ESAB LAF 1601 User manual

Service manual

0740 800 211 GB 20180112

Valid for: serial no. 935-, 126-, 536-, 744-xxx-xxxx

LAF631, LAF1001, LAF1001M,

LAF1251, LAF1251M,

LAF1601, LAF1601M

TABLE OF CONTENTS

0740 800 211 © ESAB AB 2018

READ THIS FIRST.................................................................................... 4

INTRODUCTION....................................................................................... 5

TECHNICAL DATA ................................................................................... 6

WIRING DIAGRAM................................................................................... 11

Component description ......................................................................... 11

LAF 631 – Valid for serial no. 935-xxx-xxxx ......................................... 12

LAF 631 – Valid for serial no. 126-xxx-xxxx up to and including

126-341-xxxx ........................................................................................... 14

LAF 631 – Valid from serial no. 126-342-xxxx ...................................... 16

LAF 1001, LAF 1001M – Valid for serial no. 935-xxx-xxxx .................. 18

LAF 1001, LAF 1001M – Valid for serial no. 126-xxx-xxxx up to and

including 126-341-xxxx .......................................................................... 20

LAF 1001, LAF 1001M – Valid from serial no. 126-342-xxxx ............... 22

LAF 1251, LAF 1251M, LAF 1601, LAF 1601M – Valid for serial no.

935-xxx-xxxx ........................................................................................... 24

LAF 1251, LAF 1251M, LAF 1601, LAF 1601M – Valid for serial no.

126-xxx-xxxx up to and including 126-341-xxxx ................................. 26

LAF 1251, LAF 1251M, LAF 1601, LAF 1601M – Valid from serial no.

126-342-xxxx ........................................................................................... 28

DESCRIPTION OF OPERATION.............................................................. 30

2AP3 Interference suppressor board ................................................... 30

2AP3 Component positions.................................................................. 31

Power sources LAF1001, LAF1001M, LAF1251, LAF1251M,

LAF1601 and LAF1601M ................................................................ 31

Power source LAF631 (from serial no. 744-xxx-xxxx)...................... 31

20AP1 Control board.............................................................................. 31

20AP1:1 Power supply ......................................................................... 32

Voltage monitoring............................................................................. 32

DC supplies, +24V............................................................................. 33

DC supplies, +24V_A ........................................................................ 34

DC supplies, +12V_CAN ................................................................... 34

20AP1:2 Thermal protection................................................................. 35

20AP1:3 Shunt input ............................................................................ 35

20AP1:4 Synchronizing ........................................................................ 36

20AP1:5 Arc voltage............................................................................. 36

20AP1:6 Gate pulses ........................................................................... 37

20AP1:7 CAN bus ................................................................................ 38

CAN power supply............................................................................. 39

20AP1:8 Start / Stop / Weld on............................................................. 39

20AP1:9 Analogue control.................................................................... 40

20AP1:10 Optional I/O ......................................................................... 40

TABLE OF CONTENTS

0740 800 211 © ESAB AB 2018

Digital inputs...................................................................................... 40

Digital outputs.................................................................................... 41

Analogue outputs .............................................................................. 41

20AP1:11 Processor and miscellaneous circuits.................................. 41

20AP1 Component positions................................................................ 43

FAULT CODES ......................................................................................... 44

Fault log................................................................................................... 44

Fault code description ........................................................................... 44

SERVICE INSTRUCTIONS....................................................................... 47

What is ESD? .......................................................................................... 47

Service aid .............................................................................................. 47

Special tools ........................................................................................... 48

Maintenance............................................................................................ 48

Checking diodes and thyristors ............................................................ 48

Load characteristics .............................................................................. 50

IN-SERVICE INSPECTION AND TESTING.............................................. 51

Overview ................................................................................................. 51

General requirements ............................................................................ 51

Periodic inspection and test.................................................................. 51

After repair, inspection and test ........................................................... 51

Visual inspection .................................................................................... 51

Electrical test .......................................................................................... 52

Functional test ........................................................................................ 54

Test report ............................................................................................... 55

SPARE PARTS ......................................................................................... 56

REVISION LOG ........................................................................................ 57

Rights reserved to alter specifications without notice.

READ THIS FIRST

0740 800 211

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

November 2017.

The manual is valid for:

LAF 631 with serial number 935-xxx-xxxx, 126-xxx-xxxx and 744-xxx-xxxx

LAF 1001 and LAF 1001M, with serial number 935-xxx-xxxx, 126-xxx-xxxx and 536-xxx-xxxx

LAF 1251 and LAF 1251M, with serial number 935-xxx-xxxx and 126-xxx-xxxx

LAF 1601 and LAF 1601M, with serial number 935-xxx-xxxx and 126-xxx-xxxx

Power sources with serial number 935-xxx-xxxx up to 935-040-xxxx can differ from this

manual (see section “Circuit board identity”, page31).

The power sources LAF 631, LAF 1001, LAF 1001M, LAF 1251, LAF 1251M, LAF 1601 and

LAF 1601M are designed and tested in accordance with the standards stated in the

instruction manual. On completion of service or repair work, it is the responsibility of the

person(s) performing the work to ensure that the product still complies with the requirements

of the involved standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

INTRODUCTION

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INTRODUCTION

The power sources LAF 631, LAF 1001, LAF 1001M, LAF 1251, LAF 1251M, LAF 1601 and

LAF 1601M are designed for high productivity mechanized submerged arc welding (SAW).

LAF 631, LAF 1001, LAF 1001M are also suitable mechanized MIG/MAG welding (GMAW).

Multi-voltage (M) versions are designed for mains connection including 220/230V.

Design structure of the power sources

The power sources are 3-phase connected to the mains and the welding DC power is

generated by a 3-pulse thyristor/diode full wave rectifier bridge. The power sources are fan

cooled and externally controlled by ESAB's process controller PEK via a CAN-bus or with an

I/O controller (PLC). They can also be analogue controlled by process controller PEI. See

separate instruction and service manuals for a detailed description of each control panel.

A thermal cutout switch protects the power source from overload. An indication lamp (yellow)

on the front panel illuminates when the thermal switch has tripped. The switch resets

automatically when the temperature of the thyristor heat-sink has decreased to an

acceptable level.

LAF 631 has an external power supply outlet of 230V AC, auto-connected to the primary

winding of the auxiliary transformer TC1. It is fused by a double-pole circuit breaker of 5A.

LAF 631, LAF 1001 and LAF 1001M have a basic current circuit, which improves the

waveform of the DC welding current at low settings, and therefore make them suitable for

MIG/MAG welding.

The power sources are designed both for single operation and dual operation in parallel.

Block diagram of LAF 631, LAF 1001(M), LAF 1251(M) and LAF 1601(M)

TECHNICAL DATA

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TECHNICAL DATA

LAF 631 with serial no. 935-xxx-xxxx and 126-xxx-xxxx

LAF 631

Mains connection 400/415 V, 3~50 Hz

440 V, 3~60 Hz

Primary current I

max

67 A

Permissible load at:

100% duty cycle 630 A / 44 V

60% duty cycle 800 A / 44 V

Setting range :

SAW 60-800 A / 22-44 V

MIG/MAG 75-800 A / 18-44 V

No-load voltage (U

0

) 56 V

No-load power 190 W

Efficiency 82%

Power factor 0.92

Weight 260 kg

Dimensions L × W × H 652 × 483 × 800 mm

652 × 483 × 916 mm (including foot)

Insulation class (transformer) H

Enclosure class IP 23

Application class

LAF 631 from serial no. 744-xxx-xxxx

LAF 631

Mains connection 380/400/415 V 3~50 Hz

440 V 3~60 Hz

Primary current I

max

:

SAW 69 A

MIG 69 A

Values of the conventional load:

SAW (duty cycle at 40 °C ambient temperature)

60% 800 A, 44 V

100% 630 A, 44 V

MIG (duty cycle at 40 °C ambient temperature)

60% 800 A, 44 V

100% 630 A, 44 V

Setting range:

SAW 60 A / 22 V – 800 A / 44 V

MIG 75 A / 18 V – 800 A / 44 V

No-load voltage (U

0

)

56 V

TECHNICAL DATA

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LAF 631

No-load power 172 W

Efficiency at max current (I

2

):

SAW 84%

MIG 84%

Power factor at max current (I

2

):

SAW 0.91

MIG 0.91

Apparent power at max current (I

2

)

46.4 kVA

Active power at max current (I

2

)

42 kW

S

sc min

(MVA)

5.6 MVA

Working temperature -10 °C to +40 °C

Continual sound pressure at no-load <70 dB(A)

Weight (in delivery mode) 260 kg

Dimensions L × W × H 652 × 483 × 800 mm

652 × 483 × 916 mm (including foot)

Insulation class (transformer) H

Enclosure class IP 23

Application class

Restrictive use Class A

LAF 1001 and LAF 1001M with serial no. 935-xxx-xxxx and 126-xxx-xxxx

LAF 1001 LAF 1001M

Mains connection 400/415/500 V, 3~50 Hz

400/440/550 V, 3~60 Hz

230/400/415/500 V, 3~50 Hz

230/400/440/550 V, 3~60 Hz

Primary current I

max

79 A I

max

137 A

Permissible load at:

100% duty cycle 800 A / 44 V 800 A / 44 V

60% duty cycle 1000 A / 44 V 1000 A / 44 V

Setting range :

SAW 100-1000 A / 24-44 V 100-1000 A / 24-44 V

MIG/MAG 100-1000 A / 19-44 V 100-1000 A / 19-44 V

No-load voltage 53 V 53 V

No-load power 130 W 130 W

Efficiency at maximum

current

88% 88%

Power factor at maximum

current

0.92 0.92

Weight 330 kg (727.5 lb) 330 kg (727.5 lb)

Dimensions L × W × H 646 × 552 × 1090 mm (25.4

× 21.7 × 42.9 in.)

646 × 552 × 1090 mm (25.4 ×

21.7 × 42.9 in.)

TECHNICAL DATA

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LAF 1001 LAF 1001M

Insulation class

transformer

H H

Enclosure class IP 23 IP 23

Application class

LAF 1001 and LAF 1001M from serial no. 536-xxx-xxxx

LAF 1001 LAF 1001M

Mains connection 380/400/415/500 V,

3~50Hz

440/550 V, 3~60 Hz

230/380/400/415/500 V, 3~50 Hz

230/440/550 V, 3~60 Hz

Z

max

0.04 Ohm 0.04 Ohm

Primary current I

max

84 A I

max

138 A

Values of the conventional load:

100% duty cycle 800 A / 44 V 800 A / 44 V

60% duty cycle 1000 A / 44 V 1000 A / 44 V

Setting range SAW 100-1000 A / 24-44 V 100-1000 A / 24-44 V

S

sc min

4.8 MVA 4.8 MVA

No-load voltage 53 V 56 V

No-load power 180 W 178 W

Efficiency at maximum

current

90% 86%

Power factor at maximum

current

0.95 0.96

Apparent power I

2

at

maximum current

51.6 kVA 52.9 kVA

Active power I

2

at

maximum current

48.9 kW 51.0 kW

Working temperature -10 to +40 °C

(+14to+104°F)

-10 to +40 °C (+14 to +104 °F)

Weight 330 kg (727.5 lb) 330 kg (727.5 lb)

Dimensions L × W × H 646 × 552 × 1090 mm

(25.4×21.7×42.9in.)

646 × 552 × 1090 mm

(25.4×21.7×42.9in.)

Isolation class

transformer

H H

Enclosure class IP 23 IP 23

Application class

LAF 1251 LAF 1251M

Mains connection 380/400/415/500 V,

3~50Hz

220/230/400/415/500 V, 3~50 Hz

440/550 V, 3~60 Hz 230/400/440/550 V, 3~60 Hz

Primary current I

max

104 A I

max

170 A

Permissible load at:

TECHNICAL DATA

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LAF 1251 LAF 1251M

100% duty cycle 1250 A / 44 V 1250 A / 44 V

Setting range 100-1250 A / 24-44 V 100-1250 A / 24-44 V

No-load voltage 53 V 53 V

No-load power 210 W 210 W

Efficiency at max current 89% 88%

Power factor at max

current 0.89 0.94

Apparent power at max

current 69 kVA

Active power at max

current 61.7 kW

Operating temperature -10 to +40 °C

Continual sound pressure

at no-load <70 dB(A)

Weight 490 kg 490 kg

Dimensions L × W × H 774 × 598 × 1430 mm 774 × 598 × 1430 mm

Insulation class

(transformer) H H

Enclosure class IP 23 IP 23

Application class

LAF 1601 and LAF 1601M with serial no. 935-xxx-xxxx

LAF 1601 LAF 1601M

Mains connection 400/415/500 V, 3~50 Hz

400/440/550 V, 3~60 Hz

220/230/400/415/500 V, 3~50 Hz

230/400/440/550 V, 3~60 Hz

Primary current I

max

135 A I

max

234 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

Efficiency 89% 89%

Power factor 0.86 0.86

Weight 585 kg 585 kg

Dimensions L × W × H 774 × 598 × 1430 mm 774 × 598 × 1430 mm

Insulation class

(transformer)

H H

Enclosure class IP 23 IP 23

Application class

TECHNICAL DATA

0740 800 211

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LAF 1601 and LAF 1601M from serial no. 126-xxx-xxxx

LAF 1601 LAF 1601M

Mains connection 400/415/500 V, 3~ 50 Hz 230/400/415/500 V, 3~ 50 Hz

440/550 V, 3~ 60 Hz 230/440/550V, 3~ 60 Hz

Primary current I

max

136 A 230 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

Efficiency 88% 88%

Power factor at maximum

current 0.84 0.84

Apparent power I

2

at

maximum current 95.6kVA 87.5 kVA

Active power I

2

at

maximum current 80 kW 80 kW

Continual sound pressure

at no-load < 70 dB(A) < 70 dB(A)

Weight 585 kg 585 kg

Dimensions L x W x H 774 x 598 x 1430 mm 774 x 598 x 1430 mm

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 IP23 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.

WIRING DIAGRAM

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WIRING DIAGRAM

Component description

Component Description Remark LAF 631 LAF 1001 (M) LAF 1251 (M)

LAF 1601 (M)

20AP1 Control board X X X

2AP2 Insulation board (for XS4) X X X

2AP3 Mains filter board

X

1)

X X

C1 - C5 Capacitor X X

C1 - C6 Capacitor X

FU1 Circuit breaker 2 pole 16 A X X X

FU2 Circuit breaker 20 A X X X

FU3 Fuse, slow blow (anti surge) 1.25 A X X X

FU4 Fuse, slow blow (anti surge) 1.25 A X X X

FU5 Fuse, slow blow (anti surge) 3.15 A X X X

FU6 Circuit breaker 2 pole 5 A X

HL1 Indication lamp ON White X X X

HL2 Indication lamp High temp. Yellow X X X

KM1 Main contactor X X X

KM2 Contactor X X X

L1 Inductor X X X

M1 Fan 230VAC X X X

QF Main switch X X X

R1 - R4 Resistor X X X

RC1 - RC8 RC-filter X X X

RS1 Shunt X X X

ST1 Thermal switch X X X

TC1 Auxiliary transformer X X X

TC2 Sync. transformer 3x X

TM1 Main transformer X X X

THY1 - THY3 Thyristor 3x X X X

V2:1 - V2:3 Diode (main bridge) 3x X X X

V3:1 - V3:3 Diode (basic current) 3x X X

V4 Diode (freewheel) 2x X X

V4 Diode (freewheel) 3x X

X1 Mains terminal block X X X

XS1 - XS2 Welding current outlet X X X

XS3 Socket (workpiece -) 1 pole X X X

XS4 Sleeve socket 28 pole X X X

XT2 - XT4 Terminal block X X

XT2 - XT5 Terminal block X

WIRING DIAGRAM

0740 800 211

- 12 -

1)

From serial no. 744-xxx-xxxx

LAF 631 – Valid for serial no. 935-xxx-xxxx

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

0740 800 211

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WIRING DIAGRAM

0740 800 211

- 14 -

LAF 631 – Valid for serial no. 126-xxx-xxxx up to and including

126-341-xxxx

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

0740 800 211

- 15 -

WIRING DIAGRAM

0740 800 211

- 16 -

LAF 631 – Valid from serial no. 126-342-xxxx

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

0740 800 211

- 17 -

WIRING DIAGRAM

0740 800 211

- 18 -

LAF 1001, LAF 1001M – Valid for serial no. 935-xxx-xxxx

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

WIRING DIAGRAM

0740 800 211

- 19 -

WIRING DIAGRAM

0740 800 211

- 20 -

LAF 1001, LAF 1001M – Valid for serial no. 126-xxx-xxxx up to and

including 126-341-xxxx

NOTE!

The wiring diagram shows the power source connected for 400 V / 50 Hz, mains

voltage.

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