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!
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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.
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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.
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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.
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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.
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Assembly instructions
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Diagram
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Prim. 250/400

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Sek. 250/400