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.
GB
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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.
GB
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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.
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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
GB
-- 2 1 --
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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.
GB
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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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-- 2 3 --
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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).
--
+
in
out
GB
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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.
GB
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Komponentförteckning List of components
C = Component designation in the circuit diagram
C
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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Item
no.
Qty
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
QS
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
V
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
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Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
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Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
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Tel:+3612044182
Fax:+3612044186
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Tel:+3902979681
Fax:+390297289181
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Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
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AS ESAB
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Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
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Tel: +52 8 350 5959
Fax: +52 8 350 7554
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Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
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CHINA
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Shanghai
Tel: +86 21 6539 7124
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Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
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Tel: +60 3 703 36 15
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Singapore
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Fax: +65 861 31 95
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Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
/
