ESAB LAE LAF Assembly Instruction

Valid for serial no. 3100457 566 126 2004--05--14

LAE 800/1000/1250/1600 →

LAF 800/1000/1250/1600

Conversion kit

104100

Monteringsanvisning Assembly instruction

-- 2 --

Rätt till ändring av specifikationer utan avisering förbehålles.

Rights reserved to alter specifications without notice.

SVENSKA 4..............................................

ENGLISH 16..............................................

3

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Esab Welding Equipment AB, 695 81 Laxå, Sweden, försäkrar under eget ansvar att

svetsströmkälla LAH630/LAE800/1000/1250/1600 → LAF630/800/1000/1250/1600

från serienummer 751 är i överensstämmelse med standard EN 60974--1 enligt vill-

koren i direktiv ( 73/23/EEG) med tillägg (93/68/EEG) och standard EN 50199 enligt

villkoren i direktiv 89/336/ EEG med tillägg 93/68/ EEG.

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DECLARATION OF CONFORMITY

Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee

that welding power source LAH630/LAE800/1000/1250/1600 →

LAF630/800/1000/1250/1600 from serial number 751 complies with standard EN

60974--1, in accordance with the requirements of directive (73/23/ EEA) and adden-

dum (93/68/EEA) and standard EN 50199 in accordance with the requirements of

directive 89/336/ EEA and addendum 93/68/ EEA .

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Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Laxå 98--02--16

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ENGLISH

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TOCe

1SAFETY 17...........................................................

2 INTRODUCTION 19...................................................

2.1 General 19..................................................................

2.2 Technical data 19............................................................

3 INSTALLATION 20....................................................

3.1 General 20..................................................................

3.2 Assembly instructions 20......................................................

3.3 Testing 24...................................................................

3.4 Connections 25..............................................................

4 OPERATION 27.......................................................

4.1 General 27..................................................................

5 ORDERING OF SPARE PARTS 27......................................

DIAGRAM 28............................................................

LIST OF COMPONENTS 30...............................................

SPARE PARTS LIST 31...................................................

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1SAFETY

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 recommen-

dations 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.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS 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.

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 r esponsibility to take

adequate precautions.

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2 INTRODUCTION

2.1 General

The welding power sources LAE (adapted to fit control equipment PEG--1) can be

converted to r esemble LAF by way of a conversion kit, and by that be adapted to fit

ESAB’s control box A2--A6 Process Controller (PEH) or Welding Control unit (PEI).

For rational conversion all components necessary for the work are contained in the

conversion kit.

S Instruction manual for A2--A6 Process Controller (PEH), order no. 0443 745 xxx

S Instruction manual for Welding Control Unit (PEI), order no. 0449 375 xxx

2.2 Technical data

The conversion of the power sources results in the following divergencies with

regard to the technical data, compared to previously issued documentation.

S The Emergency stop has been removed

S 0--10 V steering in contact XS4

S Reconnection of KM2 to connection block X3

S Current shunt signal in contact XS4

S U+ , U-- contact XS4

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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

WARNING

Rotating parts can cause injury, take great care.

3.2 Assembly instructions

3.2.1 Conversion of LAE 800/1000:

1. Dismount the cable stem, excluding the cables 034 and 035 for the power supply

of the control transformer.

2. Dismount all electronics boards and their fittings.

3. Dismount the control panel.

4. Remove the support with the attached fuse--bases.

5. Remove the lower fuse (K21.2 = fuse for 42 V AC from the control transformer

K9).

The other two fuses are to be re--used together with the rubber spacers, but

fitted e lsewhere in the power source.

6. Remove the multi--pole contact devices on the bottom plate and cover the holes

by way of two plastic plugs from the kit.

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7. Remove the signs (a sticker and a screwed sign marked 42 V) from the bottom

plate.

8. Dismount the terminal block on the control transformer.

9. Cover the contactor and the control transformer before drilling new mounting

holes.

10. Drill the holes according to the drilling diagra m for the attachment of

S the fuse--bases (FU1)

S the electronics board (AP1)

S the contactor (KM2)

11. Fit a new (AP1) circuit board with box on the plate, using the insulating washers

and self--tapping screws which form part of the conversion kit.

12. Connect the discharge capacitor to earth.

13. Set the two DIP switches (SW1 and SW2) on the board according to the

instructions in the LAF manual.

14. Mount the new terminal plate.

15. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate.

16. Connect a new cable stem according to the connection diagram.

17. Mount the cables for the control panel. Then connect the control panel to the

cable stem.

18. Remove (cut off) the conductor 077 between the board K45.3 and the collector

rail.

19. Only remount the RC filter fitted in the old power source.

20. Remove the old connection diagram on the inside of the cover plate.

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3.2.2 Follow the instructions belo w for the conversion of LAE 1250/1600:

1. Dismount the cable stem, excluding the cables 034 and 035 (for the connection

to the control transformer).

2. Cut off the connection to the synchronising transformers (cables marked 001,

002, 003) in the cable stem.

3. Dismount all electronics boards and their fittings.

4. Dismount the control panel.

5. Remove the fuse holder K21.2 fitted above the control transformer to the right.

The lower fuse (K21.2 = fuse for 42 V AC from the control transformer K9) is

replaced by an automatic fuse on the new control panel.

6. Remove the multi--pole contact devices on the bottom plate and cover the holes

by way of two plastic plugs from the kit.

7. Remove the signs (a sticker and a screwed sign marked 42 V) from the bottom

plate.

8. Dismount the terminal block on the control transformer.

9. Dismount the shunt (1500 A, 60 mV). N.B. Only for LAE 1600

10. Remove the current relay (K25) fixed to the +rail to the right of the auxiliary

transformer.

11. Remove the conductors (18, 47, 48) connected to the current relay.

12. Cover the contactor and the control transformer before drilling new mounting

holes.

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13. Drill the holes according to the drilling diagra m for the attachment of

S the electronics board (AP1)

S the contactor (KM2)

14. Fit a new (AP1) circuit board with box on the plate, using the insulating washers

and self--tapping screws which form part of the conversion kit.

15. Connect the discharge capacitor to earth.

16. Set the two DIP switches (SW1 and SW2) on the board according to the

instructions in the LAF manual.

17. Mount the new terminal plate.

18. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate

and connect the discharge capacitor to earth.

19. Connect a new cable stem according to the connection diagram.

20. Re--use the conductors 034 and 035 for the connection to the control

transformer (TC1).

21. Connect ( by soldering) the conductors 001, 002 and 003 in the cable stem to the

three synchronising transformers (TC2).

22. Mount the cables for the control panel. Then connect the control panel to the

cable stem.

23. Remove (cut off) the conductor 077 between the board K45.3 and the collector

rail.

24. Only remount the RC filter fitted in the old power source.

25. Remove the old connection diagram on the inside of the cover plate.

26. Mount the shunt (2000 A, 60 mV). N.B. Only for LAE 1600

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3.3 Testing

1. Connect the welding power source to the mains.

2. Before switching on the welding power source, check that the power supply to

the board is 19 V.

3. Connect control box PEH or PEI to the 28--pole contact (XS4) in the welding

power source by way of the control cable.

4. Switch on the power supply for the welding power source using the rotary switch

(QF) on the front panel.

5. Make sure the power supply is interrupted when the emergency stop (QS)is

activated.

6. Set the welding parameters over either the PEH or PEI control box.

7. Start welding by pressing the START key.

8. Make sure the relay in the welding power source is activated when the welding

starts.

9. Check that different current and voltage values can be set from either control box

PEH or PEI.

10. Mount the protective shields after finished work.

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3.4 Connections

3.4.1 General

S The connection of the control box to the automatic welding m achine is to be

done according to the A2--A6 Process Controller (PEH) instruction manual or the

Welding Control Unit (PEI) instruction manual.

3.4.2 Automatic welding machine (Submerged Arc Welding, SAW)

S Connect the control cable (4) between power source (3) and control box PEH or

PEI (2).

S Connect r eturn cable (7) between power source (3) and workpiece ( 8).

S Connect welding cable ( 6) between power source (3)and

welding machine (1).

S Connect m easuring cable (5) between power source (3) and workpiece (8).

--

+

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3.4.3 Automatic welding machine (Gas Metal Arc Welding, MIG/MAG)

S Connect control cable ( 4) between power source (3) and control box

PEH or PEI (2).

S Connect r eturn cable (7) between power source (3) and workpiece ( 8).

S Connect welding cable ( 6) between power source (3) and welding machine (1).

S Connect gas hose (9) between reducing valve (10) and gas valve (11)onthe

welding machine.

S Connect the cooling water hoses (12) between cooling unit (13) and welding

machine (1).

S Connect m easuring cable (5) between power source (3) and workpiece (8).

--

+

in

out

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4 OPERATION

4.1 General

Caution:

Have you read and understood the safety information ?

You must not operate the machine beforehand !

General safety regulations for the handling of the equipment can be found on

page 17. Read through before you start using the equipment!

5 ORDERING OF SPARE PARTS

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 desig -

nation and spare part number as shown in the spare parts list on page 31.

This will simplify dispatch and ensure you get the right part.

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Komponentförteckning List of components

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compdok

C = Component designation in the circuit diagram

C

Denomination

LAE/LAF

800/1000

LAE/LAF

1250/1600

Remarks

AP1 (K70.1) Circuit board X X

AP2 Circuit board EMC--filter X X

C1 Capacitor X X

C2 Capacitor X X

C4 Capacitor X X

FU1 (K.35) Fuse X X

FU2 (K21.2) Fuse X X 20 A

HL1 Indicator lamp, white X X 42--48 V

HL2 Indicator lamp yellow X X 28 V

KM1 (K8) Contactor X X

KM2 Contactor X X

L1 Inductor X X

M1 Fan X X

QF (K6) Main switch (black) X X

R1 Power resistor X X

R2 Power resistor X X

R3 Power resistor X

RS1 (K18) Shunt X X

ST1 Thermal relay X X

TC1 Control transformer X X

TC2 Control transformer X

TM1 T ransformer X X

V1 Thyristor X X

V2 Thyristor X X

V3 Thyristor X

V4 Thyristor X X

XS4 Burndy socket X X 28--pole

XT1 Connection block X X

XT2 Connection block X X

XT3 Connection block X X

XT4 Connection block X X

Z1, Z2 Contact protection X X

Z3, Z4 Contact protection X X

Reservdelsförteckning Spare parts list

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foespare

Conversion kit

Edition 2003--08--19

Ordering no. Denomination Notes

0456 795 880 LAE 800

0456 795 881 LAE 1000

0456 796 880 LAE 1250

0456 796 881 LAE 1600

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

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f456795s

Item

no.

Qty Ordering no. Denomination Notes C

0456795880 LAE 800

1 0456433881 Cable harness conversion kit LAF 800

2 1 0805586131 Contactor KM2

3 1 0805586113 Contact block

5 0456361882 Cable set

6 1 0193260155 Connector 7--pol. AP1.H

7 1 0193260152 Connector 4--pol.

8 1 0193260150 Connector 2--pol.

9 1 0368544003 Sleeve socket Burndy 28--pol. XS4

10 0456361883 Cable set

11 1 0193260154 Connector 6--pol.

12 1 0193260151 Connector 3--pol.

13 1 0486466880 Circuit board, insulation card

14 0456348880 Front panel complete

15 1 0320746001 Main switch QF

16 1 0192576004 Indicating lamp white 42--48 V HL1

17 1 0192576303 Indicating lamp yellow 28 V HL2

18 1 0567200610 Fuse 16 A 500 V FU1

19 1 0193586104 Automatic fuse 20 A FU2

20 1 0486368880 Circuit board AP1

21 1 0486224880 Circuit board EMC--filter AP2

22 1 0193358102 Contactor KM1

23 1 0319470016 Control transformer 42 V 900 VA TC1

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f456795s

Item

no.

Qty Ordering no. Denomination Notes C

0456795881 LAE 1000

1 0456423881 Cable harness conversion kit LAF 800

2 1 0805586131 Contactor KM2

3 1 0805586113 Contact block

5 0456861882 Cable set

6 1 0193260155 Connector 7--pol. AP1.H

7 1 0193260152 Connector 4--pol.

8 1 0193260150 Connector 2--pol.

9 1 0368544003 Sleeve socket Burndy 28--pol. XS4

10 0456361883 Cable set

11 1 0193260154 Connector 6--pol.

12 1 0193260151 Connector 3--pol.

13 1 0486466880 Circuit board, insulation card

14 0456348881 Front panel, complete

15 1 0320746001 Main switch QF

16 1 0192576004 Indicating lamp white 42--48 V HL1

17 1 0192576303 Indicating lamp yellow 28 V HL2

18 1 0567200610 Fuse 16 A 500 V FU1

19 1 0193586104 Automatic fuse 20 A FU2

20 1 0486368880 Circuit board AP1

21 1 0486224880 Circuit board EMC--filter AP2

22 1 0193358102 Contactor KM1

23 1 0319470016 Control transformer 42 V 900 VA TC1

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f457796s

Item

no.

Qty Ordering no. Denomination Notes C

0456796880 LAE 1250

1 0456434881 Cable harness conversion kit LAF 800

2 1 0805586131 Contactor KM2

3 1 0805586113 Contact block

5 0456373882 Cable set

6 1 0193260155 Connector 7--pol. AP1.H

7 1 0193260152 Connector 4--pol.

8 1 0193260150 Connector 2--pol.

9 1 0368544003 Sleeve socket Burndy 28--pol. XS4

10 0456373883 Cable set

11 1 0193260154 Connector 6--pol.

12 1 0193260151 Connector 3--pol.

13 1 0486466880 Circuit board insulation card

14 0456322880 Front panel complete

15 1 0320746001 Main switch QF

16 1 0192576004 Indicating lamp white 42--48 V HL1

17 1 0192576303 Indicating lamp yellow 28 V HL2

18 1 0567200610 Fuse 16 A 500 V FU1

19 1 0193586104 Automatic fuse 20 A FU2

20 1 0486368880 Circuit board AP1

21 1 0486224880 Circuit board EMC--filter AP2

22 1 0442849880 Contactor KM1

23 1 0319470016 Control transformer 42 V 900 VA TC1

24 1 0319828001 Transformer TC2

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