4) The IGBT is damaged 5) Abnormal connection of the main circuit. Test the following: (1) Check the output resistance by the diode step, connect the black cable to the positive pole, and the red cable to the negative pole.
- Page 36 Measure the waveform of the drive board following these steps: 1) Disconnect the wire between “+”, “-” of the rectifier bridge and insulate it. 2) Select the 10uS step, 5V step, DC step of oscilloscope, DC, single channel. 3) Short circuit JP5, JP6 of drive board (EP09100005-2). 4) Pin the oscilloprobe “+”to G, “-”to E.
- Page 37 WIRING DIAGRAM...
- Page 38 . c o m . b r R o n c h R o n c h M e x i c o U n i t e d S t a t e s ronch.com.mx ronch.us RON-MA-102-EN...
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