ESAB LHP 250 User manual

Welding rectifier

0740 800 124

9804

LHP 200/250

LHP 300/400

Service manual

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

2

INDEX PAGE

1 RATING PLATES LHP200 - 250 - 300 - 400 .......... 3

2 LHP 200 - 250 ELECTRICAL DIAGRAM ........... 4

3 LHP 300 - 400 ELECTRICAL DIAGRAM ........... 5

4 MEASUREMENTS BETWEEN MAIN TEST POINTS....... 6

4.1 MAIN SUPPLY VOLTAGE MEASUREMENT ........ 6

4.2 PRIMARY CIRCUIT VOLTAGES MEASUREMENTS . . . . . . 7

4.3 PRIMARY CIRCUIT TROUBLE SHOOTING ....... 7

4.4 SECONDARY CIRCUIT VOLTAGES MEASUREMENTS . . . . 8

4.5 SECONDARY CIRCUIT TROUBLE SHOOTING .......12

4.6 WELDING CIRCUIT VOLTAGE MEASUREMENT .......13

4.7 WELDING CIRCUIT TROUBLE SHOOTING . ........17

5 INSTRUCTION MANUAL . . . . . ...........17

6 SPARE PARTS REFERENCES LHP 200 - 250 - 300 - 400 . . . . 21

7 SPARE PARTS LIST ..................22

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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1 RATING PLATES LHP200 - 250 - 300 - 400

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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2 ELECTRICAL DIAGRAM LHP 200 - 250

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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3 ELECTRICAL DIAGRAM LHP 300 - 400

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4 MEASUREMENTS BETWEEN THE MAIN TESTS POINTS OF WELDING

MACHINES ESAB LHP 200 - 250 - 300 - 400

THE FOLLOWING MEASUREMENTS HAVE BEEN MADE WITH A MAIN SUPPLY VOLTAGE OF ABOUT

390 VAC.

ACCORDING TO THIS VOLTAGE IT IS POSSIBLE TO GET DIFFERENT RESULTS WHICH MUST BE IN

THE RANGE OF +/- 10% FROM THE VALUES STATED HEREBELOW.

4.1 MAIN SUPPLY VOLTAGE MEASUREMENT

Test the following A.C. voltage between the three main phases therefore between: R-S, S-T, T-R. Switch on

the welding machine pressing the green push botton on the front panel then repeat the measurement

between: W1-V1, V1-U1, U1-W1 obtaining the same result.

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4.2 PRIMARY CIRCUIT VOLTAGES MEASUREMENT (BETWEEN THE CENTER AND

EACH PHASE)

Measure the voltage between the center (V2-U2-W2 all connected together because we are feeding the

machine by connection 400V three-phase) and each phase (W1, V1, U1).

The same voltage must be measured also at the terminals of the contactor, of the fans and of the on lamp

because the above components are feeded by the voltage coming from V1 and V2 terminals.

4.3 PRIMARY CIRCUIT TROUBLE SHOOTING

TROUBLE POSSIBLE CAUSE

The machine does not switch on or does not

remain switched on

one or more phases missing

Thermic protections open

Off/switch open or defective

Blown fuse

Damaged or not feeded contactor coil

The machine lights up but one phase is missing If the first measurement shows that all the

phases are present while in the second

measurement one phase is absent, then check

the contactor because one contact could be

defective.

Check also the connections of the contactors.

CHECK THE ABOVE COMPONENTS AND THE CONNECTIONS BETWEEN THE CABLES.

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4.4 SECONDARY CIRCUIT VOLTAGES MEASUREMENT (ON THE INLET OF THE

RECTIFIER BRIDGE)

MEASUREMENTS TO BE DONE BETWEEN THE THREE A.C. INLETS OF THE RECTIFIER BRIDGE,

THAT IS BETWEEN: RS - ST, ST-TR, TR-ST.

THE SECONDARY OF THE TRANSFORMER IS CONNECTED TO THE THREE A.C. OF THE BRIDGE BY

A DELTA CONNECTION.

LHP 200

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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LHP 250

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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‘LHP 300

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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LHP 400

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4.5 SECONDARY CIRCUIT TROUBLE SHOOTING

NEEDLESS TO SAY THAT THE PRIMARY CIRCUIT IS NOT DEFINITIVE BECAUSE ALREADY TESTED

AS PER POINTS 6,7,8.

TROUBLE POSSIBLE CAUSE

The transformer does not give one phase

missing

Defective transformer

The connections from the transformer to the

rectifier are disconnected or short- circuited

Rectifier bridge in short-circuit

CHECK THE ABOVE COMPONENTS AND THE CONNECTIONS OF THE CABLES.

BEWARE OF THE FACT THAT WHEN THE WELDING MACHINE IS ADJUSTED TO A MINIMUM OR

NEAR THE MINIMUM IT IS NORMAL THAT THE MEASURED VOLTAGES ARE NOT EQUAL TO EACH

OTHER BUT LIGHTLY DIFFERENT.

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4.6 WELDING CIRCUIT VOLTAGE MEASUREMENT (BETWEEN THE WELDING

CONNECTIONS OF THE MACHINE OKC+, OKC-)

LHP 200

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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LHP 250

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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LHP 300

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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LHP 400

VOLTAGE AT A MINIMUM ADJUSTMENT

VOLTAGE AT A MAXIMUM ADJUSTMENT

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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4.7 WELDING CIRCUIT TROUBLE SHOOTING:

NEEDLESS TO SAY THAT THE PRIMARY AND SECONDARY CIRCUITS ARE NOT DEFECTIVE

BECAUSE ALREADY TESTED AS PER POINT 6,7,8,9,10.

TROUBLE POSSIBLE CAUSE

The O.C. voltage is very lower than foreseen or

absent

Defective rectifier

The connections from the rectifier to the outlets

are disconnected or in short- circuit

Rectifier in short-circuit

CHECK THE ABOVE COMPONENTS AND THE CONNECTIONS OF THE CABLES.

5 INSTRUCTION MANUAL

INTRODUCTION

LHP 200/250/300/400 are moving core welding rectifiers designed for welding with coated electrodes.

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’ HAZARD DATA.

ELECTRIC SHOCK - Can kill

• Install and earth the welding unit in accordance with applicable standards.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from earth and the workpiece.

• Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and the general

area.

FIRE HAZARD - Can be dangerous to health

• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

• Protect your ears. Use ear defenders or other hearing protection.

• Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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TECHNICAL DATA

LHP 200 LHP 250 LHP 300 LHP 400

Maximum load

35% duty cycle 170A/27V 235A/29V 270A/31V 370/34V

60% duty cycle 130A/25V 170A/27V 230A/29V 290A/31V

100% duty cycle 100A/24V 140A/26V 160A/26V 230A/29V

Setting range 30A/20V

200A/28V

35A/21,4V

250A/30V

35A/21V

285A/31V

45A/22V

375A/35V

Open circuit volt. 59-67V 60-68V 65-75V 69-79V

Open circuit power

consumption at 400 V

200W 250W 300W 350W

Power factor

(max current)

0,75 0,78 0,68 0,66

Efficiency

(max current)

65% 68% 63% 65%

Enclosure class IP 23 IP 23 IP 23 IP 23

Application class

SSSS

Weight 56 kg. 65 kg. 81 kg. 107 kg.

Dimens. Ixwxh, cm 52/65/60 52/65/60 52/65/60 52/65/60

These welding power sources comply with the requirements of IEC 974-1 and

EN 60974-1

The symbol S indicates that the power source is designed for use in areas with an increased electrical

hazard. Equipment marked IP 23 is designed for indoor and outdor use.

WARNING

This product is intended for industrial use. In a domestic environement this product may cause

radio interference. It is the users responsibility to take adequate precautions.

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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INSTALLATION

• Installation must be carried out by a qualified electrician.

• Check that the welding rectifier is configured for the available mains supply before connecting it to the

mains.

• See connecting to mains cable to the rectifier according to the relevant regulations and install a suitable

fuse in the main fuse box.

• Make sure the welding rectifier is not covered or positioned so that cooling is obstructed.

Connecting to mains

Mains supply LHP 200 LHP 250 LHP 300 LHP 400

Frequency 50Hz 50Hz 50Hz 50Hz

Voltage 230/400/415 V 230/400/415 V 230/400/ 415 V 230/400/ 415 V

Current at 100%

duty cycle 15/9/9A 23/13/13A 26/15/15A 41/24/24A

Current at 60%

duty cycle 20/12/12A 28/17/17A 41/24/24A 55/32/32A

Current at 35%

duty cycle 29/17/17A 37/21/21A 51/29/29A 73/42/42A

Fuse, slow 26/16/16A 25/16/16A 32/25/25A 50/25/25A

Cable area 4/1,5/1,5 4/1,5/1,5 4/2,5/2,5 6/4/4

Frequency 60Hz 60Hz 60Hz 60Hz

Voltage 230/440V 230/440V 230/440V 230/440V

Current at 100%

duty cycle 15/9/9A 23/13/13A 26/15/15A 41/24/24A

Current at 60%

duty cycle 20/12/12A 28/17/17A 41/24/24A 55/32/32A

Current at 35%

duty cycle 29/17/17A 37/21/21A 51/29/29A 73/42/42A

Fuse, slow 26/16/16A 25/16/16A 32/25/25A 50/25/25A

Cable area

(4Xmm2) 4/1,5/1,5 4/1,5/1,5 4/2,5/2,5 6/4/4

Cable areas comply with Swedish regulations.

TECHNICAL MANUAL LHP 200 - 250 - 300 - 400

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OPERATION

• Press green button (1) “I”. The white lamp (2) will light up and the fan will start.

• Adjust the welding current using the cranck (3) on the front.

• Select suitable earth and return cables and connect them to the terminals marked + and - on the front of

the rectifier. Connect the return cable to the work piece.

• The rectifier is now ready for welding.

1. On/Off

2. White lamp (power on)

3. Current setting

MAINTENANCE

LHP 200/250/300/400 normally do not require any maintenance. Once a year blow the inside of the welding

rectifier clean using dry compressed air at reduced pressure.

More often if the rectifier is used in a very dusty or dirty environment.

NOTE!

The supplier’s liability under guarantee is invalidated if the customer attempts to carry out any internal repairs

himself during the guarantee period.

Ordering spare parts

A service manual and list of spare parts can be ordered through your nearest ESAB representative, see the

last page of this booklet.

When ordering spare parts please specify the machine model, serial number and the designation and order

numbers of parts as shown in the list of spare parts. This simplifies dispatch and ensures correct delivery.

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