ESAB LHF 250 User manual

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.

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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