ESAB LAH/LAE → LAF User manual

Brand: ESAB

Model: LAH/LAE → LAF

Category: Welding System

Type: User manual

ESAB LAH/LAE → LAF is a welding equipment that can be adapted to meet specific welding needs. The LAH and LAE models can be modified using an upgrade kit to match the capabilities of the LAF model and become compatible with the PEH (A2--A6 Process Controller) control box. This conversion kit includes all the necessary components to streamline the upgrade process.

The upgraded LAF model offers enhanced functionality and features designed to improve welding precision and efficiency. With the ability to connect to the PEH control box, users gain access to advanced welding parameters and settings, enabling them to tailor the welding process to specific requirements. The LAF model also features improved safety measures, ensuring optimal protection for the user.

Valid for Serial NO 7510457 566 026 030819

LAH630

LAE800/1000/1250/1600

→ LAF 630/800/1000/1250/1600

Conversion kit

104100

Monteringsanvisning Assembly instruction

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ENGLISH

-- 1 4 --

TOCe

1 DIRECTIVE 15........................................................

2SAFETY 15...........................................................

3 INTRODUCTION 16...................................................

3.1 General 16..................................................................

3.2 Technical data 16............................................................

4 INSTALLATION 17....................................................

4.1 General 17..................................................................

4.2 Assembly instructions 17......................................................

4.3 Testing 21...................................................................

4.4 Connections 22..............................................................

5 OPERATION 24.......................................................

5.1 General 24..................................................................

6 ACCESSORIES 24....................................................

7 ORDERING OF SPARE PARTS 24......................................

LIST OF COMPONENTS 25...............................................

DIAGRAM 26............................................................

SPARE PARTS LIST 29...................................................

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1 DIRECTIVE

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 .

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

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

Laxå 98--02--16

2SAFETY

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 r adio interference. It is the user’s responsibility to take

adequate precautions.

3 INTRODUCTION

3.1 General

The welding power sources LAH and LAE (adapted to fit control equipment PEG--1)

can be converted to resemble LAF by way of a conversion kit, and by that be

adapted to fit the PEH control box (A2--A6 Process Controller).

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

conversion kit.

3.2 Technical data

The conversion of the power sources does not result in any divergencies with regard

to the technical data, compared to previously issued documentation.

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4 INSTALLATION

4.1 General

The installatio n must be executed by a p rofession al.

WARNING

Rotating parts can cause injury, take great care.

4.2 Assembly instructions

1. Follow t h e instructions belo w f o r the co n version o f LAH 630:

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

of the control transformer.

S Dismount all electronics boards and their fittings.

S Dismount the control panel.

S 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 elsewhere in the power source.

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

by way of two plastic plugs from the kit.

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

plate.

S Dismount the terminal block on the control transformer.

S Cover the contactor and the control transform er before drilling new mounting

holes.

S Drill the holes according to the drilling diagram for the attachment of

-- the fuse--bases (FU1)

-- the electronics board ( AP1)

-- the contactor (KM2)

-- the discharging board with the 12--pole contact device (XS4).

S 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.

S Connect the discharge capacitor to earth.

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

instructions in the LAF manual.

S Fit the 12--pole contact (XS4) and the discharging board on the medium plate.

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

S Mount the cables for the emergency stop on the control panel. Then connect the

control panel to the cable stem.

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

rail.

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

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

2. Follow t h e instructions belo w f o r the co n version o f LAE 800/1000:

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

of the control transformer.

S Dismount all electronics boards and their fittings.

S Dismount the control panel.

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

S 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 elsewhere in the power source.

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

by way of two plastic plugs from the kit.

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

plate.

S Dismount the terminal block on the control transformer.

S Cover the contactor and the control transform er before drilling new mounting

holes.

-- 1 9 --

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S Drill the holes according to the drilling diagram for the attachment of

-- the fuse--bases (FU1)

-- the electronics board ( AP1)

-- the contactor (KM2)

-- the discharging board with the 12--pole contact device (XS4).

S 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.

S Connect the discharge capacitor to earth.

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

instructions in the LAF manual.

S Fit the 12--pole contact (XS4) and the discharging board on the medium plate.

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

S Mount the cables for the emergency stop on the control panel. Then connect the

control panel to the cable stem.

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

rail.

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

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

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3. Follow t h e instructions belo w f o r the co n version o f LAE 1250/1600:

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

to the control transformer).

S Cut o ff the connection to the synchronising transformers (cables marked 001,

002, 003) in the cable stem.

S Dismount all electronics boards and their fittings.

S Dismount the control panel.

S 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.

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

by way of two plastic plugs from the kit.

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

plate.

S Dismount the terminal block on the control transformer.

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

S Cover the contactor and the control transform er before drilling new mounting

holes.

S Drill the holes according to the drilling diagram for the attachment of

-- the electronics board ( AP1)

-- the contactor (KM2)

-- the discharging board with the 12--pole contact device (XS4).

S 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.

S Connect the discharge capacitor to earth.

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

instructions in the LAF manual.

S Fit the 12--pole contact (XS4) and the discharging board on the medium plate

and connect the discharge capacitor to earth.

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

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

transformer (TC1).

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

three synchronising transformers ( T C2).

S Mount the cables for the emergency stop on the control panel. Then connect the

control panel to the cable stem.

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

rail.

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

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

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

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4.3 Testing

S Connect the welding power source to the mains.

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

the board is 19 V.

S Connect the PEH control box to the 12--pole contact (XS4) in the welding power

source by way of the control cable.

S Switch on the power supply for the welding power source using the rotary switch

(QF) on the front panel.

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

activated.

S Set the welding parameters over the PEH box.

S Start welding by pressing the START key.

S Make sure the relay in the welding power source is activated when the welding

starts.

S Check that different current and voltage values can be set over the PEH box.

S Mount the protective shields after finished work.

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4.4 Connections

1. 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.

2. The welding machine is connected according to the following figures.

SUBMERGED ARC WELDING -- SAW

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

A2--A6 Process Controller (PEH) (2).

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

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

(1).

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

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GAS METAL ARC WELDING -- MIG/MAG

S Connect control cable (4) between power source (3) and control box A2--A6

Process Controller (PEH) (2).

S Connect return 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) on the

welding machine.

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

machine (1).

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

out

-- 2 4 --

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5 OPERATION

5.1 General

Caution:

Have you read and understood the safety information ?

You m ust not operate the machine beforehand !

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

page 15. Read through before you start using the equipment!

6 ACCESSORIES

LAF 630

Adapter (12 to 28--pole), ordering number 0449 448 880.

7 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 29.

This will simplify dispatch and ensure you get the r ight part.

-- 2 5 --

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Komponentförteckning List of components

C = Component designation in the circuit diagram

Denomination

LAH/LAF

630

LAE/LAF

800/1000

LAE/LAF

1250/1600

Re -

marks

AP1 (K70.1) Circuit board X X X

AP2 Circuit board EMC--filter X X X

C1 Capacitor X X X

C2 Capacitor X X X

C4 Capacitor X X X

FU1 (K.35) Fuse X X X

FU2 (K21.2) Fuse X X X 20 A

FU3 (K21.1) Fuse X

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

HL2 Indicator lamp yellow X X X 28 V

KM1 (K8) Contactor X X X

KM2 Contactor X X X

L1 Inductor X X X

M1 Fan X X X

QF (K6) Main switch (black) X X X

QS Connector X X X

R1 Power resistor X X X

R2 Power resistor X X X

R3 Power resistor X X

R4 Power resistor X

RS1 (K18) Shunt X X X

ST1 Thermal relay X X X

ST2 Thermal relay X

TC1 Control transformer X X X

TC2 Control transformer X

TM1 Transformer X X X

V1 Thyristor X X X

V2 Thyristor X X X

V3 Thyristor X X

V4 Thyristor X X X

XS4 Burndy socket X X X 12--pol

XT1 Connection block X X X

XT2 Connection block X X X

XT3 Connection block X X X

XT4 Connection block X X X

XT5 (K21.1) Connection block X

Z1, Z2 Contact protection X X X

Z3, Z4 Contact protection X X X

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-- 3 0 --

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Item

no.

Qty

Ordering no.

LAH 630

Ordering no.

LAE 800

Ordering no.

LAE 1000

Ordering no.

LAE 1250

Ordering no.

LAE 1600

Denomination Notes C

0456 794 880 0456 795 880 0456 795 881 0456 796 880 0456 796 881

1 0456 459 881 0456 433 881 0456 423 881 0456 434 881 0456 434 881 Cable harness

conversion kit

LAF

800

2 1 0193 296 101 0193 296 101 0193 296 101 0193 296 101 0193 296 101 Contactor KM2

3 1 0191 632 102 0191 632 102 0191 632 102 0191 632 102 0191 632 102 Contact switch QS

4 1 0191 632 202 0191 632 202 0191 632 202 0191 632 202 0191 632 202 Emergency

stop

5 0456 372 880 0456 361 882 0456 861 882 0456 373 882 0456 373 882 Cable set

6 1 0193 260 155 0193 260 155 0193 260 155 0193 260 155 0193 260 155 Connector 7--pol. AP1.H

7 1 0193 260 152 0193 260 152 0193 260 152 0193 260 152 0193 260 152 Connector 4--pol.

8 1 0193 260 150 0193 260 150 0193 260 150 0193 260 150 0193 260 150 Connector 2--pol.

9 1 0368 544 003 0368 544 003 0368 544 003 0368 544 003 0368 544 003 Sleeve socket

Burndy

12--pol. XS4

10 0456 372 886 0456 361 883 0456 361 883 0456 373 883 0456 373 883 Cable set

11 1 0193 260 154 0193 260 154 0193 260 154 0193 260 154 0193 260 154 Connector 6--pol.

12 1 0193 260 151 0193 260 151 0193 260 151 0193 260 151 0193 260 151 Connector 3--pol.

13 1 0486 466 880 0486 466 880 0486 466 880 0486 466 880 0486 466 880 Circuit board

insulation card

14 0456 349 880 0456 348 880 0456 348 881 0456 322 880 0456 322 881 Front panel

complete

15 1 0320 746 001 0320 746 001 0320 746 001 0320 746 001 0320 746 001 Main switch QF

16 1 0192 576 004 0192 576 004 0192 576 004 0192 576 004 0192 576 004 Indicating lamp

white

42--48

HL1

17 1 0192 576 303 0192 576 303 0192 576 303 0192 576 303 0192 576 303 Indicating lamp

yellow

28 V HL2

18 1 0567 200 610 0567 200 610 0567 200 610 0567 200 610 0567 200 610 Fuze 16 A

500 V

FU1

19 1 0193 586 104 0193 586 104 0193 586 104 0193 586 104 0193 586 104 Automatic fuse 20 A FU2

20 1 0486 368 880 0486 368 880 0486 368 880 0486 368 880 0486 368 880 Circuit board AP1

21 1 0486 224 880 0486 224 880 0486 224 880 0486 224 880 0486 224 880 Circuit board

EMC--filter

AP2

22 1 0193 503 001 0193 358 102 0193 358 102 0442 849 880 0442 849 880 Contactor KM1

23 1 0319 470 016 0319 470 016 0319 470 016 0319 470 016 0319 470 016 Control

transformer

42 V

900 VA

TC1

24 1 0319 828 001 0319 828 001 Transformer TC2

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ESAB AB

SE--695 81 LAXÅ

SWEDEN

Phone + 46 584 81 000

Fax + 46 584 123 08

www.esab.com

030210

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 2 726 80 05

THE CZECH REPUBLIC

ESAB V AMBERK s.r.o.

Prague

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Copenhagen--Valby

Tel:+4536300111

Fax:+4536304003

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel:+33130755500

Fax:+33130755524

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 204

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:+3612044182

Fax:+3612044186

ITALY

ESAB Saldatura S.p.A.

Mesero (Mi)

Tel:+3902979681

Fax:+390297289181

THE NETHERLANDS

ESAB Nederland B.V.

Utrecht

Tel: +31 30 248 59 22

Fax: +31 30 248 52 60

NORWAY

AS ESAB

Larvik

Tel:+4733121000

Fax:+4733115203

POLAND

ESAB Sp.z.o.o

Warszaw

Tel: +48 22 813 99 63

Fax: +48 22 813 98 81

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 1 837 1527

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel:+421744882426

Fax:+421744888741

SPAIN

ESAB Ibérica S.A.

Alcobendas (Madrid)

Tel: +34 91 623 11 00

Fax: +34 91 661 51 83

SWEDEN

ESAB Sverige AB

Gothenburg

Tel:+4631509500

Fax:+4631509222

ESAB International AB

Gothenburg

Tel:+4631509000

Fax:+4631509360

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

BRAZIL

ESAB S.A.

Contagem--MG

Tel: +55 31 333 43 33

Fax: +55 31 361 31 51

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 44 58

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 6539 7124

Fax: +86 21 6543 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 01 88

Fax: +62 21 461 29 29

MALAYSIA

ESAB (Malaysia) Snd Bhd

Selangor

Tel: +60 3 703 36 15

Fax: +60 3 703 35 52

SINGAPORE

ESAB Singapore Pte Ltd

Singapore

Tel: +65 861 43 22

Fax: +65 861 31 95

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 861 74 42

Fax: +65 863 08 39

SOUTH KOREA

ESAB SeAH Corporation

Kyung --Nam

Tel: +82 551 289 81 11

Fax: +82 551 289 88 63

UNITED ARAB EMIRATES

ESAB Middle East

Dubai

Tel: +971 4 338 88 29

Fax: +971 4 338 87 29

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--CIS

ESAB Representative Office

Moscow

Tel: +7 095 937 98 20

Fax: +7 095 937 95 80

ESAB Representative Office

St Petersburg

Tel: +7 812 325 43 62

Fax: +7 812 325 66 85

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB LAH/LAE → LAF User manual

Brand: ESAB

Model: LAH/LAE → LAF

Category: Welding System

Type: User manual

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ESAB LAH/LAE → LAF User manual

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