LHF 630/800

Service manual

0740 800 028

9208-1

Valid from machine no. 701-xxx-xxx

LIST OF CONTENTS

Page
3 4 7 8 9 11 14 16 18

RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION OF OPERATION OF LHF 630/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK DIAGRAM, LHF 630/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT DESCRIPTION, CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM, LHF 630/800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION OF OPERATION, CIRCUIT BOARD K70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM, CIRCUIT BOARD K70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT POSITIONS, CIRCUIT BOARD K70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACEMENT OF THYRISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Note that only the English part of the instruction manual has been included. INSTRUCTION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATIC CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EFFICIENCY AND POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 20 22 23 23 24 25 25 27

This service manual is valid from machine no 701--XXX--XXX. The date on the front page is followed by a one (9208 --1), this means that the layout has been altered, the contents are still the same as in 9208 though.

Rights reserved to alter specifications without notice.

cmja0de1

-2-

RATING PLATE

cmja0p01

1. 2. 3. 4.

The symbols indicate that the LHF 630 incorporates a transformer and a rectifier. Current/voltage characteristic for MMA welding. Indicates that the unit is intended for connection to a 3-phase supply at 50 or 60 Hz. The machines serial number, consisting of three groups of figures (xxx yyy vzzz). The first group (xxx) indicates the version. The numerals indicate the year and week of approval of the design version. The second group (yyy) indicates the year and week of the machines final testing: e.g. 203 indicates 1992, week 3. The final (vzzz) group consists of three or four numerals and is a consecutive serial number from 0001 to 9999.

5.

These letter and numeral combinations indicate that ESAB complies with existing national and international standards. X = Intermittance factor: indicates for how long welding can be carried out at the specified welding data, expressed as a percentage of a 5-minute period. I2 = Current at the respective intermittance factor. U2= Arc voltage. Uo= No-load (open-circuit) voltage. Supply voltages and primary current at various intermittance factors.

6.

7.

cmja0de1

-3-

DESCRIPTION OF OPERATION OF LHF 630/800

GENERAL DESCRIPTION The LHF 630/800 are thyristor-controlled welding power sources incorporating mains voltage compensation and intended for MMA welding, TIG welding and air-arc gouging. The mains voltage compensation ensures that the arc voltage and welding current remain stable even though supply voltage may vary. Electronic control ensures that the welding current maintains its set value at all times. A single knob regulates the welding current over its entire range. The following description refers to the block diagram on page 7. 1 2 3,4,5 Reference potentiometer K57 for adjusting the welding current. The current setting is as defined by the ISO line. Reference potentiometer, connected to remote control socket K24, for remote adjustment of the welding current. Galvanically isolated remote control device. The remote control circuit employs a double-winding transformer (K52), associated rectifier and voltage stabilisation circuit, A/D converter, optocoupler and D/A converter. A pulsed voltage transfers the reference voltage from the remote control terminal socket via the optocoupler to the D/A converter, the output of which is an analog reference voltage. Selector switch K33 selects local or remote control of the reference voltage. The actual switching of the voltage reference signals is effected by analog switches: the block diagram shows the switching only schematically. Current reference boost in response to short circuits. Reference voltage input from the local and external potentiometers respectively. This circuit boosts the welding current in the event of an arc short circuit, thus preventing the electrode from burning on to the work during welding. The current reference signal is increased electronically via 7) and 20). Assists striking of the arc by means of an elevated current reference signal during starting. See 14), Hot start. Reduces the welding current in the event of a long-duration short circuit, i.e. if the electrode has burnt on to the workpiece. See 13), Foldback. Input for current signal from elevated shunt voltage.

7 8 9

10 11 12

cmja0de1

-4-

13

Foldback. This is a timer circuit that starts when the arc is short-circuited. It reduces the welding current via 11) if the short circuit persists, i.e. if the electrode has burnt on to the workpiece. This helps to protect the thyristors against abnormally high and/or long-duration short circuits. The foldback feature operates only in the MMA welding mode. Elevated starting current (starting boost, hot start) The starting current circuit briefly increases the welding current when starting to weld. The peak value of the starting pulse is about twice the set value of welding current, and gives the power source good starting characteristics during MMA welding. Switch K79 (see 22), below) disconnects the feature during TIG welding. Power supply unit for the electronic equipment, supplying stabilised DC at 15 V. The neutral of the electronic circuitry is connected to the positive of the welding voltage (+ on K13). The power supply unit receives a three-phase alternating voltage from the synchronising windings K1s3. Control comparator/amplifier, which compares the voltage signals from 8-12) and then amplifies the summing voltage to provide a suitable control voltage signal to the trigger unit 17). The good dynamic welding performance of the LHF 630/800 is partly due to the characteristics of the amplifier. The no-load detector 21) reduces the amplifier output signal when there is no arc. Trigger unit The trigger unit consists of three identical circuits (one for each phase). Each circuit provides trigger pulses for its thyristors, with phase angles in proportion to the output voltage from the control amplifier. Auxiliary windings on the main transformer provide synchronising signals. Thermal overload cutout, which interrupts the pulses to the thyristors in the event of high temperature of the thyristor cooling fins. Shunt amplifier, amplifying the signal from the current shunt to a suitable level for input to 12). Short-circuit detector, sensing short circuits of the arc. See also 13). No-load detector, senses no-load (open-circuit) voltage. See also 14) and 16). Switch K79 (MMA/TIG), switching the control characteristics between MMA and TIG. When the switch is in the TIG position, the elevated starting current and foldback circuits are disconnected: if this were not done, there would be considerable risk of burning through the workpiece. Switching is effected electronically: the block diagram shows only a schematic representation.

14

15

16

17

18 19 20 21 22

cmja0de1

-5-

23

Control amplifier for air-arc gouging, producing a DC voltage that is proportional to the reference voltage signal from 6), to give a constant-voltage characteristic. The shunt signal from 19) is used to provide a current limit that protects various parts of the system, including the thyristor rectifier 26).

24

Changeover switch for air-arc gouging, in the form of a three-position switch on the front panel, which also controls selection of MMA and TIG welding. (See 22).) Main transformer (three-phase). Thyristor rectifier. Basic current resistor, 8.6 5%. Basic current rectifier. Freewheel diode. Shunt for measurement of welding current. Inductor for smoothing welding current.

25 26 27 28 29 30 31

cmja0de1

-6-

BLOCK DIAGRAM, LHF 630/800

cmja0de1

-7-

COMPONENT DESCRIPTION, CIRCUIT DIAGRAM

K1 K2.1 K2.2 K2.3 K2.4 K6 K11 K12 K13 K14 K18 K24 K27.1 K27.3 K27.4 K28 K31 K33 K38 K45.1 K45.2 K45.3 K45.4 K45.5 K45.6 K47 K50 K52 K57 K70 K79 Main transformer Main thyristors Main diodes Basic current diodes Freewheel diode Mains switch Mains terminal block Inductor Welding current terminals Basic current resistor, 8.6 5%. Shunt - 120 mV at 630 A (LHF 630) and at 800 A (LHF 800). Remote control socket Transient protection Capacitor 0.1F Capacitor 5F Fan Thermal overload cutout: breaks at 68C, resets at 59C, tolerance 3C. LOCAL/REMOTE control selector switch Indicating lamp, 28 V. Contact, 15-way, male Contact, 15-way, female Contact, 12-way, male Contact, 12-way, female Contact, 6-way, male Terminal block Starting capacitor for cooling fan, 3F 400 V. Terminal block Control power supply transformer, supplied at 35 V from K1s3. The secondary winding supplies 19 V AC to circuit board K70. Potentiometer (2 k) for controlling the welding current. Fine-resolution type, fitted with planetary reduction gear. Main control circuit board Selector switch, TIG/MMA/Air-arc gouging.

cmja0de1

-8-

CIRCUIT DIAGRAM, LHF 630/800

cmja0de1

-9-

cmja0de1

- 10 -

DESCRIPTION OF OPERATION, CIRCUIT BOARD K70

This description refers to the circuit diagram on page 14. The same reference numbers that were used in the block diagram on page 7 are also used in the description of the circuit board. 1 Reference input. Reference potentiometer K57 (2k 10% 2W, linear) is supplied at +15V and connected to A2, A4 and A5. The reference voltage is limited to 0-10V by potential divider R3/R4, and connected to analog switch IC1. Remote control device. The remote control device, which can be a potentiometer or a pulse generator, is connected to circuit board terminals A10, A11 and A12 via remote control input K24. It is supplied at 15 V via pins F and H in input K24. The reference voltage from the remote control device is connected to pin G. 0 V between G and H results in minimum current, and 15 V gives maximum current. 3 A/D converter. The A/D converter and the voltage reference unit (see 4), below) are galvanically isolated from the rest of the control circuitry by optocoupler IC12 (see 5), below). The A/D converter converts the reference signal to a pulse train, in which the mark/space ratio represents the magnitude of the reference signal. Optocoupler IC12 transfers the pulse train to the D/A converter, thus ensuring complete galvanic isolation between the voltage signal from the remote control input and the other electronic equipment. If selector switch K33 is in the REMOTE position, but no remote control device is connected, the power source will give low welding current, as R112, in the A/D converter 3), produces a low value of current reference signal. 4 Galvanically isolated voltage reference. The secondary output voltage from winding K1s3 on the main transformer supplies 35 V to control power supply transformer K52. The secondary voltage from K52 supplies 19 V to remote control output voltage regulator VR1 via terminals B6 and B7 and diode bridge BR1. The output voltage from VR1 is 16.2 V, which is reduced to 15.6 V after diode D12. The regulator is current-limited to 120 mA by resistors R104-107, transistor Q19 and diode D12, making the remote control connection short circuit-proof. 5 The D/A converter, which recreates the mean value of the reference signal from the pulse train from 3). The input signal is first amplified and filtered: trimming potentiometer R87 adjusts the output signal from IC4:1 to 0 V when the remote control potentiometer is at its minimum position and to +11.5 V when the potentiometer is at its maximum position. The signal is then passed to analog switch IC1, which is controlled by the LOCAL/REMOTE selector switch.

cmja0de1

- 11 -

LOCAL/REMOTE selector switch. Three analog switches (IC1) control signal switching for selection of local (internal) or remote (external) control of the welding current. These switches are, in turn, controlled by selector switch K33. The control voltage, which can be measured at terminal A3, is either 0 V ((K33 closed = internal reference) or about +27 V (K33 open = remote reference). IC1 contains four identical analog switches, of which three are used for local/remote changeover switching. The fourth switch is used for selection of the Hot Start function. The switches conduct with a control voltage of +15 V on pins 6, 12 and 13, and are open-circuit with a control voltage of 0 V.

15

Control power supply. The control power supply is obtained from winding K1s3 on the main transformer, which is connected in star. The voltage between the star point and the respective phase terminals is about 19 V, and the star point is connected to B5, which is the neutral in the electronic circuitry. The phase voltages are connected to B10, B11 and B12: capacitors C51, C52 and C53 decouple any HF interference. Resistors R125-127 are film resistors that protect the synchronising winding against any short circuits on the circuit board. Together with capacitors C54-C58, they also filter out transient peaks in the 19 V supply caused by the thyristors firing. Voltage regulator VR2 produces a +15 V stabilised voltage: trimming potentiometer R129 provides fine adjustment. Resistors R128 and R130 restrict the range over which the voltage can be adjusted to a maximum voltage of +18 V, which is the maximum permissible supply voltage for the CMOS circuits. D21 stabilises the negative voltage to - 15 V. The power rating of R131 is such as to allow the circuit to supply a load current of 30 mA.

17

The trigger unit converts the DC signal from the control amplifier 16) to ignition pulses that fire the thyristors at the correct point in the cycle. The unit consists of three identical sections, one for each thyristor. A synchronising winding K1s2, connected to terminals B13-15, provides synchronising information for correct firing. The voltage between B13/B14/B15 is approximately 35 V. The ignition pulses are connected to each thyristor. The gate connections are twisted together with the associated neutral connections in order to minimise the risk of interference in the gate circuit.

cmja0de1

- 12 -

18

The thermal overload switch interrupts the power supply to output transistors Q9, Q12 and Q15 in the trigger unit in the event of excessive thyristor temperature. The switch interrupts the circuit at a temperature of 68 C, and resets automatically when the temperature has fallen to 59C. Operation of the thermal overload switch prevents the thyristors from receiving any trigger pulses. The current flowing in the main welding circuit is then limited to the basic current of 8 A.

19

The shunt amplifier amplifies the voltage signal from the shunt. Trimming potentiometer R132 adjusts the output voltage from the amplifier to - 20 mV when no welding current is flowing. The shunt provides an output voltage signal of 120 mV for 630 A welding current in LHF 630 and 120 mV for 800 A welding current in LHF 800. The MMA/TIG selector switch. Changeover between MMA and TIG welding modes is controlled by transistor Q16, which is controlled by switch K79. In the MMA welding mode, the control voltage at A1 is about - 25 V (switch K79 open), while in the TIG welding mode it is 0 V (K79 closed). Air-arc gouging/MMA changeover. A contact on switch K79 links contacts A9-A12 in the galvanically isolated remote control circuit to change the operating mode to air-arc gouging. (Switch K79 also selects MMA or TIG welding modes.) Optocoupler IC11 is activated in the air-arc gouging mode, and in turn activates the air-arc gouging control circuits.

22

24

cmja0de1

- 13 -

CIRCUIT DIAGRAM, CIRCUIT BOARD K70

cmja1e03

cmja0de1

- 14 -

cmja1e04

cmja0de1

- 15 -

COMPONENT POSITIONS, CIRCUIT BOARD K70

cmva2eba

cmja0de1

- 16 -

cmva2ebb

cmja0de1

- 17 -

REPLACEMENT OF THYRISTORS
When fitting replacement thyristors, it is extremely important that they are correctly secured, i.e. with a clamping force of 4500 N (450 kp) 10% for LHF 630 and 5490-5530 N for LHF 800. Clean the flat surfaces of the thyristors and heat sinks carefully, and remove any burrs or traces of grease or oil. Apply a very thin film of silicone grease to the contact surfaces of the heat sink, and position the thyristor between the surfaces with the symbol on the thyristor facing in the direction as shown in the diagram below. Centre the thyristor by locating the pin projecting from the pressure cap in the depression in the thyristor body. Start by finger-tightening the nuts enough to remove play between the nuts and washers. Then, using a dial gauge or depth gauge, measure the distance from the plate to the spring as shown in the diagram below. Tighten the nuts alternately with a spanner until the distance has decreased by 0.9 0.05 mm for LHF 630 and 1.0 0.05 mm for LHF 800.

FITTING OF THYRISTORS

cmja2p02

cmja0de1

- 18 -

INSTRUCTION MANUAL

cmja0de1

- 19 -

WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill S Install and earth the welding unit in accordance with applicable standards. S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. S Insulate yourself from earth and the workpiece. S Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health S Keep your head out of the fumes. S 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. S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. S Protect bystanders with suitable screens or curtains. FIRE HAZARD S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!

LHF 630 and LHF 800 - two thyristor controlled welding rectifiers with mains voltage compensation designed for hand welding, TIG welding and arc-air gouging. The mains voltage compensation ensures constant welding current and arc voltage regardless of mains voltage variations. The electronic control circuitry maintains pre-set welding current value. A single setting knob takes care of the entire welding current range. All LHF rectifiers are provided with two sturdy lifting eyelets facilitating transport by crane, shop traveller or lifttruck. Hand welding LHF 630 and 800 have excellent striking and welding properties. The open circuit voltage and a well balanced current boost, i.e. a start surge, facilitate striking and restriking of the electrode. The LHF anti-stick action greatly reduces the risk of the electrode sticking to the workpiece, the welding current is quickly reduced to 8A (the basic current level), which makes it easy to separate the electrode from the workpiece. This function primary facilitates the welding of root runs and saves electrodes. The dynamic characteristics of the LHF produce a quiet and spatter-free arc and an easily controlled molten pool. LHF accepts all hand welding electrodes, including basic electrodes. TIG welding LHF 630 and LHF 800 are designed with optimal TIG welding characteristics. When TIG welding thin plate, low min. current is required. LHFs min. current of only 8A definitely meets this demand. When TIG welding, the start surge and the antistick action is disconnected by the switch located on the front panel. Suitable, optimal accessory TIG equipment includes: auxiliary transformer, SEIRION DC or TIG-Aid, gas bottle, gas regulator, TIG-torch, etc. Arc-air gouging The LHF 630/800 have been optimized for hand welding and arc-air gouging. Arc-air gouging is not only a way of removing welding defects, it can also be used for the preparation of root runs and for other forms of weld preparation. It is also an efficient and profitable method of cleaning up and removing faults from castings as well as cutting off steel reinforcements in concrete castings. The LHF can be used with carbon rods with diameters of up to 10 and 13 mm, respectively. Compressed air and a torch are needed together with the LHF when arc-air gouging.

- 21 -

THE ADAPTABILITY OF LHF TO YOUR WORKSITE LHF is available with spacer bars, solid rubber wheels, pneumatic tyres and a four-wheel chassis - all according to your particular requirement. With the spacer bars the rectifier can be used as a stationary unit. The LHF also becomes stackable when provided with spacer bars, i.e. one machine can be placed on top of the other. The pneumatic tyres facilitate transport on uneven or soft surfaces and the four-wheel chassis can often eliminate the use of a lifting device. To feed TIG add-on units such as the ESAB TIG-aid, the LHF rectifier can be fitted with a 24V, 150V A auxiliary transformer. ESAB driers can also be connected to this transformer. If you want to change your LHF to fit e.g. a new work-site, the above mentioned equipment can be ordered in component sets. In addition, remote control units, hot-start, long-pulse units and connection cables are available upon request. Remote control unit PHB 1 A light-weight and easy to use one-hand unit, featuring a planetary gear for accurate setting. Remote control unit PHB 2 Heavy-duty design, featuring steplessly course and fine setting for accurate adjustment. Heavy-duty design, featuring stepless coarse and fine welding current setting from minimum. By limiting the maximum current the fine setting becomes more sensitive. Remote control unit PHC 2 Robust design with the working range of the machine divided into 10 sectors (in 10 steps). Fine adjustment gives extremely accurate settings within each sector. Pulse unit PHA 5 When a pulsating current for TIG welding is required, or when welding stainless steel, a PHA 5 can be connected to the LHF rectifier. The current pulse can be set between 0.3 and 2 or 4 seconds duration. The pulse current is continually variable between the LHF rectifiers minimum and maximum current settings. A switch giving continuous current enables the PHA 5 to be used as a remote control unit. Long pulse unit PHA 4 can not be used with LHF rectifiers. Hot-start unit PHA 2 When combining the LHF rectifier with a PHA 2, the operator can choose between two entirely independent current levels. The selector for these two levels is mounted on the electrode holder. This is used, for example after switching electrodes in one-side welding with a backing piece. The higher current is then selected, which melts down welding faults (pipes and cratercracks, etc.) which often occur when welding is interrupted. The two current levels can be set independently.

- 22 -

OPERATION
All LHF controls are located on the front panel. These include ON and OFF switch, indicator light, toggle switch for TIG or hand welding and arc-air gouging, setting knob for welding current, switch for with or with-out remote control unit, and a socket for the remote control unit. The sockets for connection of welding cable and ground return cable connectors are located below the front panel and the grille. Starting instructions 1. 2. 3. Turn the switch to the I position. The indicator lamp will light up and the fan will start. Make sure that the air inlet is not blocked. Set the toggle switch for TIG welding, hand welding or arc-air gouging in correct position.

INSTALLATION
The LHF rectifiers are reconnectable for 220/380/415/500 V 50 Hz - 220/440/550 V 60 Hz. 1. Make sure that the rectifier is correctly wired for the mains voltage available. You can check this by comparing connection block K11 with the connection drawings on the circuit diagram. Mains cable area and fuse size, see table on next page. The mains cable is connected to terminals R, S and T on the connection block K11. Phase sequence is of no importance. Cable lead-in and stress-relieving clamp are located at the very bottom left on the back of the rectifier. Ground. The rectifier must be grounded in accordance with relevant regulations. Ground to be connected to bolt marked main transformer. 5. next to the connection blocks above the

2. 3.

4.

Welding and ground return cables. The conduit area (Cu) of the LHF 630 should be 70 mm2 and 120 mm2 for LHF 800. When welding with exceptionally long cables, it may be necessary to use cables of larger dimensions in order to limit voltage drop and maintain stable arc voltage. Make sure the cables are properly connected to the cable connectors, electrode holder, and ground clamp. Connection of auxiliary transformer for TIG add-on unit, or electrode drier. Remove the plastic plugs at the very bottom right of the back plate. The auxiliary transformer is plugged in by connecting the wires to connection block K50 (see circuit diagram enclosed with the auxiliary transformer).

6.

- 23 -

TECHNICAL DESCRIPTION
The LHF rectifiers consist of one power unit and one control unit. The fan-cooled power unit comprises the main transformer, a rectifier bridge, an inductor, a basic current circuit, a cooling fan, terminal blocks for voltage change-over, mains connection and the mains connection switch. The control circuit constitutes an enclosed dust- proof area located at the front of the power source, which is screened off from the ventilated power unit. The control unit includes a potentiometer for current adjustment, a socket for the remote control unit including switch, electronic control circuitry, indicator light and a transformer, feeding the physically separated remote control unit. Overload protection The welding rectifier is provided with a thermal cut-out, which protects the equipment against overheating caused by overloading or insufficient cooling. The thermal cut-out is dust and moisture proof. The thermal cut-out is located on the heat sink close to the semi- conductors and is automatically re-set when the power unit has cooled down sufficiently. Control unit The control unit is dust-proof. The front plate, on which the controls are located, is easily removed by means of four snapcatches with quarterturn locking action. The control unit includes the current setting potentiometer with planetary gear. This gear has built-in safety clutch, which provides improved welding current adjustment and eliminates the risk of mechanical potentiometer damage. The control unit comprises a single, printed electronic circuit card with gate connection wires provided with flat pin-plugs and two unmistakable plug-in couplings. The entire circuit card has been dipped twice in a special, protective polyurethane type lacquer. When using a remote control unit, a physical separation between the remote control potentiometer signals and the control amplifier is made. This will eliminate problems, such as creeping current in humid weather, break-down due to pinched control cable, and it will also prevent external interference from penetrating the electronic circuitry. TECHNICAL DATA
LHF 630 Permitted load at 35% duty factor at 60% duty factor at 100% duty factor Setting range Open--circuit voltage No--load rating (kW) Power factor () at 150A/ at max A Weight, approx. Efficiency () Temperature class Design criteria Class of use 630A/44V 500A/40V 400A/36 8A/20V -- 630A/44V 65 -- 72V 0,6 0.56 / 0,87 235 kg 0,71 H (180C) IP 23 AF LHF 800 800A/44V 630A/44V 500A/40V 8A/20V -- 800A/44V 69 -- 76V 0,65 0,52 / 0,82 275 kg

K
- 24 -

Mains connection LHF 630 Voltage (V) Current (A) Fuse, slow (A) Cable area (mm2) Fuse, fast (A) Cable area (mm2)

50/60 Hz 3x220 70 80 4x25 100 4x35

50 Hz 3x380 40 50 4x10 63 4x10

50 Hz 3x415 37 50 4x10 63 4x10

60Hz 3x440 37 50 4x10 63 4x10

50 Hz 3x500 31 35 4x6 63 4x10

60 Hz 3x550 31 35 4x6 63 4x10

Mains connection LHF 800 Voltage (V) Current (A) Fuse, slow (A) Cable area (mm2) Fuse, fast (A) Cable area (mm2)

50/60 Hz 3x220 92 100 4x35 125 4x50

50 Hz 3x380 53 63 4x10 80 4x25

50 Hz 3x415 49 63 4x10 80 4x25

60Hz 3x440 49 63 4x10 80 4x25

50 Hz 3x500 40 50 4x10 63 4x10

60 Hz 3x550 40 50 4x10 63 4x10

Note! Primary currents refer to a 100 duty cycle. Cable areas according to Swedish regulations. Mains voltage -a mains voltage variation of 10 gives a compensation welding current variation of only 0.2. Standards comply with: VDE 0542, ISO R700, SEN 8301, NF A 85-011

MAINTENANCE
LHF 630 and LHF 800 require a minimum of maintenance and service. Under normal operating conditions, the machine should be blown clean with compressed air at reduced pressure once a year. When used in dusty or dirty areas, the machine must be blown clean more often.

- 25 -

STATIC CHARACTERISTICS
Arc-air gouging LHF 630 LHF 800

= standardized load voltage as per ISO R 700, VDE 0542

EFFICIENCY AND POWER FACTOR

LHF 630 LHF 800

U2 = standardized load voltage

- 26 -

DIMENSION DRAWING

Stationary type

With solid rubber wheels

- 27 -

SPARE PARTS LIST LHF 630/800

Spare parts list - Reservdelsfrteckning - Ersatzteilverzeichnis - Liste de pices dtaches 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. Reservdelar bestlls genom nrmaste ESAB--representant, se sista sidan. Vid bestllning var vnlig uppge typ och tillverkningsnummer samt benmningar och bestllningsnummer enligt reservdelsfrteckningen. Die Ersatzteile knnen bei der nchsten ESAB--Vertretung bestellt werden, siehe letzte Seite. Bitte geben Sie Typenbezeichnung und Herstellungsnummer sowie Bezeichnungen und Bestellnummern laut Ersatzteilverzeichnis an. Au dos de la brochure, vous trouverez ladresse du reprsentant ESAB le plus proche. Prire de lui adresser votre commande, aprs avoir pris le soin de mentionner le type et le numro de srie de lunit ainsi que le numro de commande et la dsignation conformment la liste de pices dtaches.

sparefram

- 27 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

630 = LHF 630 (220 V - 550 V) 800 = LHF 800 (220 V - 550 V) Component designation in the circuit diagram (K57)

Item

Qty 630 1 1 1 1 1 2 1 1 2 1 6 2 2 2 3 2 1 1 1 1 2 2 1 1 1 1 1 1

Qty 800 1 1 1 1 2 1 1 2 1 6 2 2 2 3 2 1 1 1 1 2 2 1 1 1 1 1

Ordering no.

Denomination

Remarks

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

2188 106-02 466 937-001 466 940-001 147 866-001 193 219-001 321 497-001 321 001-001 467 230-002 467 229-002 320 939-001 365 038-001 365 046-001 2157 010-19 320 023-001 319 738-001 319 455-002 160 362-881 160 362-882 160 360-882 160 360-883 367 972-005 368 544-003 467 230-001 467 229-001 320 939-002 321 000-001 2188 012-01 318 113-004 147 866-002 193 219-002 192 576-003 368 120-001 2188 107-84

Indicator Front panel Front panel Switch Switch Top cover Ring Side panel LHF 800 Side panel LHF 630 Holder Wheel Axle Circlip Support beam Foot Rubber damper Welding receptacle Welding receptacle Cable connector Cable connector Sleeve in socket Remote socket Side panel LHF 800 Side panel LHF 630 Holder Handle Rubber grip Control knob Switch Switch Indicator lamp Connection diagram Knob Offshore Offshore

K33 K33

K13 K13

K24

(K6) K79 K79 K38

(K57)

cmja0se1

- 28 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

cmja0se1

- 29 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

630 = LHF 630 (220 V - 550 V) Qty 630 1 1 1 22 1 1 22 1 1 4 4 1 1 1 1 2 Qty 800 1 1 1 22 1 1 22 1 1 4 4 1 1 1 1 2 800 = LHF 800 (220 V - 550 V) Component designation in the circuit diagram K70+K45.1 + K45.4 K70+K45.1 + K45.4 15 pole K45.2

Item 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215

Ordering no. 319 876-880 319 876-881 192 784-016 192 784-101 192 784-014 192 784-013 192 784-102 319 828-001 320 131-880 2121 086-49 365 958-001 192 724-007 317 942-001 192 753-006 192 784-015 365 745-001

Denomination Printed circuit Substitute printed circuit *) Socket Pins for plugs K45.1, and K45.3 Socket Plug Insert for sockets K45.2 and K45.4 Control transformer Grille Locking screw Anti-locking washer Potentiometer Planetary gear Connection block Plug Holder, Peb

Remarks

12 pole 12 pole

K45.4 K45.3

K52

M6x12

K57 (K57) 6 pole 15 pole K45.5 K45.1

*) To obtain this circuit card the old card must be returned.

cmja0se1

- 30 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

cmja0se1

- 31 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

630 = LHF 630 (220 V - 550 V) Qty 630 1 1 1 3 1 1 1 1 1 2 1 3 2 1 1 1 1 1 1 2 1 3 1 1 1 3 3 3 1 1 Qty 800 1 1 1 3 1 1 1 1 1 2 1 3 2 1 1 1 1 1 2 2 6 1 1 1 3 3 3 1 1 800 = LHF 800 (220 V - 550 V) Component designation in the circuit diagram K47 K47 3-pole K50 K14 K2.3 12- pole K45.6

Item

Ordering no.

Denomination

Remarks

301 302 303 304 305 306 307 308 309 310 311 312 313 314

191 085-103 191 085-106 5231 041-02 0407 055-01 192 716-004 5231 041-05 319 837-004 319 838-001 162 430-001 162 430-002 162 548-005 317 660-001 319 944-880 319 944-881 319 928-880 319 928-881 0408 940-01 319 947-892 319 947-894 319 947-895 319 973-881 319 968-880 192 884-002 320 745-003 319 690-882 319 932-880 192 883-003 4906 006-06 4906 006-26 319 904-880 319 923-880 319 911-880 319 911-881 319 999-001 319 690-883 319 932-881 0410 516-06 320 028-001 318 726-001 191 309-112 192 041-139

Capacitor Capacitor Connection block Connection block Silicon diode Connection block Rear panel Fan casing Fan Fan Series resistor Element rod Inductor Inductor Coil Coil Main connection block Main transformer Main transformer Main transformer Coil, main transf. Coil, main transf. Capacitor Circuit switch Thyristor bridge Thyristor bridge Capacitor Diode Silicon diode Diode bridge Diode bridge Shunt Shunt Thermostat Tensioning device Tensioning device Transient protector Thyristor Thyristor Cable clamp Cable grommet Offshore Offshore

K28 K28 K14 K14 K12 K12 (K12) (K12) K11 K1 K1 K1 (K1) (K1) K27.4 K6 K2.1 K2.1 K27.3 K2.4 (K2.2) K2.2 K2.2 K18 K18 K31

315 316 317 318 319 320 321 322 323 324 325 326 327 328 329

K27.1 (K2.1) (K2.1)

cmja0se1

- 32 -

Reservdelsfrteckning - Spare parts list - Ersatzteilverzeichnis - Liste de pcees dtaches

cmja0se1

- 33 -

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 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: +36 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.o.o 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 Ibrica 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 International 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

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 Middle East Dubai Tel: +971 4 338 88 29 Fax: +971 4 338 87 29

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

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 & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 44 58

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

ESAB Welding Equipment AB SE- 695 81 LAX SWEDEN Phone +46 584 81 000 Fax +46 584 123 08 www.esab.com
001004