ESAB LAF 1601,LAF 1601M Instruction manual

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LAF 1601 / LAF 1601M

Instruction manual

Valid for serial no. 0935-xxx-xxxx0449 507 001 2009-08-24

ENGLISH 4..............................................

Rights reserved to alterspecifications without notice.

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ENGLISH

1SAFETY 5...........................................................

2 INTRODUCTION 8...................................................

2.1 General 8..................................................................

2.2 Technical data 8............................................................

3 INSTALLATION 9....................................................

3.1 General 9..................................................................

3.2 Location 9..................................................................

3.3 Connections 10..............................................................

4 OPERATION 11.......................................................

4.1 General 11..................................................................

4.2 Controls 11..................................................................

5 MAINTENANCE 12....................................................

5.1 General 12..................................................................

5.2 Cleaning 12.................................................................

6 ORDERING OF SPARE PARTS 12......................................

DIAGRAM 13............................................................

LIST OF COMPONENTS 14...............................................

CONNECTION INSTRUCTION 15..........................................

SPARE PARTS LIST 17..................................................

TOCe

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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 recommendations 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. Note! Do not use safety

gloves when replacing wire.

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.

SafeArcW GB

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WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURER'S 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 keep fumes and gases 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 inflam-

mable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection. S Warn bystanders of the risk.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

SafeArcW GB

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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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 electromagnic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

WARNING!

Read and understand the instruction manual before installing or operating.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

CAUTION!

The welding power source and control box PEH can't be used together.

SafeArcW GB

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2 INTRODUCTION

2.1 General

LAF 1601 / LAF 1601M are remote-controlled 3-phase welding power sources designed for high-efficiency m echanical 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 car ried out automatically when the temperature has decreased to a permitted level.

2.2 Technical data

LAF 1601 LAF 1601M

Mains connection: 400/415/500 V, 3µ50 Hz

400/440/550 V, 3µ60 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, 3µ50 Hz 230/400/440/550 V, 3µ60 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 IP 23 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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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Location

WARNING - TIPPING RISK!

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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3.3 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 15.

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 10).

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 Cablearea(mm

(A) 136 108 136 108

1eff

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

Fuse, slow (A) 160 125 160 125

LAF 1601M 50 Hz 60 Hz Voltage (V) 230 400 / 415 500 230 400 / 440 550 Phase current I Cablearea(mm Fuse, slow (A) 200 160 125 200 160 125

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(A) 235 136 108 235 136 108

1eff

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

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4OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on page 5. Read through before you start using the equipment!

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

4.2 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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5 MAINTENANCE

5.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the welding power source during the warranty period.

5.2 Cleaning

5.2.1 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.

5.2.2 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.

6 ORDERING OF SPARE PARTS

LAF 1601/ LAF 1601M is designed and tested in accordance with the international and European standards IEC/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 are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 17. This will simplify dispatch and ensure you get the right part.

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DIAGRAM

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LIST OF COMPONENTS

C = Component designation in the circuit diagram

Denomination Remarks

AP1 Circuit board AP2 Circuit board, insulation AP3 Circuit board, EMC filter

C1, C2, C3,C4Capacitor

FU1 Automatic fuse 16 A FU2 Automatic fuse 20 A

FU3 Fuse 1,25 AT FU4 Fuse 1,25 AT FU5 Fuse 3,15 AT

HL1 Indicating lamp (white) HL2 Indicating lamp (yellow) KM1 Contactor 42 V, 50 Hz

KM2 Contactor L1 Inductor

M1 Fan QF Main switch (black)

R1, R2, R4 Resistor RS1 Shunt ST1 Thermal guard

TC1 Control transformer 42 V, 900VA TC2 Transformer

TM1 Transformer THY1, THY2,

Thyristor

THY3

V2 Silicon diode

V4 Diode bridge XT2,XT3,XT4 Connection block RC1 - RC5 Contact protection XS1 Socket 1 pole XS2 Socket 1 pole XS3 Socket 1 pole XS4 Sleeve socket 28 pole

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CONNECTION INSTRUCTION

LAF 1601

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LAF 1601M

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SPARE PARTS LIST

Edition 2009-08-24

Ordering no. Denomination Notes

0460515880 Welding power source LAF 1601

0460515881 Welding power source LAF 1601M

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

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Item

Qty. Ordering no. Denomination Remarks C

no.

0460515880 Welding power source LAF 1601

1 1 0551203082 Shunt 2000 A RS1 2 1 0191085104 Capacitor 400 V C4 3 3 0490600606 Silicon diode V4 4 1 0320445883 Inductor L1 5 1 0320444883 Inductor coil 8 1 0460294880 Fan M1

9 3 0321452880 Thyristor bridge 10 2 0041051606 Contact protection RC 11 3 0321427001 Thyristor 1500 A/ 500 V THY1- THY3 12 2 0194077008 Automatic fuse 16 A FU1 13 1 0320746002 Main switch (black) QF 14 1 0192576004 Indicating lamp (white) HL1 15 1 0192576303 Indicating lamp (yellow) HL2 16 1 0193586104 Automatic fuse 20 A FU2 19 1 0487399886 Circuit board AP1 19 1 0487399880 Circuit board From serial no. 0935-xxx-xxxx

1 0487399886 Circuit board From serial no. 0935-xxx-xxxx

20 1 0805586131 Contactor KM2 21 1 0442849880 Contactor KM1 22 3 0319828001 Transformer TC2 23 1 0460092002 Control transformer 42 V, 900 VA TC1 24 1 0486224880 Circuit board, EMC filter AP3 25 2 0158115880 Cable inlet 26 1 0469843880 Transformer coil 27 1 0469845881 Transformer TM1 28 2 0320923880 Diode brige

28.1 6 0490600626 Silicon diode V2 33 1 0487068880

0368544006 34 1 0191093135 Resistor 680R R4 35 1 0523300201 Measure terminal 36 1 0319445001 Thermostat ST1

Circuit board, insulation Sleeve socket

The circiut board must be configured when installed

Circuit board configured for LAF 1601 version.

28-pole, Burndy

AP1

AP2 XS4

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Item

Qty. Ordering no. Denomination Remarks C

no.

0460515881 Welding power source LAF 1601M

1 1 0551203082 Shunt 2000 A RS1 2 1 0191085104 Capacitor 400 V C4 3 3 0490600606 Silicon diode V4 4 1 0320445883 Inductor L1 5 1 0320444883 Inductor coil 8 1 0460294880 Fan

9 3 0321452880 Thyristor bridge 10 2 0041051606 Contact protection RC 11 1 0321427001 Thyristor 1500 A/ 500 V V1 12 2 0194077008 Automatic fuse 16 A FU1 13 1 0320746002 Main switch (black) QF 14 1 0192576004 Indicating lamp (white) HL1 15 1 0192576303 Indicating lamp (yellow) HL2 16 1 0193586104 Automatic fuse 20 A FU2 18 2 0156388001 Handle 19 1 0487399880 Circuit board From serial no. 0935-xxx-xxxx

1 0487399886 Circuit board From serial no. 0935-xxx-xxxx

20 1 0805586131 Contactor KM2 21 1 0442849881 Contactor KM1 22 3 0319828001 Transformer TC2 23 1 0460092002 Control transformer 42 V, 900 VA TC1 24 1 0486224880 Circuit board, EMC filter AP3 25 2 0158115880 Cable inlet 26 1 0469843880 Transformer coil 27 1 0469845881 Transformer TM1 28 2 0320923880 Diode brige

28.1 6 0490600626 Silicon diode V2 33 1 0487068880

0368544006 34 1 0191093135 Resistor 680R R4 35 1 0523300201 Measure terminal 36 1 0319445001 Thermostat ST1

Circuit board, insulation Sleeve socket

The circiut board must be configured when installed

Circuit board configured for LAF 1601 version.

28-pole, Burndy

AP1

AP2 XS4

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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

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:+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: +49 212 298 218

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:+3612044182 Fax:+3612044186

ITALY

ESAB Saldatura S.p.A. Mesero (Mi) Tel:+3902979681 Fax:+390297289181

THE NETHERLANDS

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

NORWAY

AS ESAB Larvik Tel:+4733121000 Fax:+4733115203

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

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel:+421744882426 Fax:+421744888741

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:+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 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:+6568614322 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

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

LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280

LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060

Distributors

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

www.esab.com

ESAB AB SE--695 81 LAXÅ SWEDEN Phone +46 584 81 000

www.esab.com

081016

ESAB LAF 1601,LAF 1601M Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual