ESAB LHF 250 User manual

GB
Valid for serial no. 906--xxx--xxxx0455 675 101 GB 050816
LHF 250, LHF 400,
LHF 630, LHF 800
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
4 TECHNICAL DATA 4.................................................
5 INSTALLATION 5....................................................
5.1 Connecting to mains 5.......................................................
6 OPERATION 6.......................................................
6.1 Controls and connections 6...................................................
7 MAINTENANCE 7....................................................
8 ORDERING OF SPARE PARTS 7......................................
ASSEMBLY INSTRUCTIONS 8...........................................
DIAGRAM 9............................................................
SPARE PARTS LIST 13...................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source LHF 250 / 400 / 630 / 800 from serial number 550 complies with standard IEC/EN
60974--1, in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC)
and with standard EN 50199 in accordance with the requirements of directive (89/336/EEC) and add-
endum (93/68/EEC).
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Paul Karlsson
Managing Director
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 1995--04--10
2SAFETY
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!
GB

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3 INTRODUCTION
LHF 250/400/630/800 are thyristor controlled welding rectifiers designed for welding
with coated electrodes, TIG welding and arc air gouging.
The welding rectifiers can be used with the following remote control devices:
PHA 1, PHA 2, PHA 5, PHB 1, PHB 2, och PHC 2.
An auxiliary control unit is required for TIG welding with high frequency arc ignition.
LHF 400/630, versions with meters and timed cooling fan.
These welding rectifiers are equipped with a volmeter, ammeter and a circuit that
reduces the idle speed of the cooling fan.
The meters allow current and voltage settings to be read from the front of the
rectifier.
To minimise the amount of dust and dirt that is drawn into the rectifier the fan runs at
a reduced idle speed of 300 rpm. When welding with currents greater than 30 A the
fan speed increases to its working speed of around 1350 rpm. A timer relay
maintains the higher speed setting for 6 1/2 minutes after welding has stopped to
ensure adequate cooling of the rectifier.
4 TECHNICAL DATA
LHF 250 LHF 400 LHF 630 LHF 800
Maximum load
35 % duty cycle 250 A/30 V 400 A/36 V 630 A/44 V 800 A/44 V
60 % duty cycle 200 A/28 V 315 A/33 V 500 A/40 V 630 A/44 V
100 % duty cycle 160 A/26 V 250 A/30 V 400 A/36 V 500 A/40 V
Setting range 8A/20V--250A/30
(33)V 8A/20V--400A/36 V8A/20V--630A/44 (49)V 8A/20V--800A/44 (50)V
Open circuit volt. 78--84 V 80--87 V 65--72 V 65--72 V
Open circuit output
at 400 V 300 W 340 W 615 W 640 W
Power factor
(max current) 0,88 0,90 0,87 0,82
Efficiency
(max current) 68 % 74 % 77 % 78 %
Enclosure class IP 23 IP 23 IP 23 IP 23
Application class
Weight 160 kg 195 kg 260 kg 295 kg
Dimens. lxwxh 1310/765/705 1310/765/705 1310/765/705 1310/765/705
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 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.
GB

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5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
SInstallation must be carried out by a qualified electrician.
SCheck that the welding rectifier is configured for the available mains supply
before connecting it to the mains.
SSee Connecting to mains for cable rating and fuse rating.
SConnect the mains cable to the rectifier according to the relevant regulations and
install a suitable fuse in the main fuse box.
SMake sure the welding rectifier is not covered or positioned so that cooling is
obstructed.
5.1 Connecting to mains
LHF 250 LHF 400 LHF 630 LHF 800
Frequency 50 Hz 50 Hz 50 Hz 50 Hz
Voltage 400/415/500 V 400/415/500 V 400/415/500 V 400/415/500 V
Current at
100% duty cycle 11/11/9A 19/19/16 A 38/38/30 A 49/49/40 A
60% duty cycle 14/14/11 A 24/24/20 A 47/47/38 A 62/60/50A
35% duty cycle 18/18/14 A 31/31/25 A 59/59/47A 79/79/63A
Fuse,slow 16/16/16 A 25/25/20 A 50/50/35 A 63/63/50A
Cable area (4xmm2) 1,5/1,5/1,5 4/4/2,5 10/10/6 10/10/10
LHF 250 LHF 400 LHF 630 LHF 800
Frequency 60 Hz 60 Hz 60 Hz 60 Hz
Voltage 440/550V 440/550V 440/550V 440/550V
Current at
100% duty cycle 11/9 A 19/16 A 38/30 A 49/40 A
60% duty cycle 14/11 A 24/20 A 47/38 A 62/50 A
35% duty cycle 18/14 A 31/25 A 59/47 A 79/63 A
Fuse,slow 16/16 A 25/20 A 50/35 A 63/50 A
Cable area (4xmm2) 1,5/1,5 4/2,5 10/6 10/10
Cable areas comply with Swedish regulations.
GB

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6OPERATION
SSet switch (1) to position ”I”. The white lamp (2) will light and the fan will start.
SSelect the welding method using the toggle switch (3).
SAdjust the welding current using the knob (7) on the front, and set the toggle
switch (8) to the position nearest the socket.
SSelect suitable earth and return cables and connect them to the terminals
marked + and -- on the front of the rectifier. Connect the return cable to the work
piece.
SThe rectifier is now ready for welding.
6.1 Controls and connections
1. On/Off
2. White lamp (power on)
3. Method selector switch
4. Arc air gouging
5. MMA
6. TIG
7. Current setting
8. Remote switch
9. Remote socket
10. Yellow lamp (thermal cut--out)
The yellow lamp comes on when the thermal cut--out trips.
When the rectifier has cooled down the thermal cut -- out is automatically reset.
GB
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7 MAINTENANCE
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
Cleaning
Check regularly that the power source is free from dirt.
How often, and to what extent, cleaning should be carried out depends on the
welding process, arc time, disposition and the surrounding environment. It will
normally suffice to blow the power source clean using compressed air (reduced
pressure) once a year.
If the power source is very dirty, brushing and vacuuming are recommended.
SDisconnect the welding power source from the mains current supply.
SRemove the adapter from the socket. Lock the socket to prevent unauthorised
connection.
At fixed installations, the safety switch should be set to the off position. Lock
the switch.
SRemove the power source’s safety plates for best access.
After cleaning, all safety plates must be mounted before you connect the power
source to the mains supply.
8 ORDERING OF SPARE PARTS
LHF 250, LHF 400, LHF 630, LHF 800 is designed and tested in accordance with the in-
ternational an European standards IEC/EN 60 974--1 and EN 60 974--1.
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 13.
This will simplify shipment and ensure you get the right part.
GB

Assembly instructions
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Diagram
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Prim. 250/400

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Sek. 250/400

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Prim. 630/800

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Sek. 630/800

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Spare parts list
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Valid for serial no. 906--xxx--xxxx
Ordering numbers for LHF 250, LHF 400, LHF 630, LHF 800
0319 782 882 LHF 250, 400/415/500V 50Hz,440/550V 60Hz
0319 783 882 LHF 400, 400/415/500V 50Hz, 440/550V 60Hz
0319 783 886 LHF 400 Offshore, 400/415/500V 50Hz, 440/550V 60Hz
0319 950 882 LHF 630, 400/415/500V 50Hz, 440/550V 60Hz
0319 950 882 LHF 630 Offshore, 400/415/500V 50Hz, 440/550V 60Hz
0319 951 884 LHF 800 Offshore, 400/415/500V 50Hz, 440/550V 60Hz
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the
cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to
the spare parts list.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.

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C = component designation in the circuit diagram
Item
no. Qty Ordering no. Denomination Notes C
101 12 0151 270 001 Quick--locking nut
102 40192 547 001 Nut
103 60320 029 002 Ground link
104 20468 797 001 Gasket
105 20468 796 001 Support plate
106 202121 030 05
107 10321 497 001 Top cover
108 10455729 001 Side plate
109 10469 937 002 Cover plate with screen
110 10466 931 002 Cover with text LHF 250
111 20365 038 001 Wheel
112 10365 046 001 Axle
113 10320 939 002 Bracket left
114 10469 937 001 Cover plate with screen
115 10466 931 001 Cover with text LHF 250
116 10320 939 001 Bracket right
117 20321 001 001 Ring
118 202188 012 02 Rubber handle
119 20321 000 001 Handle
120 602157 010 19 Circlip
121 20319 738 001 Foot
122 20319 455 002 Foot
123 80192 562 105 Nut M6/t=0.7--1.6
124 40192 562 106 Nut M6/t=1.8--2.6
125 21 0192 562 108 Nut M8/t=1.8--2.6

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101 102 103
106
107
108
111 112
113
116 117
118
119
120 121
122 123
124
125
104
105
109
110
114
115

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C = component designation in the circuit diagram
Item
no. Qty Ordering no. Denomination Notes C
201 20318 980 001 Insulating ring
202 20317 660 001 Element rod
203 10162 548 005 Resistor K14
204 100407 055 01 Connection block 2 pole
205 10320 178 001 Washer
206 10319 838 001 Fan casing
207 10162 430 001 Fan LHF 250/400/800 K28
208 10162 430 002 Fan LHF 800 K28
209 10191 085 202 Capacitor, 2uf, 400V LHF 250/400/630 K47
210 10191 085 106 Capacitor LHF 800 K47
211 10193 587 005 Connection block 5 pole K50
212 10320 131 880 Front panel
213 10469 950 880 Cable clamp
214 20320 805 881 Capacitor K27.3
215 20215 201 218 Seal o--ring, 24.2x3 LHF 250, LHF 400
30215 201 218 Seal o--ring, 24.2x3 LHF 630, LHF 800
216 20160 362 881 Cable connector OKC 50 LHF 250, LHF 400 K13
30160 362 881 Cable connector OKC 50 LHF 630 K13
217 30160 362 882 Cable connector OKC 120 LHF 800 K13
218 10486 216 880 Filter K69
219 10162 772 001 Connection block K11
220 10319 774 880 Choke LHF 250 K12
221 10319 774 883 Inductor LHF 250 K12
222 10319 774 881 Inductor LHF 400 K12
223 10319 774 882 Inductor LHF 400 Offshore K12
224 10319 944 880 Inductor LHF 630 K12
225 10319 944 882 Inductor LHF 630 Offshore K12
226 10319 944 883 Inductor LHF 800 Offshore K12
227 10469 920 880 Transformer LHF 250 K1
228 10469 920 881 Transformer LHF 250 Offshore K1
229 10469 920 882 Transformer LHF 400 K1
230 10469 920 883 Transformer LHF 400 Offshore K1
231 10469 923 880 Transformer LHF 630 K1
232 10469 923 881 Transformer LHF 630 Offshore K1
233 10469 923 883 Transformer LHF 800 Offshore K1

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201 202
203
204
205
206
207, 208
209, 210
211
212
213
214
215
216, 217218
219
220--226
227--233

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C = component designation in the circuit diagram
Item
no. Qty Ordering no. Denomination Notes C
301 10193 655 012 Terminal 12 pole K45.6
302 60192 716 004 Diode 6A 400W LHF 250, LHF 400 K2.3
30192 716 004 Diode 6A 400W LHF 630, LHF 800 K2.3
303 10469 947 001 Sign
304 10162 781 008 Connection block 9 pole K30
305 10456 111 001 Sign
307 10341 035 880 Circuit board Current relay K25
308 10156 688 001 Magnetic plate K25
309 10193 296 101 Contactor K62.2
310 10193 764 001 Time relay K51
311 10193 298 101 Bar
312 10191 085 202 Capacitor 2uF, 400V K27.5
313 10365 028 001 Control transformer K52.2
314 10162 772 001 Connection block 3 pole K30.2
315 10040 894 001 Connection block 6 pole K30

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C = component designation in the circuit diagram
Item
no. Qty Ordering no. Denomination Notes C
401 23 0192 784 102 Cap
402 10192 784 014 Socket 12 pole K45.4
403 10192 784 013 Connector pin plug 12 pole K45.3
404 23 0192 784 101 Pin
405 10192 784 016 Sleeve plug 15 pole K45.2
406 10192 784 015 Plug 15 pole K45.1
407 10320 498 002 Ammeter K19
408 10320 497 001 Voltmeter K20
409 10469 929 001 Front plate LHF 400 V/A
410 10469 932 001 Front plate LHF 630 V/A
411 10469 927 001 Front plate LHF 250
412 10469 928 001 Front plate LHF 400
413 10469 930 001 Front plate LHF 630
414 10469 933 001 Front plate LHF 800
415 20365 745 001 Circuit card holder
416 10320 745 001 Switch LHF 250 K6
417 10320 745 002 Circuit braker LHF 400 K6
418 10320 745 003 Switch LHF 630/800 K6
419 10192 884 002 Capacitor 5uF K27.4
420 10319 828 001 Transformer K52.1
421 10319 876 880 Circuit card K70, K45.1,
K45.4
422 20468 797 001 Gasket
423 402121 086 49 Screww M6x12
424 102188 107 84 Knob
425 10318 113 003 Knob LHF 250/400
426 10318 113 004 Knob LHF 630/800
427 10147 866 001 Toggle switch K79
428 10193 219 001 Toggle switch Offshore K79
429 10194 057 008 Relay K62.1
430 10369 733 009 Indicating lamp Yellow K38.2
431 10369 733 008 Indicating lamp White K38.1
432 10366 285 001 Dust cap 12 pole
433 10368 544 003 Burndy socket 12 pole
434 10319 187 001 Indicator
435 10317 942 001 Gearing for rheostat
436 10192 724 007 Potentiometer K57
437 10147 866 001 Toggle switch LHF 250/400 K33
438 10193 219 001 Toggle switch LHF 250/400 Offshore K33
439 10147 866 002 Toggle switch LHF 630/800 K33
440 10193 219 002 Toggle switch LHF 630/800 Offshore K33