LAF 635/LAF 635R
GB
LAF 635/LAF 635R
Instruction manual
0457 795 501 GB 2007--04--20
Valid for serial no. 712
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, declares under sole responsibility that
welding power source LAF 635 / LAF 635R from serial number 712 (2007 w.12) is designed and
tested in conformity with standard EN 60974--1 and EN 60974--10 in accordance with the conditions in
the directives (2006/95/EC) and (2004/108/EC).
-----------------------------------------------------------------------------------------------------------------------------------------------------------Laxå 2007--03--30
Kent Eimbrodt
Global Director
Equipment and Automation
2
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
3.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling and placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
8
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
12
14
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.
fja5SafE
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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 user’s 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!
fja5SafE
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GB
2
INTRODUCTION
2.1
General
LAF 635 and LAF 635R 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
Main connection
Permissible load at:
100 % duty cycle
60 % duty cycle
Setting range:
No--load voltage
No--load power
Effiency
Power factor
Weight
Dimensions L x W x H
Class of enclosure
LAF 635/LAF 635R
400/415 V 3μ50 Hz
440 V 3μ60 Hz
630 A/44 V
800 A/44 V
75 A / 18 V -- 800 A / 44 V (46 V)
54 V
150 W
0,84
0,90
260 kg
652 x 483 x 800
652 x 483 x 916 (including foot)
IP 23
Class of application
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.
fja5d1ea
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GB
3
INSTALLATION
3.1
General
The installation must be executed by a professional.
3.2
Assembling and placing
WARNING - TIPPING RISK!
Fasten the equipment -- particularly if the ground is uneven or sloping.
S
Fit the supports supplied. Place the welding power source in such a way that the
cooling air intake and outlet remain free.
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 14.
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, placed on the
backside of the welding power source.
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 (1) on the front of the welding power source.
S
Connect 1 pin socket measure cable (2).
S
Connect a suitable welding and return cable to the contact rails marked + and The rails are placed inside the lid (3) on the front of the welding power source.
fja5i1ea
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.
GB
3.4
Mains connection
LAF 635/LAF 635R
50 Hz/60 Hz
Voltage V
400/415/440 V
Current A 100%
52
Cable area mm2
4 x 16
Fuse slow A
63
3.5
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 1 and 3 to “OFF” (Open)
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.
fja5i1ea
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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 FU2 for 42 V supply voltage.
5. Pushbuttons, for the resetting of automatic fuse FU3
for 230 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).
fja5o1ea
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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 635/ LAF 635R 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.
fja5m1ea
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sida
-- 11 --
Diagram
fja5e11a
-- 12 --
fja5e11a
-- 13 --
Connection instruction
fja5c12a
-- 14 --
Spare parts list
Edition 2007--04--02
Ordering no.
Denomination
Notes
0457 350--880
Welding power source
LAF 635
0457 350--882
Welding power source
LAF 635R
Abbreviations used in the spare parts list:
C = Component designation in the circuit diagram
spareFja5
-- 15 --
Item
Qty
LAF 635R
Qty
LAF 635
Ordering no.
Denomination
0457 350 880
0457 350 882
Welding power source
Welding power source
Notes
C
LAF 635
LAF 635R
2
1
1
0320 415 880
Diode bridge
3
6
6
0490 600 626
Diode
4
2
2
0193 586 101
Automatic fuse
5
1
1
0191 085 203
Capacitor
6
2
2
0194 077 008
Automatic fuse
7
1
1
0193 503 101
Contactor
KM1
8
1
1
0193 296 101
Contactor
KM2
10
1
1
0320 746 002
Main switch
V2
5A
FU3
C4
16 A, 400 V
FU1
Black
QF
20 A
FU2
11
2
2
0457 583 001
Foot
12
1
1
0193 586 104
Automatic fuse
13
1
1
0320 620 881
Thyristor bridge
14
2
2
0490 600 606
Diode
V4
15
3
3
0320 946 001
Thyristor
V1
16
1
1
0319 445 001
Thermal Relay
ST1
17
3
3
041 051 606
Contact protection
Z1
18
1
1
0369 827 001
Fan
M1
19
1
1
0192 576 303
Indicating lamp (yellow)
HL2
20
1
1
0192 576 004
Indicating lamp (white)
HL1
21
1
1
0467 970 882
Transformer
TM1
22
1
1
0486 368 880
Circuit board
AP1
23
1
1
0460 092 001
Control transformer
TC1
24
2
2
0467 176 001
Handle
25
2
1
0321 003 881
Resistor
26
1
1
0321 489 881
Base current bridge
f457350s
-- 16 --
f457350s
-- 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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