ESAB LHF 400 User manual

Valid for serial no. 318, 318, 3290349 301 080 070108
LHF 400, LHF 630
LHF 800
Instruction manual

ENGLISH
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TOCe
1 DIREC IVE 3........................................................
2 SAFE Y 3...........................................................
3 IN RODUC ION 5...................................................
4 ECHNICALDA A 5.................................................
5 INS ALLA ION 6....................................................
5.1 Connectingtomains 6.......................................................
6 OPERA ION 7.......................................................
6.1 Controlsandconnections 7...................................................
7 MAIN ENANCE 8....................................................
8 ORDERINGOFSPAREPAR S 8......................................
ASSEMBLYINS RUC IONS 9...........................................
DIAGRAM 12............................................................

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1 DIREC IVE
DECLARA ION OF CONFORMI Y
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source LHF 400 / LHF 6 0 / LHF 800 from serial number 18/ 18/ 29 complies with standard
IEC/EN 60974--1, in accordance with the requirements of directive (7 /2 /EEC) and addendum
(9 /68/EEC) and with standard EN 60974--10 in accordance with the requirements of directive
(89/ 6/EEC) and addendum (9 /68/EEC).
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Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 1.08.2005
2 SAFE Y
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
. 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.
WARNING
READ AND UNDERS AND HE INS RUC ION MANUAL BEFORE INS ALLING OR OPERA ING.
ARC WELDING AND CU ING CAN BE INJURIOUS O YOURSELF AND O HERS. AKE PRECAU-
IONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFE Y PRAC ICES WHICH SHOULD BE
BASED ON MANUFAC URERS’ HAZARD DA A.
ELEC RIC 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.
MALFUNC ION -- Call for expert assistance in the event of malfunction.
PRO EC YOURSELF AND O HERS!
ESAB can provide you with all necessary welding protection and accessories.
Do not use the power source for thawing frozen pipes.
WARNING!
his product is solely intended for arc welding.
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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3 IN RODUC ION
LHF 400/630/800 are thyristor controlled welding rectifiers designed for welding with
coated electrodes and TIG welding.
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 00 rpm. When welding with currents greater than 0 A the
fan speed increases to its working speed of around 1 50 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 ECHNICAL DA A
LHF 400 LHF 630 LHF 800
Maximum load
5 % duty cycle 400 A/ 6 V 6 0 A/44 V 800 A/44 V
60 % duty cycle 15 A/ V 500 A/40 V 6 0 A/44 V
100 % duty cycle 250 A/ 0 V 400 A/ 6 V 500 A/40 V
Setting range 8A/20V--400A/ 6V 8A/20V--6 0A/44(49)
V8A/20V--800A/44(50) V
Open circuit volt. 80--87 V 65--72 V 65--72 V
Open circuit output
at 400 V 40 W 615 W 640 W
Power factor
(max current) 0,90 0,87 0,82
Efficiency
(max current) 74 % 77 % 78 %
Enclosure class IP 2 IP 2 IP 2
Application class
Weight 195 kg 260 kg 295 kg
Dimens. lxwxh 1 10/765/705 1 10/765/705 1 10/765/705
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 INS ALLA ION
The installation must be executed by a professional.
Note
Connect the power source to the electricity mains with a network impedance of 0.256
Ω (LHF 400) 0.127 Ω
(LHF 630) or lower. If the network impedance is higher there is a risk of flicker in the illuminators.
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.
The power supply should be lifted by means of its lifting
eye. The handle is only intended for pulling it along the
ground.
Lifting instructions
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 400 LHF 630 LHF 800
Frequency 50 Hz 50 Hz 50 Hz
Voltage 400/415/500 V 400/415/500 V 400/415/500 V
Current at
100% duty cycle 19/19/16 A 8/ 8/ 0 A 49/49/40 A
60% duty cycle 24/24/20 A 47/47/ 8 A 62/60/50A
5% duty cycle 1/ 1/25 A 59/59/47A 79/79/6 A
Fuse, slow 25/25/20 A 50/50/ 5 A 6 /6 /50A
Cable area (4xmm2) 4/4/2,5 10/10/6 10/10/10
LHF 400 LHF 630 LHF 800
Frequency 60 Hz 60 Hz 60 Hz
Voltage 440/550V 440/550V 440/550V
Current at
100% duty cycle 19/16 A 8/ 0 A 49/40 A
60% duty cycle 24/20 A 47/ 8 A 62/50 A
5% duty cycle 1/25 A 59/47 A 79/6 A
Fuse, slow 25/20 A 50/ 5 A 6 /50 A
Cable area (4xmm2) 4/2,5 10/6 10/10
Cable areas comply with Swedish regulations.
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6 OPERA ION
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 ( ).
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)
. 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 MAIN ENANCE
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 PAR S
LHF 400, LHF 630, LHF 800 is designed and tested in accordance with the international
and European standards IEC/EN 60974--1 and 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 pro-
duct still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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LHF 400, LHF 630, LHF 800
Edition 070108
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Valid for serial no. 318, 318, 329--XXX--XXXX
Ordering numbers
0 19 78 882 LHF 400 400/415/500V 50Hz, 440/550V 60Hz
0 19 78 886 LHF 400 Offshore 400/415/500V 50Hz, 440/550V 60Hz
0 19 950 882 LHF 6 0 400/415/500V 50Hz, 440/550V 60Hz
0 19 950 886 LHF 6 0 Offshore 400/415/500V 50Hz, 440/550V 60Hz
0 19 951 884 LHF 800 Offshore 400/415/500V 50Hz, 440/550V 60Hz