ESAB | LAF 1601 / LAF 1601M | Instruction manual | ESAB LAF 1601 / LAF 1601M User manual

ESAB LAF 1601 / LAF 1601M User manual
LAF 1601 /
LAF 1601M
Instruction manual
0449 507 001 2009-08-24
Valid for serial no. 0935-xxx-xxxx
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
-- 2 --
4
3
ENGLISH
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
8
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
6 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
LIST OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
TOCe
-- 4 --
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. Note! Do not use safety
gloves when replacing wire.
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.
-5SafeArcW GB
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 MANUFACTURER'S 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.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
-6SafeArcW GB
GB
CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
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!
CAUTION!
The welding power source and control box PEH can't be used together.
-7SafeArcW GB
GB
2
INTRODUCTION
2.1
General
LAF 1601 / LAF 1601M are remote-controlled 3-phase welding power sources
designed for high-efficiency mechanical submerged-arc welding (SAW).
The welding power sources are fan-cooled and are monitored by a thermal cutout
against overload. When the thermal cutout is deployed the yellow lamp on the front
panel illuminates automatically. The reset is carried out automatically when the
temperature has decreased to a permitted level.
2.2
Technical data
Mains connection:
LAF 1601
400/415/500 V, 3µ50 Hz
400/440/550 V, 3µ60 Hz
LAF 1601M
220/230/400/415/500 V, 3µ50 Hz
230/400/440/550 V, 3µ60 Hz
Primary current
Imax 136 A
Imax 235 A
Permissible load at:
100 % duty cycle
1600 A/ 44 V
1600 A /44 V
Setting range
100-1600 A /24-44 V
100-1600 A /24-44 V
No-load voltage
56 V
56 V
No-load power
230 W
230 W
Effiency
89%
89%
Power factor
0,86
0,86
Weight
585 kg
585 kg
Dimensions L x W x H
774 x 598 x 1430
774 x 598 x 1430
Insulation class (transformer):
H
H
Enclosure class
IP 23
IP 23
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.
-8hja2d1ea
GB
3
INSTALLATION
3.1
General
The installation must be executed by a professional.
3.2
Location
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
-9hja2i1ea
GB
3.3
Connections
S
On delivery the welding power source is connected
for 400 V.
S
For other supply voltage:
Remove the left side plate.
Perform the switchings on the main and control
transformer in accordance with the connection
instruction on page 15.
S
Select the mains cable with the correct cable area
and fuse the cable with the correct fuse in accordance
with local regulations (see the table on page 10).
S
Remove the front plates (x 2).
S
Connect the ground cable to the screw marked
S
Tighten the cable clamp (1).
S
Connect the mains cables to the main connection terminals L1, L2 and L3 (5).
S
Connect the control cable between the welding power source and the control
box to the 28-pin connector (2) on the inside of the welding power source.
S
Connect the 1-pin measuring cable (4) for measuring the arc voltage to the
return cable/ welding head.
S
Connect a suitable welding and return cable in the connectors (3) marked
+ and - on the front of the welding power source.
S
Fit the side/front plates.
.
Mains connection
LAF 1601
50 Hz
60 Hz
Voltage (V)
400 / 415
500
400 / 440
550
Phase current I1eff (A)
136
108
136
108
Cable area (mm2)
3 x 70+35
3 x 50+35
3x70+ 35
3x70+ 35
Fuse, slow (A)
160
125
160
125
LAF 1601M
50 Hz
60 Hz
Voltage (V)
230
400 / 415
500
230
400 / 440
550
Phase current I1eff (A)
235
136
108
235
136
108
Cable area (mm2)
3x120+70
3x70+35
3x50+35
3x120+70
3x70+ 35
3x70+ 35
Fuse, slow (A)
200
160
125
200
160
125
- 10 hja2i1ea
GB
4
OPERATION
4.1
General
General safety regulations for the handling of the equipment can be found on
page 5. 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 circuit-breaker for switching the mains voltage and the fan on
and off in the welding power source.
S
Position "1" On
S
Position "0" Off
2.
S
The indicator lamp (white) illuminates when the main switch is
switched on.
3.
Indicator lamp for overheating (yellow)
4.
S
The indicator lamp illuminates when the thermal cutout is
deployed due to excess temperature in the welding power
source.
S
The indicator lamp goes out when the temperature in the
welding power source has decreased to a permitted level.
Pushbutton resetting the automatic fuse FU2 for 42 V supply
voltage.
- 11 hja2o1ea
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 welding power source during the warranty
period.
5.2
Cleaning
5.2.1
Welding power source
WARNING!
Blocked air inlets or outlets will lead to overheating.
S
Clean the welding power source as necessary.
Dry compressed air is recommended for the purpose.
5.2.2
Contactor
WARNING!
Never use compressed air to clean the contactor without first taking it apart
completely.
Note:
To ensure the reliable operation of the contactor, the magnetic parts must be kept
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.
6
ORDERING OF SPARE PARTS
LAF 1601/ LAF 1601M is designed and tested in accordance with the international and
European standards IEC/EN 60974-1 and 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 17.
This will simplify dispatch and ensure you get the right part.
- 12 hja2m1ea
DIAGRAM
hja2schema
-- 13 --
LIST OF COMPONENTS
C = Component designation in the circuit diagram
C
Denomination
AP1
Circuit board
AP2
Circuit board, insulation
AP3
Circuit board, EMC filter
C1, C2, C3,
C4
Capacitor
FU1
Automatic fuse
16 A
FU2
Automatic fuse
20 A
FU3
Fuse
1,25 AT
FU4
Fuse
1,25 AT
FU5
Fuse
3,15 AT
HL1
Indicating lamp (white)
HL2
Indicating lamp (yellow)
KM1
Contactor
KM2
Contactor
L1
Inductor
M1
Fan
QF
Main switch (black)
R1, R2, R4
Resistor
RS1
Shunt
ST1
Thermal guard
TC1
Control transformer
TC2
Transformer
TM1
Transformer
THY1, THY2,
THY3
Thyristor
V2
Silicon diode
V4
Diode bridge
Remarks
42 V, 50 Hz
42 V, 900VA
XT2,XT3,XT4 Connection block
RC1 - RC5
Contact protection
XS1
Socket
1 pole
XS2
Socket
1 pole
XS3
Socket
1 pole
XS4
Sleeve socket
28 pole
hja2kompforteck
-- 14 --
CONNECTION INSTRUCTION
LAF 1601
hja1inkoppling
-- 15 --
LAF 1601M
hja1inkoppling
-- 16 --
SPARE PARTS LIST
Edition 2009-08-24
Ordering no.
Denomination
Notes
0460515880
Welding power source
LAF 1601
0460515881
Welding power source
LAF 1601M
Abbreviations used in the spare parts list:
C = Component designation in the circuit diagram
hja2reserv
-- 17 --
Item
no.
Qty.
Ordering no.
Denomination
Remarks
0460515880
Welding power source
LAF 1601
C
1
1
0551203082
Shunt
2000 A
RS1
2
1
0191085104
Capacitor
400 V
C4
3
3
0490600606
Silicon diode
V4
4
1
0320445883
Inductor
L1
5
1
0320444883
Inductor coil
8
1
0460294880
Fan
9
3
0321452880
Thyristor bridge
10
2
0041051606
Contact protection
11
3
0321427001
Thyristor
1500 A/ 500 V
THY1- THY3
12
2
0194077008
Automatic fuse
16 A
FU1
13
1
0320746002
Main switch (black)
QF
14
1
0192576004
Indicating lamp (white)
HL1
15
1
0192576303
Indicating lamp (yellow)
HL2
16
1
0193586104
Automatic fuse
19
1
0487399886
Circuit board
19
1
0487399880
Circuit board
From serial no. 0935-xxx-xxxx
The circiut board must be configured
when installed
AP1
1
0487399886
Circuit board
From serial no. 0935-xxx-xxxx
Circuit board configured for LAF 1601
version.
AP1
20
1
0805586131
Contactor
KM2
21
1
0442849880
Contactor
KM1
22
3
0319828001
Transformer
TC2
23
1
0460092002
Control transformer
24
1
0486224880
Circuit board, EMC filter
25
2
0158115880
Cable inlet
26
1
0469843880
Transformer coil
27
1
0469845881
Transformer
M1
RC
20 A
FU2
AP1
42 V, 900 VA
TC1
AP3
TM1
28
2
0320923880
Diode brige
28.1
6
0490600626
Silicon diode
33
1
0487068880
0368544006
Circuit board, insulation
Sleeve socket
28-pole, Burndy
AP2
XS4
680R
R4
34
1
0191093135
Resistor
35
1
0523300201
Measure terminal
36
1
0319445001
Thermostat
h460515s
V2
ST1
-- 18 --
h460515s
-- 19 --
Item
no.
Qty.
Ordering no.
Denomination
Remarks
0460515881
Welding power source
LAF 1601M
C
1
1
0551203082
Shunt
2000 A
RS1
2
1
0191085104
Capacitor
400 V
C4
3
3
0490600606
Silicon diode
V4
4
1
0320445883
Inductor
L1
5
1
0320444883
Inductor coil
8
1
0460294880
Fan
9
3
0321452880
Thyristor bridge
10
2
0041051606
Contact protection
11
1
0321427001
Thyristor
1500 A/ 500 V
V1
12
2
0194077008
Automatic fuse
16 A
FU1
13
1
0320746002
Main switch (black)
QF
14
1
0192576004
Indicating lamp (white)
HL1
15
1
0192576303
Indicating lamp (yellow)
HL2
16
1
0193586104
Automatic fuse
18
2
0156388001
Handle
19
1
0487399880
1
20
RC
20 A
FU2
Circuit board
From serial no. 0935-xxx-xxxx
The circiut board must be configured
when installed
AP1
0487399886
Circuit board
From serial no. 0935-xxx-xxxx
Circuit board configured for LAF 1601
version.
AP1
1
0805586131
Contactor
KM2
21
1
0442849881
Contactor
KM1
22
3
0319828001
Transformer
TC2
23
1
0460092002
Control transformer
24
1
0486224880
Circuit board, EMC filter
25
2
0158115880
Cable inlet
26
1
0469843880
Transformer coil
27
1
0469845881
Transformer
42 V, 900 VA
TC1
AP3
TM1
28
2
0320923880
Diode brige
28.1
6
0490600626
Silicon diode
33
1
0487068880
0368544006
Circuit board, insulation
Sleeve socket
28-pole, Burndy
AP2
XS4
680R
R4
34
1
0191093135
Resistor
35
1
0523300201
Measure terminal
36
1
0319445001
Thermostat
h460515s
V2
ST1
-- 20 --
h460515s
-- 21 --
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.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
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 2326 3000
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 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
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
081016
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