LAF 630/ 800/ 1250/ 1600 DC - ESAB Welding & Cutting Products
Contents
1. claf0e12 To reduce the sensitivity of the communications circuits to interference the communica tion bus is galvanically isolated from other circuits on the circuit board by means of transformer T1 If a communication failure is suspected check the resistance of the mains side of the transformer with an ohmmeter between pins C5 C6 NB Contact C must be disconnected when making the measurement The correct winding resistance is about 1 ohm For reliable communication over the bus it must be terminated by a filter at each end This filter is connected by a link at BY1 If a power unit is connected to the bus then the filter must be connected by linking BY1 START STOP Ra D KM1 KM2 4 V d 129 H4 y d4 009 e o 028 H y 3 TC KM2 FU2 H5 45 025 007 EEK 024 amp HL 212 M 026 claf0e13 Outputs H4 H5 control the power unit main contactor KM1 for starting and stopping welding clafOde1 19 9 TEST INPUT claf0e14 Contact K enables the power unit to be controlled without the PEH control unit A special test device can be used see the drawing on page 21 With the switch on the test device at Position 1 input K4 0 V a special test routine in the program is called Main contactor KM1 operates and the thyristor firing angles can be controlled by a 0 5 V analogue2. claf0se1 33 emm Fer E a p pee A 1 1 0551 203 081 Shunt 0551 203 082 Shunt 0191 085 105 Capacitor 0490 600 606 Silicon diode 0320 445 883 Inductor 0320 444 883 Inductor coil 0320 445 882 Inductor 0320 444 882 Inductor coil 0320 951 001 Fan 0320 924 882 Thyristor bridge 0321 452 880 Thyristor bridge 0041 051 606 Contact protection 0320 946 001 Thyristor 1100 A 300 V 0321 427 001 Thyristor 1500 A 500 V 0567 200 610 Fuse 16 A 500 V 0318 113 003 Main switch black ON DO oT F WO Iw ao E 2 o0 0192 576 004 Indicating lamp white 0192 576 303 Indicating lamp yellow 0193 586 103 Automatic fuse 0191 632 202 Emergency stop 0156 388 001 Handle 0486 368 880 Circuit board 0486 525 880 Flash memory 0193 296 101 Contactor 0442 849 001 Contactor 42 V 50 Hz 0319 828 001 Transformer 0319 470 016 Contract transformer 42 V 900 VA 0486 224 880 Circuit board EMC filter 0158 115 880 Cable inlet 0469 842 880 Transformer coil 0469 843 880 Transformer coil 0469 845 880 Transformer 0469 845 881 Transformer 0490 600 626 Silicon diode clafOse1 34 12 13 14 15 16 17 18 i i i GE j a clafOse1 35 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges m b H Vienna Liesing Tel 43 1 888 25 11 Fax 43 1 888 25 11 85 BELGIUM
3. LAF 630 800 1250 1600 DC WS WE 0 Ayo oon EE Service manual 740 801 008 990409 Valid from machine no 615 XXX XXXX LIST OF CONTENTS Page REAPP THIS FIRST EE 3 SOFTWARE VERSIONS 3 HARDWARE VERSIONS 3 COMPONENT DESCRIPTION LAF 630 800 1250 1600 5 CONNECTION DIAGRAM LAF 630 6 CONNECTION DIAGRAM LAF 800 8 CONNECTION DIAGRAM LAF 1250 1600 10 COMPONENT POSITIONS ON THE CIRCUIT BOARD Ab Circuit board with part no 0486 368001 12 COMPONENT POSITIONS ON THE CIRCUIT BOARD AP1 Circuit board with part no 0486 368 001A 13 DESCRIPTION OF OPERATION 14 TESTMDEVIGE EE 21 LOAD CHARACTERISTICS 22 INSTRUCTION MANUAL sssssee hm eue 23 GENERAL As ee Mete rte hea nbot UY Rer E NER EE iure 23 INSTALLATION nt ore ERERRE M Bet Dee ERAN uie eg ds 24 OPERATION sect tI RE Rete OF d RR RC ne etre e er dr dus 27 MAINTENANGE 20 Siam nement lea sa REES cba UE 27 CONNECTION INSTRUCTION 28 SPARE PARTS LIST sein en ben E ba teat 29 Rights reserved to alter specifications
4. S A ESAB N V Brussels Tel 32 2 745 11 00 Fax 32 2 726 80 05 THE CZECH REPUBLIC ESAB VAMBERK s r o Prague Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Copenhagen Valby Tel 45 36 30 01 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 298 0 Fax 49 212 298 204 GREAT BRITAIN ESAB Group UK Ltd Waltham Cross Tel 44 1992 76 85 15 Fax 44 1992 71 58 03 ESAB Automation Ltd Andover Tel 44 1264 33 22 33 Fax 44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel 36 1 20 44 182 Fax 436 1 20 44 186 ITALY ESAB Saldatura S p A Mesero Mi Tel 39 02 97 96 81 Fax 39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B V Utrecht Tel 31 30 248 59 22 Fax 31 30 248 52 60 NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp z 0 0 Warszaw Tel 48 22 813 99 63 Fax 48 22 813 98 81 PORTUGAL ESAB Lda Lisbon Tel 351 1 837 1527 Fax 351 1 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A Alcobendas Madrid Tel 34 91 623 11 00 Fax 34 91 661 51 83 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB Internati
5. ov shoot 028 TT BE TT xT BEE ados mise Jupe E 029 88 8 83565 Le 7 ps nisu 036 2304 1 i 1 t o L1 be LA Ve a 5060v50Hz o 1T2To D I2 DoD 2 028 c Tel Te T e a S 3 SE E Gs 8 8s 3 5 e fe O36 1 L L a Li l2 3 L 400V 604z le 48v 028 Gli 2 ofif2lofi 2 T T t F T T XT2 029 00 orc FEES RE i2 88 88 36 036 250 L i I c L1 12 L3 L 440V 60Hz 4BV 028 leo ep 2 o 1 2 029 49Y E TT TT XT2 42v 018 sooo 27 BONO UNS S828 036 250 1 L 1 A Li L2 L3 029 1 TEL 550V 60Hz 48V 028 C 1121 0 11 219 1 2 T Tes TT T x12 42v 018 Ry ius eem Te 8 88 3S8 036 258 Ne de E L f ei LiF L2 L3 claf0de1 28 LAF 800 e TOI SEK 42V MAIN TRANSFORMER XT2 SETS Ee 48V 028 Aus 102 424 018 1 pisa deutet 8v 028 TUNE XT2 Fin ze p M ba o A 500V 504z E 48V 028 2523 4004 424 018 H 00 oze 28 ee i NA 400V 60Hz XT2 r c KEN E 1 s 440V 60H2 U s557 48V 028 42V O18 gelt i 036 250 J Ch Py A 550V 6CHz SPARE PARTS LIST Edition 990409 LAF 630 800 1250 1600 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 GSAB LAP 800 DE 0456 320 880 Welding power source 0456 3
6. 40 A Max 1250 A 1200 2000 0 400 800 17 V 44 V 22N 44 V 1600 l2 A Min 40 A 1200 2000 l2 A 22V Max 1600A 46V 22 INSTRUCTION MANUAL This chapter contains an extract from edition 990114 of the LAF 630 800 1250 1600 instruction manual GENERAL LAF 630 800 1250 1600 are remote controlled 3 phase welding power sources designed for high efficiency mechanical gas metal arc welding MIG MAG or sub arc welding SAW It is always to be used in combination with ESAB s control box A2 A6 Process Controller PEH LAF is fan cooled and monitored by a thermal overload protection When the protection 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 monitored 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 A2 A6 Process Controller PEH instr
7. 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 Install and earth the welding unit in accordance with applicable standards Do not touch live electrical parts or electrodes with bare skin wet gloves or wet clothing Insulate yourself from earth and the workpiece e Ensure your working stance is safe FUMES AND GASES Can be dangerous to health Keep your head out of the fumes e Use ventilation extraction at the arc or both to keep fumes and gases from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin Protect your eyes and body Use the correct welding screen and filter lens and wear protective clothing e Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing e Protect your ears Use ear defenders or other hearing protection Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS WARNING This product is intended for industrial use In a domestic environment this product may cause radio interference It is the us
8. BOARD AP1 Circuit board with part no 0486 368 001 oloslolo CON D aj S C50 a eo olojo o eo BIETET o z Rod N a EI OT O o OO claf0de1 O 3 EJE ER ep aq E 3 BCe E g g EEB EE T 3 EE ap gt BE BBE Kc KS in e W I E CO ver ml T CET NT LAE BEH EE s SS E E B Sf E a DD Be ac ef E RE r E SEH B El ER D Eine r Ep Bee E BDG EET BEERISSEEPEEERRREE gee EE GND 12 claf0e01 COMPONENT POSITIONS ON THE CIRCUIT BOARD AP1 Circuit board with part no 0486 368 001A BE ag ag Eres D ENT m TE ag GO AME LE me z E ru Ca Toa d B G e bidl Sidi vns Cong E 2 E KR Et T Bes E ER D ER DD a Bi 8 r d L Jee mp me wo 2D SES Des ep 5 Ss S ENE Mie mm Ee EE e SR Je fa SE w c ag Ir DU dob wo e Cn eOjloro p 60 0 ovo ae df versi esu Ur GND claf0e01 001A clafOde1 13 DESCRIPTION OF OPERATION Circuit board AP1 Main features Circuit board AP1 is built up around a microprocessor and associated program memory There are two DIP switches on the circuit board see page 26 e SW1 for entering the power unit s address e SW2 for entering the size of the power unit The circuit board communicates with the PEH control unit and with any other
9. arc voltage between the welding torch and the workpiece regardless of the polarity of the filler wire The maximum arc voltage that can be handled is 90 V clafOde1 17 6 THYRISTOR FIRING CIRCUITS S 1A5 i IM1 ED UM icis 146 e e Res T E ici 4 B b vi 1 Lo ult Lets Lf sf SE Geet 8 i i zs ira 7 5 amp 15 T DIE Im 15 2A3 100 E Iz RIIS E d gt gt 9 A D d k d amp RE ICI2 A 12 es s p 13 BF TPI8 oA At ll 3 Riel pmi j a A e HERE ov 3 E E vi 4 xs xs2 claf0e06 The firing signals for the thyristors are carried on outputs A1 A2 A3 A4 and AS A6 The firing pulse peak voltage is about 20 V when the thyristors are disconnected and the pulse duration is about 350 us NEVER disconnect individual thyristors This can unbalance the thyristor bridge and destroy the other thyristors clafode1 18 T 8 COMMUNICATIONS INTERFACE XS4 Fi CS BY 1 mm Bri w R5 cae cer d d
10. pus TT ES 55 S E ci E GC Not inuse 8 6 BAFA 3 Not in use AP x PARALLELLC ge Es leet 23 22 eds 2 22222 1 1 I 2 SE C4 G CZ C221 C1 M t s ver o all L1 o DER POWER SUPPLY THERMAL OVERLOAD CUTOUT SHUNT INPUT SYNCHRONISING ARC VOLTAGE claf0e3b THYRISTOR FIRING CIRCUITS COMMUNICATIONS INTERFACE START STOP TEST INPUT ND Numbers 1 9 refer to the description of operation on pages 15 20 clafode1 9 CONNECTION DIAGRAM LAF 1250 1600 Connection block XT2 is connected for 400 415 V 50 Hz see the connection instruction on page 28 006 ke Nos vo Or o roooco EO ud 2 42v E T2 SI4TSTe7 S e d x15 LJ o DO 7 o NODSTOPPSKEDJA 5 r EMERGENCY STOP 046 L3 045 L2 04 4 L1 claf0e4a claf de1 10 904 INTERMEDIATE PLATE 903 FRONT PLATE FU2 ENN m SERRE ci H3 fenes XS3 2 gt 2 5 C1 c tH 3 8 ot in use ar2 E We PARALLELLC d d Ee E apa freen 4 CA AAA o D III CORE yoy CE c34K ij cof L x cru r S X 1 C1 ai I 046 N N 045 E 2 1 NS ut o XS2 LE Cr Dre POWER SUPPLY 6 THYRISTOR FIRING CIRCUITS clafde4b THERMAL OVERLOAD CUTOUT 7 COMMUNICATIONS INTERFACE SHUNT INPUT 8 START STOP SYNCHRONISING 9 TEST INPUT ARC VOLTAGE Numbers 1 9 refer to the description of operation on pages 15 20 claf de1 11 COMPONENT POSITIONS ON THE CIRCUIT
11. voltage signal between inputs K2 and K1 OV e 0 V With the potentiometer in position 0 min minimum thyristor conduc tion about 0 V arc voltage e 5 V With the potentiometer in position 100 max max thyristor conduction about 50 V arc voltage 10 PROCESSOR The processor controls the arc voltage and the welding current as well as communication with the PEH control unit and any other units that may be connected The power unit has two current limits e A hardware current limit which reduces the current after about 10 ms e A lower current limit which is monitored by the processor Its setting is matched to the respective power unit and it disconnects the power unit after about three seconds The current limits are for LAF 630 700 A for LAF 800 1050 A for LAF 1250 1300 A for LAF 1600 1700 A The processor monitors the thermal cutout switch and lights indicating lamp HL2 if the temperature becomes too high thus interrupting welding claf0de1 20 TEST DEVICE Potentiometer Switch LAF TAF V nr 516402 clafOde1 21 LOAD CHARACTERISTICS 0 200 400 600 800 MIG MAG Min 50 A SAW Max 630 A Min 30 A Max 630 A LAF 1250 1000 1200 o 200 400 600 800 lo V 17V MIG MAG Min 50 A 44 V Max 800 A 21V SAW Min 40 A 44 V Max 800 A LAF 1600 LAF 800 1000 1200 l2 V 17V 45 V 22V 45 V MIG MAG Min 60A SAW claf0de1 Max 1250 A Min
12. without notice READ THIS FIRST This service manual is intended for use by technicians with electrical electronic training for help in connection with fault tracing and or repair Use the connection diagram as a form of index for the description of operation and the component description The circuit board is divided into numbered blocks which are described individually in more detail in the description of operation All component names in the connection diagram are listed in the component description This manual contains details of all design changes that have been made up to and including November 1998 SOFTWARE VERSIONS From production start July 1997 486525880 LAF 1 00A 98 09 01 486525880 LAF 2 0 Stainless steel welding improved error 39 This software works only together with the new power source board 0486368001A TAF is supported by the program HARDWARE VERSIONS 98 09 01 Circuit board 486368880 with component layout 496367001A Software version LAF2 0 Modification Hardware has been upgraded for improved stainless steel welding New transformer T1 used Switch IC 30 added for improved stainless steel welding Function only accessible together with software version LAF2 0 and higher see also comments for software version LAF 2 0 Improvements in voltage and current measuring C11 and C21 added D39 and D40 added to improve max output voltage from power source clafOde1 9 A WARNING A ARC WELDING
13. 06 0041 051 606 0320 946 001 0158 115 880 0162 772 001 0318 113 003 0567 200 610 0192 576 004 0192 576 304 0193 586 103 0191 632 202 0156 388 001 0486 368 880 0486 525 880 0193 296 101 0193 358 102 0319 470 016 0486 224 880 0321 468 003 0321 489 880 0318 040 883 0490 600 626 0567 900 129 LAF 800 Transformer Transformer coil Transformer coil Transformer coil Switch Capacitor Fan Resistor Connection block Shunt Thermal guard Thyristor bridge Silicon diode Contact protection Thyristor Cable inlet Connection block Main switch black Fuse Indicating lamp white Indicating lamp yellow Automatic fuse Emergency stop Handle Circuit board Flash memory Contactor Contactor Control transformer Circuit board EMC filter Silicon diode Base current bridge Inductor Silicon diode Fuse V4 Z1 Z2 Z3 V1 16 A 500V 42 V 900 VA 32 j 16 1718 Che 20 21 22 4 5 6 M EN Op X IW 24 Mp Sp DL 25 ele _ 26 32 jupe EL pL ei a i ell ni 15 d HL 4 E e I 9g m OF SZ L RTK RER AE SAT e dE MT d d g 1 a 1 s BI i t o d A VEUT E Peg LLL aay A 8 9 10111213 28 29 30 Gs HN m
14. 21 880 Welding power source 0456 323 880 Welding power source 0456 324 880 Welding power source C Component designation in the circuit diagram clafose1 29 eee qmm E 0456 320 880 LAF 630 0321 033 880 Diode bridge 0320 415 880 Diode bridge 0490 600 626 Silicon diode 0160 362 881 Cable connector 0318 060 001 Capacitor 0567 200 610 Fuse 16 A 500 V 0193 503 001 Contactor 0193 296 101 Contactor 0320 746 001 Switch 0486 368 880 Circuit board 0486 525 880 Flash memory 0457 202 001 Foot 0320 007 001 Resistor 0320 620 880 Thyristor bridge 0321 033 880 Diode bridge 0320 622 881 Diode bridge 0320 460 885 Transformer 0321 008 880 Resistor 0320 286 001 Fan 0318 113 003 Main switch black 0192 576 004 Indicating lamp white o DO aA BB ON o 0192 576 304 Indicating lamp yellow 0193 586 103 Automatic fuse 0191 632 202 Emergency stop 0156 388 001 Handle claf se1 30 20 21 22 23 24 i o o 3 i 31 clafOse1 eme FE o M Oo 0c BR Q o clafOse1 0456 321 880 0469 844 882 0469 841 884 0469 841 885 0469 841 886 0320 746 001 0318 060 001 0318 022 001 0321 003 881 0040 894 001 0551 202 980 0319 445 001 0320 116 881 0490 600 6
15. 60 5 C and resets at a temperature of 130 15 C 3 SHUNT INPUT DEn H2 K us A XS1 claf0e09 Inputs H2 and H1 measure the shunt signal For the LAF 630 the shunt RS1 generates a signal of 60 mV at 600 A For the LAF 800 and LAF 1000 the shunt RS1 generates a signal of 60 mV at 1000 A For the LAF 1250 and LAF 1600 the shunt RS1 generates a signal of 60 mV at 1500 A DIP switch SW2 see page 26 is used to set the correct shunt signal clafode1 16 4 SYNCHRONISING LAF 630 ac i See LAF 800 Cm m TU 53 B5 17 T CET Er ST T E 1 2 o o SA D f w claf0e10 TC2 R8 LAF 1250 STE a SE LAF 1600 ES 7 E E B3 83 mm LJ 1 S QURE Er ST T M 1 2 o o SA F i ON claf0e10 The thyristor firing circuits are synchronised with the mains by three zero crossing detec tors with the phase voltages being sensed at inputs B1 B2 and B3 respectively The voltage between the inputs must be 12 5 V AC 2 V 5 ARC VOLTAGE D R23 R25 R26 XS4 Ici boo Iti a C18 8 vdj ci D re ak il mi NE V NEZ NI ES sos 8 sh ik p a JR e a Ww E BL w w YN Ww R20 Di claf0e11 Inputs C1 and H3 measure the
16. er s responsibility to take adequate precautions claf de1 4 COMPONENT DESCRIPTION LAF 630 800 1250 1600 Unless otherwise stated the components listed below are those as used in the LAF 630 LAF 800 LAF 1250 and LAF 1600 AP1 Circuit board AP2 Circuit board EMC filter only for LAF 800 1250 1600 C1 Capacitor 1 0 UF CA Capacitor FU1 Fuse 16 A slow blow FU2 Automatic fuse 15 A FU3 Fuse 315 mA only for LAF 800 HL1 Indicating lamp white for Power On indication HL2 Indicating lamp yellow for indication of excess temperature KM1 Main contactor KM2 Auxiliary contactor see page 15 L1 Inductor M1 Fan QF Main On Off switch see page 27 Qs Emergency stop pushbutton R1 R2 Resistor 50W 80 Q R3 Resistor only for LAF 630 800 R4 Resistor inductor only for LAF 630 RS1 Shunt see page 16 ST1 Thermal cutout see page 16 ST2 Thermal cutout only for LAF 630 see page 16 TM1 Main transformer TC1 Control power supply transformer 42V 900 VA TC2 Transformer for synchronising pulses only LAF 1250 1600 V1 Thyristor 1100A 300V only for LAF 630 800 1250 1500A 500V only for LAF 1600 V2 Diode V3 Diode bridge basic current bridge only for LAF 630 800 V4 Diode only for LAF 800 1250 1600 Diode bridge basic voltage bridge only for LAF 630 XS4 Burndy contact 12 pole XS3 Pole terminal for voltage measurement XT2 Terminal block Z1 Z3 Suppressor clafOde1 5 CONNECTION DIAGRAM LAF 630 Co
17. g e Place the welding power source on a level foundation don t forget to block the wheels for LAF 630 e Make sure there is nothing to prevent the cooling LIFTING INSTRUCTIONS LAF 630 Connections e On 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 28 e Make 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 25 e Connect the earth cable to the screw marked e e Tighten the cable support 1 e Connect the mains cable to the main terminal blocks L1 L2 and L3 e Connect the control cable between the LAF welding power source and the control unit to the 12 pole contact 2 inside the welding power source e Connect 1 pin socket measure cable 4 e Connect a suitable welding and return cable to the contacts 3 marked and on the front of the power source claf de1 24 LAF 630 with MIG MAG welding e Connect the welding cable from the wire feed unit to the socket marked e Connect the return cable from the workpiece to either of the sockets marked e Socket A is used for short arc welding this sheet or root beads and aluminium e Socket B is used for short arc welding but gives a slightly hotter welding cycle than socket A Socket C i
18. le East Dubai Tel 971 4 338 88 29 Fax 971 4 338 87 29 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 359 2 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 322 36 74 RUSSIA CIS ESAB Representative Office Moscow Tel 7 095 937 98 20 Fax 7 095 937 95 80 ESAB Representative Office St Petersburg Tel 7 812 325 43 62 Fax 7 812 325 66 85 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com EE ESAB Welding Equipment AB SE 695 81 L SWEDEN Phone 46 584 81 000 Fax 46 584 123 08 www esab com 001004
19. nnection block XT2 is connected for 400 V 50 Hz see the connection instruction on page 28 N road A2v T T2 3IsISjel7T8 o d x5 U LII 2 50 NODSTOPPSKEDJA EMERGENCY STOP al ke L3 claf0e2a claf de1 wl Ba Unos qs ge 905 RIGHT TRANSFORMER 904 INTERMEDIATE PLATE 905 FRONT PLATE ca Brown d POWER SUPPLY THERMAL OVERLOAD CUTOUT SHUNT INPUT SYNCHRONISING ARC VOLTAGE D a 2 m 5 inci uel 8 d 7 E 5 N TE i mr No w us rn el Li ui THLE lt lt tt lt lt OOOOoO Oo 0 ND a Te Tee en A BEES i e H3 XS3 9 H3 TE 5 c1 3 Not in use AP2 y aA H PARALLELLC d J r I nacon r Eh te ALL c1 ER c C5 F xS4 Cac C3 kK C2 L I T o M RS 5 XS Oo C SEEN e B a A m THYRISTOR FIRING CIRCUITS COMMUNICATIONS INTERFACE START STOP TEST INPUT Numbers 1 9 refer to the description of operation on pages 15 20 clafode1 D at claf0e2b CONNECTION DIAGRAM LAF 800 Connection block XT2 is connected for 400 415 V 50 Hz see the connection instruction on page 28 as eras x KEE Qs roo085u20866 T OV TT EISISISISUISIS O X75 LT 3400 NOJSTOPPSKED JA EMERGENCY STOP L3 LI claf0e3a claf de1 8 Gis PS re 904 INTERMEDIATE PLATE 903 FRONT PLATE oS 95 KM2 22 1 85886 AP1 Ex YU C1 TEN o 9 H
20. nt rises to 0 6 A their resistance rises and they interrupt the current When they have cooled they will conduct again Checking the internal power supplies A green LED fitted to the circuit board indicates that the 5 V supply is on This voltage and other power supply voltages can be measured by a voltmeter at terminal block P see the position on the circuit board on page 12 Connect the negative terminal of the voltmeter to GND see the circuit board on page 12 P1 5V 0 1V P2 8 V tolerance 0 3 0 1 V P3 8 V tolerances 0 1 0 3 V P4 25 V 3 0 V Loss of power supply If main contactor KM1 opens then auxiliary contactor KM2 also opens The voltage at input G1 then becomes 0 V and a message is sent to the PEH control unit that the power supply is about to fail This causes the PEH unit to store the set values of welding parameters clafOde1 15 2 THERMAL OVERLOAD CUTOUT IC15 f4 Y F4 e F3 FS Fl J FA ST2 r2 J F2 claf0e05 Thermal overload cutout switch ST1 in the power unit operates opens at a temperature of 92 3 C raising the voltage at input F1 to about 20 V The voltage at output F4 then rises to about 18 V which lights lamp HL2 on the front panel of the power unit At normal temperature the voltage at input F1 OV Thermal cutout switch ST1 resets closes at a temperature of 73 3 C Thermal cutout switch ST2 is fitted only to the LAF 630 It operates at a temperature of 1
21. onal AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 333 43 33 Fax 55 31 361 31 51 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 52 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 44 58 Asia Pacific AUSTRALIA ESAB Australia Pty Ltd Ermington Tel 61 2 9647 1232 Fax 61 2 9748 1685 CHINA Shanghai ESAB A P Shanghai Tel 86 21 6539 7124 Fax 86 21 6543 6622 INDIA ESAB India Ltd Calcutta Tel 91 33 478 45 17 Fax 91 33 468 18 80 INDONESIA P T Esabindo Pratama Jakarta Tel 62 21 460 01 88 Fax 62 21 461 29 29 MALAYSIA ESAB Malaysia Snd Bhd Selangor Tel 60 3 703 36 15 Fax 60 3 703 35 52 SINGAPORE ESAB Singapore Pte Ltd Singapore Tel 65 861 43 22 Fax 65 861 31 95 ESAB Asia Pacific Pte Ltd Singapore Tel 65 861 74 42 Fax 65 863 08 39 SOUTH KOREA ESAB SeAH Corporation Kyung Nam Tel 82 551 289 81 11 Fax 82 551 289 88 63 THAILAND ESAB Thailand Ltd Samutprakarn Tel 66 2 393 60 62 Fax 66 2 748 71 11 UNITED ARAB EMIRATES ESAB Midd
22. order to inform the A2 A6 process controller PEH about the rating of the power source that is connected Setting of DIP switch SW1 o e Set pole 6 to position OFF and all other poles to position ONT Setting of DIP switch SW2 LAF 630 e Set all poles to ON position LAF 800 H eo s e Set pole 1 to OFF position and all other poles to ONT LAF 1250 e Set pole 2 to OFF position and all other poles to ON LAF 1600 e Set pole 1 and 2 to OFF position and all other ra 725 EN poles to ONT 12345678 Welding power source program E OFF Open The welding power source program is stored in the flash memory IC 6 The capsule is fitted in a holder and is replaceable claf0de1 26 OPERATION Controls The front panel contains 1 Main switch QF 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 FU2 for 42 V supply voltage 5 Emergency pushbutton When the button is activated the main contactor in the power source trips and the su
23. pply voltage for the control box is broken The emergency button on the control unit has the same function 6 LAF 630 Pushbutton for the resetting of automatic fuse FU4 for 230 V supply voltage Start up e Connect the return cable to the work piece e Set the main switch 1 to position I The white indicating lamp 2 goes on and the fan starts e Set the welding parameters and start welding by way of the control box see the A2 A6 Process Controller 443 745 XXX instruction manual MAINTENANCE Cleaning e Clean the welding power source as necessary Dry compressed air is recommended for the purpose NN sit Blocked air inlets or outlets will lead to overheating claf de1 27 CONNECTION INSTRUCTION LAF 630 LAF 1250 1600 Cl SEK 42V MAIN TRANSFORMER X72 L 0 1 210 1 2 9 11 2 028 0239 409 Lm d 03e 2304 400V 50Hz o L 48V oli 2 o i Inr 028 029 400 Garg ch 230 4 5V 50Hz l 0 L 48V 028 z o t2ToeD 2 529 too 42V 018 Ke 036 250 200V 60Hz 0 JE D 48V 028 o 1 2 o 2 o 1 2 029 T 42V 018 H 036 250 440V 60Hz l 0 c TC1 SEK 42V MAIN TRANSFORMER X72 T 400 415V50Hz Je
24. s used for spray arc welding in thick plate e Connect the water cooling unit if applicable D i LAF 630 Mains connection LAF 630 Voltage V Current A 100 80 60 Cable area mm Fuse slow A LAF 800 1 800 ae V a 15 Current A 100 Cable area mm2 4x16 4x16 4x16 4x16 4x16 4x16 Fuse slow A LAF 1250 Voltage V Lett 415 500 o e a 440 550 Current A 100 99 99 80 99 99 80 Cable area mm2 3x35 25 3x35 25 3x25 16 3 x35 25 3 x35 25 3x25 16 Fuse slowA 125 125 80 100 100 80 clafOde1 25 LAF 1600 ET EE EE Voltage V 400 415 500 400 440 550 Current A 100 136 136 108 136 136 108 Cable area mm2 3 x 70435 3 x 70435 3 x 50435 3x70 35 3x70 35 3x70 35 Fuse slow A 160 160 125 160 160 125 PC board DIP switches The Circuit board AP1 has two DIP switches SW1 and SW2 which are preset on delivery The settings are not to be changed For the supply of spare parts the settings of the DIP switches must be checked and set if necessary before fitting the PC board into the welding power source e DIP switch SW1 To make the communication with the A2 A6 Process Controller PEH work DIP switch 1 SW1 must be set es DIP switch SW2 DIP switch 2 SW2 must be set in
25. uction manual Technical data RAF eso pro DEI LAF 1600 400 415 V 400 415 500 V 400 415 500 V 400 415 500 V 3 50 Hz 3 50 Hz 3 50 Hz 3 50 Hz 400 440 V 400 440 550 V 400 440 550 V 400 440 550 V 3 60 Hz 3 60 Hz 3 60 Hz 3 60 Hz Permissible load at 100 duty cycle 500 A 39 V 800 A 44 V 1250 A 44 V 1600 A 44 V 80 duty cycle 560 A 42 V 60 duty cycle 630 A 44 V Setting range MIG MAG 50A 17V 50A 17V 800A 45V 60A 17V 1250A 44V 630A 44V SAW 30A 21V 40A 22V 800A 45V 40A 22V 1250A 44V 40A 22V 1600A 46V 630A 44V No load voltage 52V 52V 51V 54V No load power 145W 145W 220W 220W Effiency 0 81 0 84 0 87 0 86 Power factor 0 92 0 95 0 92 0 87 Weight 230 kg 330 kg 490 kg 585 kg Dimensions LxWxH 540 x 460 x 930 646 x 552 x 1090 774 x 598 x 1430 774 x 598 x 1430 720 x 885 x 930 including wheels Class of enclosure jp 23 Class of application S 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 clafOde1 23 Application class The symbol S indicates that the power source is designed for use in areas with increased electrical hazard INSTALLATION General The installation shall be executed by a skilled person Unpacking and placement A WARNING TIPPING RISK Fasten the equipment particularly if the ground is uneven or slantin
26. units that may be in use by means of a two wire serial bus a LON bus There are also analogue circuits on the circuit board for measuring the arc voltage and shunt signals together with circuits for firing the power unit s thyristors The board can be divided into three function blocks e Internal power supply Supplies power at the appropriate voltages to the electronics on the board e Processor Controls the welding voltage and current and communication with the PEH control unit e Analogue section Converts measurement and control signals to levels that the processor can deal with and converts the processor s output signals to levels as required by the power unit Program monitoring A red LED is fitted to the circuit board and lights if the microprocessor cannot read its program If this LED is lit or flashing check that memory chip IC6 see page 26 is fitted and that it is correctly orientated claf0de1 14 Sections 1 9 below refer to the circuit diagrams on pages 6 11 1 TC1 POWER SUPPLY KM2 Te oi Ee G2 K 62 H G4 n as K B5 Checking the external power supply Measure the incoming power supply at contact G between terminals G4 and G5 The voltage must be 19 V 2 V AC Short circuit protection for the circuit board is provided by PTC resistors R57 and R58 If the curre
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