ESAB LAF 1601, LAF 1601M Instruction manual

GB

LAF 1601/ LAF 1601M

Instruction manual

Valid for serial no. 935-xxx-xxxx,126-xxx-xxxx0449 507 001 GB 20110713

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1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Controls 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Cleaning 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Welding power source 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Contactor 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ORDERING OF SPARE PARTS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTION INSTRUCTION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rights reserved to alter specifications without notice.

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1 SAFETY

Users of ESAB 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 equipment. The following recommendations should be ob served 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 equip ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation S location of emergency stops S its function S relevant safety precautions S welding and cutting

2. The operator must ensure that: S no unauthorized 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 drafts

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.

CAUTION

This product is solely intended for arc welding.

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WARNING

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

S Install and earth the 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.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

CAUTION

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

CAUTION

Read and understand the instruction manual before installing or operating.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary welding protection and accessories.

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2 INTRODUCTION

LAF 1601/ LAF 1601M are remote-controlled 3-phase welding power sources designed for high-efficiency mechanical submerged-arc welding (SAW).

The welding power sources are fan-cooled and are monitored by a thermal cutout against overload. When the thermal cutout is deployed the yellow lamp on the front panel illuminates automatically. The reset is carried out automatically when the temperature has decreased to a permitted level.

3 TECHNICAL DATA

LAF 1601 LAF 1601M

Mains connection: 400/415/500 V, 350 Hz

400/440/550 V, 360 Hz

Primary current I

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

Effiency 89% 89%

Power factor 0,86 0,86

Weight 585 kg 585 kg

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

Insulation class (transformer): H H

Enclosure class IP 23 IP 23

Application class

136 A I

max

220/230/400/415/500 V, 350 Hz 230/400/440/550 V, 360 Hz

235 A

max

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.

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4 INSTALLATION

The installation must be carried out by a professional.

Note

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the power quality of the grid. Therefore connection restrictions or requirements regarding the maximum permissible mains impedance or the required minimum supply capacity at the interface point to the public grid may apply for some types of equipment (see technical data). In this case it is the responsibility of the installer or user of the equipment to ensure, by consultation with the distrubution network operator if necessary, that the equipment may be connected.

4.1 Location

WARNING

Fasten the equipment - particularly if the ground is uneven or sloping.

S Place the welding power source on a level foundation.

S Make sure there is nothing to prevent the cooling.

Lifting instructions

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4.2 Connections

S On delivery the welding power source is connected

for 400 V.

S For other supply voltage:

Remove the left side plate.

Perform the switchings on the main and control transformer in accordance with the connection instruction on page 16.

S Select the mains cable with the correct cable area

and fuse the cable with the correct fuse in accordance with local regulations (see the table on page 8).

S Remove the front plates (x 2).

S Connect the ground cable to the screw marked .

S Tighten the cable clamp (1).

S Connect the mains cables to the main connection terminals L1, L2 and L3 (5).

S Connect the control cable between the welding power source and the control

box to the 28-pin connector (2) on the inside of the welding power source.

S Connect the 1-pin measuring cable (4) for measuring the arc voltage to the

return cable/ welding head.

S Connect a suitable welding and return cable in the connectors (3) marked

+ and - on the front of the welding power source.

S Fit the side/front plates.

Mains connection

LAF 1601 50 Hz 60 Hz

Voltage (V) 400 / 415 500 400 / 440 550

Phase current I

Cable area (mm

Fuse, slow (A) 160 125 160 125

(A) 136 108 136 108

1eff

2)

3 x 70+35 3 x 50+35 3x70+ 35 3x70+ 35

LAF 1601M 50 Hz 60 Hz

Voltage (V) 230 400 / 415 500 230 400 / 440 550

Phase current I

Cable area (mm

Fuse, slow (A) 200 160 125 200 160 125

Note:

The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. They may not be applicable in other countries: make sure that the cable area and fuse sizes comply with the relevant national regulations.

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(A) 235 136 108 235 136 108

1eff

2)

3x120+70 3x70+35 3x50+35 3x120+70 3x70+ 35 3x70+ 35

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5 OPERATION

General safety regulations for handling of the equipment can be found on page 4. Read through before you start using the equipment!

Note! Never use the welding power source without side plates.

Note! The power source must be set to analogue mode to use the PEI control unit.

5.1 Controls

The front panel contains:

1. Main circuit-breaker for switching the mains voltage and the fan on and off in the welding power source.

S Position "1" On

S Position "0" Off

2. S The indicator lamp (white) illuminates when the main switch is

switched on.

3. Indicator lamp for overheating (yellow)

S The indicator lamp illuminates when the thermal cutout is

deployed due to excess temperature in the welding power source.

S The indicator lamp goes out when the temperature in the

welding power source has decreased to a permitted level.

4. Pushbutton resetting the automatic fuse FU2 for 42 V supply voltage.

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6 MAINTENANCE

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any work in the product during the guarantee period in order to rectify any faults.

6.1 Cleaning

6.1.1 Welding power source

WARNING!

Blocked air inlets or outlets will lead to overheating.

S Clean the welding power source as necessary.

Dry compressed air is recommended for the purpose.

6.1.2 Contactor

WARNING!

Never use compressed air to clean the contactor without first taking it apart completely.

Note:

To ensure the reliable operation of the contactor, the magnetic parts must be kept clean. If the contactor has to be cleaned it must be taken apart, and all the pieces be cleaned. Alternatively, the contactor can be replaced.

7 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman. Use only ESAB original spare and wear parts.

LAF 1601/ LAF 1601M is designed and tested in accordance with the international and European standards EN 60974-1 and EN 60974-10. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.

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NOTES

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notes

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Diagram

Valid for serial no 935-xxx-xxxx

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Valid for serial no 126-xxx-xxxx

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Connection instruction

LAF 1601

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LAF 1601M

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LAF 1601/ LAF 1601M

Ordering number

Ordering no. Denomination Notes

0460 515 880 Welding power source LAF 1601

0460 515 881 Welding power source LAF 1601M

0459 839 059 Spare parts list LAF 1601/ LAF 1601M

The spare parts list is available on the Internet at www.esab.com

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NOTES

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notes

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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 2 745 11 28

BULGARIA

ESAB Kft Representative Office Sofia Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

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: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

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 2191 4333 Fax: +55 31 2191 4440

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 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 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 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors

For addresses and phone numbers to our distributors in other countries, please visit our home page

www.esab.com

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

www.esab.com

ESAB LAF 1601, LAF 1601M Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual