GB
LAF 1000/ 1000M
DC
Instruction manual
0456 512 301 GB 2007--02--02
Valid for serial no. 644
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source LAF 1000/ LAF 1000M from serial number 606 complies with standard EN 60974--1, in
accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
-----------------------------------------------------------------------------------------------------------------------------------------------------------------Laxå 2006--04--19
Kent Eimbrodt
Global Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN
Tel: + 46 584 81000
2
Fax: + 46 584 411721
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
6
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3.1
3.2
3.3
3.4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking and erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
8
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
6 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
12
13
15
Rights reserved to alter specifications without notice.
TOCe
-- 3 --
GB
1
SAFETY
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 recommendations 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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from draughts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
fja4SafE
-- 4 --
GB
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S 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 take fumes and gases away 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.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
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 users responsibility to take adequate
precautions.
WARNING!
Read and understand the instruction manual
before installing or operating.
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!
fja4SafE
-- 5 --
GB
2
INTRODUCTION
2.1
General
LAF 1000/ 1000M are remote--controlled 3--phase welding power sources designed
for high--efficiency mechanical gas metal arc welding (MIG/MAG) or sub arc welding
(SAW). They are always to be used in combination with ESAB‘s control box
A2--A6 Process Controller (PEH) or A2 Welding Control Unit (PEI).
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 instruction manual for either the
A2--A6 Process Controller or the A2 Welding Control Unit.
2.2
Technical data
LAF 1000
400/415/500 V, 3μ50 Hz
400/440/550 V, 3μ60 Hz
LAF 1000M
230/400/415/500 V, 3μ50 Hz
230/400/440/550 V, 3μ60 Hz
Permissible load at:
100 % duty cycle
60 % duty cycle
800 A/44 V
1000 A/44 V
800 A/44 V
1000 A/44 V
Setting range
MIG/MAG
SAW
50 A/17 V -- 1000 A/45 V
40 A/22 V -- 1000 A/45 V
50 A/17 V -- 1000 A/45 V
40 A/22 V -- 1000 A/45 V
No--load voltage
52 V
52 V
No--load power
145 W
145 W
Effiency
Power factor
0,84
0,95
0,84
0,95
Weight
330 kg
330 kg
Dimensions L x W x H
646 x 552 x 1090
646 x 552 x 1090
Enclosure class
IP 23
IP 23
Voltage
Application class
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.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
fja4d1ea
-- 6 --
GB
3
INSTALLATION
3.1
General
The installation must be executed by a professional.
3.2
Unpacking and erection
WARNING - TIPPING RISK!
Fasten the equipment -- particularly if the ground is uneven or sloping.
S
Place the welding power source on a level foundation.
S
Make sure there is nothing to prevent the cooling.
Lifting instructions
3.3
Connections
S
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 13.
S
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 8).
S
Connect the earth cable to the screw marked
S
Tighten the cable support (1).
S
Connect the mains cable to the main terminal
blocks L1, L2 and L3.
S
Connect the control cable between the LAF
welding power source and the control unit to the
28--pole contact (2) inside the welding power
source.
S
Connect 1 pin socket measure cable (4).
S
Connect a suitable welding and return cable to the contacts (3) marked + and -on the front of the power source.
fja4i1ea
-- 7 --
.
GB
Mains connection
LAF 1000
50 Hz
60 Hz
Voltage V
400
415
500
400
440
550
Current A
100%
60%
64
80
64
80
52
65
64
80
64
80
52
65
4 x 16
4 x 16
4 x 16
4 x 16
4 x 16
4 x 16
63
63
63
63
63
63
Cable area mm2
Fuse, slow A
LAF 1000M
50 Hz
60 Hz
Voltage V
230
400
415
500
230
400
440
550
Current A
100%
60%
111
138
64
80
64
80
52
65
111
138
64
80
64
80
52
65
Cable area mm2
4x50
4 x 16
4 x 16
4 x 16
4x50
4 x 16
4 x 16
4 x 16
Fuse, slow A
125
63
63
63
125
63
63
63
3.4
PC board
DIP switches
The PC board (AP1) has two DIP switches (SW1 and SW2) which are preset on
delivery. The settings are not to be changed.
When spare parts are supplied the settings of the DIP switches must be checked
(and set, if necessary) before fitting the PC board into the welding power source.
S
DIP switch SW1
To make the communication with the
A2--A6 Process Controller (PEH) work
DIP switch 1 (SW1) must be set.
S
DIP switch SW2
DIP switch 2 (SW2) must be set in order to
inform the A2--A6 process controller (PEH)
about the rating of the power source that is
connected.
Setting of DIP switch SW1
S
Set pole 6 to “OFF“ position and all other
poles to “ON“.
Setting of DIP switch SW2
S
Set pole 3 to “OFF“ position and all other
poles to “ON“.
Welding power source program
The welding power source program is stored in the flash
memory IC 6. The capsule is fitted in a holder and is
replaceable.
fja4i1ea
-- 8 --
GB
4
OPERATION
4.1
General
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
Note! Never use the welding power source without side plates.
4.2
Controls
The front panel contains:
1. Main switch, 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 FU1 for 42 V supply voltage.
4.3
Start--up
S
Connect the return cable to the work piece.
S
Set the main switch (1) to position “I“.
The white indicating lamp (2) goes on and the fan starts.
S
Set the welding parameters and start welding by way of the control box
(see instruction manual 0443 745 xxx for A2--A6 Process Controller or
instruction manual 0449 331 xxx for the A2 Welding Control Unit).
fja4o1ea
-- 9 --
GB
5
MAINTENANCE
5.1
General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
5.2
S
Cleaning
Clean the welding power source as necessary.
Dry compressed air is recommended for the purpose.
WARNING!
Blocked air inlets or outlets will lead to overheating.
Note:
In order to ensure safe operation of the contactor, keep the magnetic parts clean.
If the contactor has to be cleaned it must be taken apart, and all the pieces be
cleaned.
Alternatively, the contactor can be replaced.
WARNING!
Never use compressed air to clean the contactor without first taking it apart
completely.
6
ORDERING OF SPARE PARTS
LAF 1000/ LAF 1000 is designed and tested in accordance with the international and
European standards IEC/EN 60974--1 and IEC/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 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 designation and spare part number as shown in the spare parts list on page 15.
This will simplify dispatch and ensure you get the right part.
fja4m1ea
-- 10 --
Diagram
fja4s12a
-- 11 --
List of components
C = Component designation in the circuit diagram
C
Denomination
C
Denomination
V3
Diode bridge
QF
Main switch (black)
V2
Silicon diode
HL1
Indicating lamp (white)
C4
Capacitor
HL2
Indicating lamp (yellow)
FU1
Fuse
XT2
Connection block
FU2
Automatic fuse
RS1
Shunt
FU3
Fuse
ST1
Thermal guard
KM1
Contactor
KM2
Contactor
AP1
Circuit board
TC1
Control transformer
V4
Diode bridge
AP2
Circuit board, insulation
TM1
Transformer
AP3
Circuit board, EMC--filter
R3
Resistor
M1
Fan
fja4com
Z1, Z2, Z3 Contact protection
V1
L1
-- 12 --
Thyristor
Inductor
Connection instruction
LAF 1000
fja4c12a
-- 13 --
LAF 1000M
fja4c12a
-- 14 --
Spare parts list
Edition 2006--06--26
Ordering no.
Denomination
Notes
0456 321 881
Welding power source
LAF 1000
0456 321 882
Welding power source
LAF 1000M
Abbreviations used in the spare parts list:
C = Component designation in the circuit diagram
sparefram
-- 15 --
Item
1
Qty
1
2
Ordering no.
Denomination
0456 321 881
0456 321 882
LAF 1000
LAF 1000M
0469 844 882
Transformer
0469 841 880
Transformer coil
Notes
C
TM1
4
1
0318 060 001
Capacitor
C4
5
1
0318 022 001
Fan
M1
6
1
0321 003 881
Resistor
R3
7
2
0040 894 001
Connection block
XT2
8
1
0551 202 980
Shunt
RS1
9
1
0319 445 001
Thermal guard
ST1
10
1
0320 116 881
Thyristor bridge
11
2
0490 600 606
Silicon diode
V4
12
3
0041 051 606
Contact protection
Z1, Z2, Z3
13
3
0320 946 001
Thyristor
V1
0158 115 880
Cable inlet
15
1
0162 772 001
Connection block
16
1
0320 746 002
Main switch
Black
QF
17
2
0194 091 002
Fuse
16 A, 690 V
FU1
18
1
0192 576 004
Indicating lamp (white)
HL1
19
1
0192 576 304
Indicating lamp (yellow)
HL2
20
1
0193 586 104
Automatic fuse
22
2
0156 388 001
Handle
23
1
1
0486 368 880
0486 525 880
Circuit board
Flash memory
14
24
20 A
FU2
AP1
IC6
0805 586 131
Contactor
25
1
1
0193 358 102
0442 849 880
Contactor
Contactor
LAF 1000
LAF 1000M
KM1
KM1
26
1
0460 092 001
Control transformer
42 V, 900 VA
TC1
27
1
0486 224 880
Circuit board, EMC filter
28
3
0321 468 003
Silicon diode
29
1
0321 489 880
Base current bridge
30
1
0318 040 883
Inductor
L1
0490 600 626
Silicon diode
V2
31
KM2
AP3
32
1
0567 900 129
Fuse
315 mA
FU3
33
1
0487068880
0368544006
Circuit board, insulation
Sleeve socket
28--pole, Burndy
AP2
XS24
0191093135
Resistor
680R
R4
35
0523300201
Positive terminal
36
0320266880
Diode bridge
34
f456321s
1
-- 16 --
f456321s
-- 17 --
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 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
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: +49 212 298 218
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 2485 377
Fax: +31 30 2485 260
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
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 Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
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
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 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 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 8027 9869
Fax: +60 3 8027 4754
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
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
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
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 57 48
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
061127
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