ESAB LHP 400 is a high-performance welding rectifier designed for professional welding applications. With a maximum output current of 370A at 34V, it delivers excellent arc characteristics for a wide range of welding tasks, including stick electrode welding. The LHP 400 features precise current adjustment, allowing you to fine-tune your settings for optimal weld quality. Its robust construction and IP23 enclosure rating make it suitable for use in harsh industrial environments. Additionally, the LHP 400 boasts a high power factor and efficiency, ensuring energy savings and reliable operation.
ESAB LHP 400 is a high-performance welding rectifier designed for professional welding applications. With a maximum output current of 370A at 34V, it delivers excellent arc characteristics for a wide range of welding tasks, including stick electrode welding. The LHP 400 features precise current adjustment, allowing you to fine-tune your settings for optimal weld quality. Its robust construction and IP23 enclosure rating make it suitable for use in harsh industrial environments. Additionally, the LHP 400 boasts a high power factor and efficiency, ensuring energy savings and reliable operation.
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
3
1 RATING PLATES LHP200 - 250 - 300 - 400
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
4
2 ELECTRICAL DIAGRAM LHP 200 - 250
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
5
3 ELECTRICAL DIAGRAM LHP 300 - 400
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
6
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
7
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
8
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
9
LHP 250
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
10
‘LHP 300
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
11
LHP 400
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
12
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
13
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
14
LHP 250
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
15
LHP 300
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
16
LHP 400
VOLTAGE AT A MINIMUM ADJUSTMENT
VOLTAGE AT A MAXIMUM ADJUSTMENT
TECHNICAL MANUAL LHP 200 - 250 - 300 - 400
17
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
18
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
19
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
20
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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ESAB LHP 400 User manual
- Type
- User manual
ESAB LHP 400 is a high-performance welding rectifier designed for professional welding applications. With a maximum output current of 370A at 34V, it delivers excellent arc characteristics for a wide range of welding tasks, including stick electrode welding. The LHP 400 features precise current adjustment, allowing you to fine-tune your settings for optimal weld quality. Its robust construction and IP23 enclosure rating make it suitable for use in harsh industrial environments. Additionally, the LHP 400 boasts a high power factor and efficiency, ensuring energy savings and reliable operation.
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