ESAB LAF 1000 User manual

GB
Valid for serial no. 712−xxx−xxxx0456 512 401 GB 100615
LAF 1000/ 1000M DC
Instruction manual

82
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE−695 81 Laxå, Sweden, declares under sole responsibility that
welding power source LAF 1000/ 1000M from serial number 712 (2007 w.12) is designed and tested
in conformity with standard EN 60974−1 and EN 60974−10 in accordance with the conditions in the
directives (2006/95/EC) and (2004/108/EC).
-----------------------------------------------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2007−03−30

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Technical data 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 General 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Unpacking and erection 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 PC board 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Controls 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Start−up 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 General 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Cleaning 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 ORDERING OF SPARE PARTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF COMPONENTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION INSTRUCTION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 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 recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well−acquainted with the operation of the welding
equipment. 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:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno−one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from draughts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame−proof
clothing, safety gloves.
SDo not wear loose−fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK −Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES −Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE −Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION −Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING
This product is intended for industrial use. In a domestic environment this prod-
uct may cause radio interference. It is the users responsibility to take adequate
precautions.
WARNING!
Read and understand the instruction manual
before installing or operating.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation 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 our local representative.
By applying this European Directive you will improve the environment and human health!
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2 INTRODUCTION
2.1 General
LAF 1000/ 1000M are remote−controlled 3−phase welding power sources designed
for high−efficiency mechanical gas metal arc welding (MIG/MAG) or sub arc welding
(SAW). They are always to be used in combination with ESAB‘s control box
A2−A6 Process Controller (PEH) or A2 Welding Control Unit (PEI).
LAF is fan−cooled and monitored by a thermal overload protection. When the protec-
tion enters into action a yellow indicating lamp on the front panel goes on and is
reset automatically as soon as the temperature has gone down to an acceptable
level.
The welding power sources and the control unit are linked together over a 2−wire
bus enabling precision control of the welding process.
All welding parameter settings for the power source can be made by the operator on
the front panel of the control unit. The operation of the power source is completely
controlled and monitored by this unit. Even the start and stop qualities can be set by
way of the control unit. The preset welding current parameters can also be moni-
tored in the course of welding.
For more detailed information regarding the settings and the working mode of the
welding power source, please refer to the instruction manual for either the
A2−A6 Process Controller or the A2 Welding Control Unit.
2.2 Technical data
LAF 1000 LAF 1000M
Voltage 400/415/500 V, 350 Hz
400/440/550 V, 360 Hz
230/400/415/500 V, 350 Hz
230/400/440/550 V, 360 Hz
Permissible load at:
100 % duty cycle
60 % duty cycle
800 A/44 V
1000 A/44 V
800 A/44 V
1000 A/44 V
Setting range
MIG/MAG
SAW
50 A/17 V −1000 A/45 V
40 A/22 V −1000 A/45 V
50 A/17 V −1000 A/45 V
40 A/22 V −1000 A/45 V
No−load voltage 52 V 52 V
No−load power 145 W 145 W
Effiency 0,84 0,84
Power factor 0,95 0,95
Weight 330 kg 330 kg
Dimensions L x W x H 646 x 552 x 1090 646 x 552 x 1090
Enclosure class IP 23 IP 23
Application class
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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3 INSTALLATION
3.1 General
The installation must be executed by a professional.
3.2 Unpacking and erection
WARNING −TIPPING RISK!
Fasten the equipment −particularly if the ground is uneven or sloping.
SPlace the welding power source on a level foundation.
SMake sure there is nothing to prevent the cooling.
Lifting instructions
3.3 Connections
SOn delivery the welding power source is connected
for 400 V. For other supply voltage, switch over to
the desired voltage on the main transformer and
the control transformer according to the connection
instructions on page 94.
SMake sure the mains cable has the right sectional
area and fuse it with an adequate fuse according to
applicable local directions (see table on page 88).
SConnect the earth cable to the screw marked .
STighten the cable support (1).
SConnect the mains cable to the main terminal
blocks L1, L2 and L3.
SConnect the control cable between the LAF
welding power source and the control unit to the
28−pole contact (2) inside the welding power
source.
SConnect 1 pin socket measure cable (4).
SConnect a suitable welding and return cable to the contacts (3) marked +and −
on the front of the power source.
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Mains connection
LAF 1000 50 Hz 60 Hz
Voltage V 400 415 500 400 440 550
Current A
100%
60%
64
80
64
80
52
65
64
80
64
80
52
65
Cable area mm24 x 16 4 x 16 4 x 16 4 x 16 4 x 16 4 x 16
Fuse, slow A 63 63 63 63 63 63
LAF 1000M 50 Hz 60 Hz
Voltage V 230 400 415 500 230 400 440 550
Current A
100%
60%
111
138
64
80
64
80
52
65
111
138
64
80
64
80
52
65
Cable area mm24x50 4 x 16 4 x 16 4 x 16 4x50 4 x 16 4 x 16 4 x 16
Fuse, slow A 125 63 63 63 125 63 63 63
3.4 PC board
DIP switches
The PC board (AP1) has two DIP switches (SW1 and SW2) which are preset on
delivery. The settings are not to be changed.
When spare parts are supplied the settings of the DIP switches must be checked
(and set, if necessary) before fitting the PC board into the welding power source.
SDIP switch SW1
To make the communication with the
A2−A6 Process Controller (PEH) work
DIP switch 1 (SW1) must be set.
SDIP switch SW2
DIP switch 2 (SW2) must be set in order to
inform the A2−A6 process controller (PEH)
about the rating of the power source that is
connected.
Setting of DIP switch SW1
SSet pole 6 to “OFF“ position and all other
poles to “ON“.
Setting of DIP switch SW2
SSet pole 3 to “OFF“ position and all other
poles to “ON“.
Welding power source program
The welding power source program is stored in the flash
memory IC 6. The capsule is fitted in a holder and is
replaceable.
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4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 84. Read through before you start using the equipment!
Note! Never use the welding power source without side plates.
4.2 Controls
The front panel contains:
1. Main switch, breaking the incoming mains voltage for the welding power source.
2. Indicating lamp (white), showing that the main switch is activated.
3. Indicating lamp (yellow), showing that the thermal protection has entered into
action due to overheating in the transformer. The lamp is reset when the
temperature has gone down to an acceptable level.
4. Pushbutton, for the resetting of automatic fuse FU1 for 42 V supply voltage.
4.3 Start−up
SConnect the return cable to the work piece.
SSet the main switch (1) to position “I“.
The white indicating lamp (2) goes on and the fan starts.
SSet the welding parameters and start welding by way of the control box
(see instruction manual 0443 745 xxx for A2−A6 Process Controller or
instruction manual 0449 331 xxx for the A2 Welding Control Unit).
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5 MAINTENANCE
5.1 General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
5.2 Cleaning
SClean the welding power source as necessary.
Dry compressed air is recommended for the purpose.
WARNING!
Blocked air inlets or outlets will lead to overheating.
Note:
In order to ensure safe operation of the contactor, keep the magnetic parts clean.
If the contactor has to be cleaned it must be taken apart, and all the pieces be
cleaned.
Alternatively, the contactor can be replaced.
WARNING!
Never use compressed air to clean the contactor without first taking it apart
completely.
6 ORDERING OF SPARE PARTS
LAF 1000/ LAF 1000 is designed and tested in accordance with the international and
European standards IEC/EN 60974−1 and IEC/EN 60974−10.
It is the obligation of the service unit which has carried out the service or repair work
to make sure that the product still conforms to the said standard.
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list on page 97.
This will simplify dispatch and ensure you get the right part.
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