Product Manual RPB 320

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Instruction manual

RPB 320/420/520 Power source


505 890-102
2005-09
The information in this document can be subject to change without prior notice and should not be
regarded as an undertaking from ABB. ABB assumes no responsibility for errors that can appear in
this document.

ABB is not responsible for damage incurred by the use of this document or software or hardware
described in this document.

The document, or parts there of, may not be reproduced or copied without prior permission from ABB.
It may neither be imparted to a third party nor otherwise used without authorisation. Infringement here
of will be subject to action in accordance with applicable laws.

Further copies of this document can be obtained from ABB at current prices.

ABB Automation Technology Products AB

Article number: 505 890-102

Date: 2005-09

ABB Automation Technology Products AB

Arc Welding & Application Equipment

S-695 82 Laxå

Sweden
RPB 320/420/520

LIST OF CONTENTS
Page

1 Introduction ................................................................................................................. 5
1.1 Safety ................................................................................................................. 5
1.2 Description......................................................................................................... 6

2 Start-up ........................................................................................................................ 7
2.1 Placing ............................................................................................................... 7
2.2 Connection to the mains .................................................................................... 8

3 Controls and utilization .............................................................................................. 9


3.1 Main switch ON/OFF (I/O) ............................................................................... 9
3.2 Indicating lamps................................................................................................. 9
3.3 The function of the fan....................................................................................... 9

4 Maintenance/Service ................................................................................................... 11
4.1 Cables................................................................................................................. 11
4.2 Power source...................................................................................................... 11
4.3 Functional trouble .............................................................................................. 12

5 Technical Data ............................................................................................................. 15

6 Diagram........................................................................................................................ 17
6.1 RPB 320 ............................................................................................................. 17
6.2 RPB 420 ............................................................................................................. 18
6.3 RPB 520 ............................................................................................................. 19

7 Reservdelsförteckning/Spare Parts List ..................................................................... 21


7.1 RPB 320 ............................................................................................................. 22
7.2 RPB 420 ............................................................................................................. 26
7.3 RPB 520 ............................................................................................................. 30

505 890-102 3
RPB 320/420/520

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This manual is intended for use by technicians with appropriate electrical training
for fault-tracing and repair.

The product complies with the demands for CE marking.

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• Install and earth the welding equipment in accordance with applicable
standards.
• Do not touch live electrical parts or electrodes with bare hands, wet gloves
or wet protecting clothing.
• Insulate yourself from earth and from the workpiece.
• Ensure your working stance is safe.

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• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from
your breathing zone and the general area.

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• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protecting clothing.
• Protect bystanders with suitable welding helmets or curtains.

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• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
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H12 H11
5
S11
S11 Main switch I/O
02
Mounting opening for
02
control panel

H11 Indicating lamp I/O

Indicating lamp for ther-


H12
mal protection

5 Welding dynamics control

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X11, X12
01 Mains cable grommet

X13 F11 Fuse for control panel 6.3 A, Slow


01
F12 Fuse for mains terminal 1,0 A Slow
F11
X14 Welding and return cable Parallel
X11
X16 connection
X15
Welding and return cable Parallel
X12
F12 connection

Welding and return cable


X13
connection

X14 Control cable connection Parallel


X15

By productive earhed outlet 1~”230V/


X16 isolated safety transformer, 250VA”
RPB 420/520

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max. 15°

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• Preferably place the machine above floor level.


• Make sure there is DWOHDVW 20 cm free space behind and in front of the
power source for the cooling air to circulate.
• Protect the power source from heavy rain and under hot conditions also
from direct sunlight.

60°

rain water

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See to that the machine is positioned away from line of particle spray, created by
grinding tools etc.

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The power source is supplied with 5 m mains cable without plug.

1RWHMounting or replacing the mains connection cable and plug shall only be exe-
cuted by an expert.

1RWHFor the mounting of the cable, first remove the right-hand side panel.

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Pass the cable through the hole on the rear of the power source and lock it by way
of the cable retainer (05). Connect the phase conductor of the cable to the connec-
tions L1, L2 and L3. Connect the yellow/green earth conductor to the connection.

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/

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05

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RPB 320 RPB 420 RPB 520

Nominal voltage 400V 3~ 400V 3~ 400V 3~


Mains voltage range 360V ......440V 360V ......440V 360V ......440V

Fuses 25A 25A 35A

Connection cable *mm2 4 x 2,5 S 4 x 6,0 S 4 x 6,0 S

*S-type
cables include a yellow/green conductor for protective earthing.

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When the switch is set to position ,the indicating lamp (+ on the front goes on
to indicate that the power source is ready for use.

H12
H11

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There are two indicating lamps (H11, H12) on the power source, se Figure 6.:

The green lamp (H11) for stand-by mode is always on when the power source is
connected to the mains and the main switch is in position I.

The yellow lamp (H12) for thermal cut-out goes on when the thermostat has tripped
as a result of overheating. The fans cool the power source and when the lamp goes
out the power source is ready for use again (resetting takes place automatically).

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RPB 320 has one fan and RPB 420/520 has two fans running simultaneously.
• The fans run for a while when the main switch is turned to position I.
• The fans go on when the power source after a period of welding is heated
and stops 1-10 minutes after the welding is terminated.
• At idle running the fans enter into function for about 60 sec. every 30 min.

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The degree of utilization as well as exterior conditions influence the demand for
service of the power source to a high extent. Sensible use and preventive mainte-
nance will guarantee problem-free operation.

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Check the condition of the welding and return cable every day.

1RWHNever use damaged cables!

Make sure the connection cables conform to the regulations valid.

1RWHRepair and mounting of mains connection cables shall only be executed by


an authorized electrician.

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1RWHUnplug the cable from the wall socket and wait about 2 min. (due to capacitor
discharge) before removing the cover plate.

Check the following points at least once every six months:


• The electrical connections of the machine - clean oxidized components and
tighten loose parts.

1RWHBefore the connection work is started, inform yourself about the right tight-
ening torques.

• Clean the inner parts of the power source from dust and filth, using a soft
brush and a vacuum cleaner.

1RWHDo not use compressed air as there is a risk that filth hereby can get packed
even harder in the apertures of the cooling profiles!

1RWHDo not use high-pressure washing!

1RWHRepair of the power source is only to be executed by an authorized electri-


cian.

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1RWHIn the event of functional trouble, please contact your nearest FAC/ABB
agency.

Check the service points before sending the power source to the workshop.

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The yellow indicating lamp for thermal overload (H12) goes on when the thermostat
has tripped as a result of overheating of the power source.

The thermostat trips if the power source is continuously overloaded beyond the nor-
mal values, or if the circulation of the cooling air is blocked.

The fans cool the power source, and when the lamp goes out the power source is
ready for use again (resetting takes place automatically.)

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The fuse (F11, 6.3 A, slow) on the rear of the power source functions as a protection
for the terminal of the remote control cable X14-15.

The supply voltage unit for extra equipment (single-phase, alternating current, 30V/
240 VA) has a separate fuse (F12 1.0 A, slow).

1RWHUse the same type and size of fuse as indicated beside the fuse holder.

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The primary circuits of the machine are protected against sudden, short over-volt-
ages.

The machine is designed for continuously withstanding 3 x 440V, (see Technical


Data: 415V +6%). Check that the voltage remains within the permissible limits, par-
ticularly when the voltage is supplied by for example a generator, driven by an inter-
nal combustion engine.

If there is under-voltage on the mains (below 300 V) the control of the power source
automatically ceases to function.

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Phase dropout leads to considerably worse welding properties compared to normal


conditions, or that it is not possible to start the power source at all.

Phase dropout can be caused by:

 A tripped mains fuse

 A defect mains cable

 Bad connection of the mains cable to the terminal block or to the socket
outlet.

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The MIG and MAG welding dynamics are controlled over the same potentiometer.

Setting the MIG and MAG welding dynamics:

The setting of the MIG/MAG welding dynamics influences the stability of the weld-
ing and the amount of spatter coming up.

The welding result can be optimized for each type of wire and each mixture of
shielding gas by way of the setting.

-9...-1 A soft arc is used to cause less spatter.

0 Recommended basic setting for all types of wire.

1...9 A hard arc is used to maximize the stability of the arc within the short-arc
range, for example, or for steel welding using 100% CO2 shielding gas, (position
7...9).

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RPB 320 RPB 420 RPB 520

Electric connection, 3-phase 50/60 Hz 400 V ±10% 400 V ±10% 400 V ±10%
a.c.
80% duty cycle 420 A/19,7 kVA 520 A/26,6 kVA
Connection power 100% duty cycle 320 A/14,6 kVA 400 A/18,6 kVA 440 A/20,0 kVA

4x6S - 5m/25 A slow


Connection cable and fuses

Permissible load 80% duty cycle 420 A/36,8 V 520 A/40.0 V


Max. 40º(rated values) 100% duty cycle 320 A/32,8 V 400 A/36 V 440 A/37,6 V

Setting range
for welding current and
voltage (steppless) MIG/MAG 10 V...36 V 10 V...41 V 10 V...45 V

Max. welding voltage 46 V/300 A 46 V/400 A 50 V/500 A

Open-circuit voltage ca 65 V ca 65 V ca 65 V

No-load power < 75 W < 75 W < 75 W

Efficiency at rated values ca 85% ca 85% ca 85%

Power factor at rated values ca 0,93 ca 0,93 ca 0,93

Storing temperature -40...+60 °C -40...+60 °C -40...+60 °C

Working temperature -20...+40 °C -20...+40 °C -20...+40 °C

Temperature class H (180 °C)/B (130 °C) H (180 °C)/B (130 °C H (180 °C)/B (130 °C

Protection class IP 23 IP 23

Outer dimensions Length 530 mm 530 mm 530 mm


without handle Width 230 mm 230 mm 230 mm
Height 520 mm 520 mm 520 mm

Weight 37 kg 41 kg 48 kg

Terminal 230V Single fase, Single fase, Single fase,


X16 alternating current, alternating current, alternating current,
230 V/250 VA 230 V/250 VA 230 V/250 VA
slow fuse 1,0 A slow fuse 1,0 A slow fuse 1,0 A

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6.1 RPB 320

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6.2 RPB 420

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6.3 RPB 520

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20 505 890-102
RPB 320/420/520
Reservdelsförteckning/Spare Parts List

7 Reservdelsförteckning/Spare Parts List


Reservdelar beställs genom ABB Automation Technologies AB. Vid beställning
var vänlig uppge typ och tillverkningsnummer samt benämningar och beställnings-
nummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technologies AB. Kindly indi-
cate type of unit, serial number, denominations and ordering number according to
the spare parts list.
Rights reserved to alter specifications without notice.

505 890-400 21
RPB 320/420/520
Reservdelsförteckning/Spare Parts List

Beställningsnummer Anmärkningar
Benämning Denomination
Ordering number Remarks

505 063-880 Strömkälla RPB 320 Power source RPB 320

505 068-880 Strömkälla RPB 420 Power source RPB 420

505 069-880 Strömkälla RPB 520 Power source RPB 520

22 505 890-400
505 890-102

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