LHH 250 -400
Bruksanvisning och reservdelsförteckning
Instruction manual and spare parts list
Betriebsanweisung und Ersatzteilverzeichnis
Manuel d'instructions et liste des pièces détachées
320 865-002
83-06
| INNERALLOPONILONNING | Siudii | |
|---|---|---|
| Allmän beskrivning | 1 | |
| Installation | 1 | |
| Drift | 2 | |
| Tekniska data | 2 | |
| Teknisk beskrivning | 2 | |
| Skötsel och service | 3 | |
| Reservdelsbeställning | 3 | |
| Felsökningsschema | 4 | |
| Máttskiss | 22 | |
| Statisk karakteristik | 23 | |
| Förbindningsschema | 24 | |
| Verkningsgrad och effekt- | ||
| faktor | 25 | |
| Reservdelsförteckning, | ||
| LHH | 26–31 | |
| Reservdelsförteckning, | ||
| tillbehör | 31–33 | |
| LIST OF CONTENTS | page |
|---|---|
| Presentation | 8 |
| Installation | 8 |
| Operation | 9 |
| Technical data | 9 |
| Technical description | 9 |
| Maintenance and service | 10 |
| Ordering spare parts | 10 |
| Trouble shooting | 11 |
| Dimensional drawing | 22 |
| Static characteristics | 23 |
| Wiring diagram | 24 |
| Efficiency and power factor . | 25 |
| Parts list, LHH | 26–3 |
| Parts list, optional | |
| equipment | 31–33 |
| INHAL TVERZEICHNIS | Soito |
|---|---|
| Ocite | |
| Präsentation | 15 |
| Installation | 15 |
| Betrieb | 16 |
| Technische Daten | 16 |
| Technische Beschreibung | 16 |
| Pflege und Wartung | 17 |
| Ersatzteilbestellung | 17 |
| Störungssuche | 18 |
| Maßskizze | 22 |
| Statische Kennlinie | 23 |
| Schaltplan | 24 |
| Wirkungsgrad und Leistungs- | |
| faktor | 25 |
| Ersatzteilverzeichnis, LHH | 26-31 |
| Ersatzteilverzeichnis, | |
| Zubehöre | 31-33 |
Rätt till ändning av specifikation förbehålles
ESAB reserves the right to alter specifications without notice
Änderungen vorbehalten
Instructions – LHH 250 and LHH 400 Inverters
Presentation
The LHH inverter is a welding rectifier designed according to the inverter principle and intended for covered electrode and TIG welding. Some of the advantages provided by the advanced electronics are fast control, low power consumption, excellent welding characteristics, and mains voltage compensation. The inverter technique was a contributing factor to low weight and small dimensions.
The rating plate including serial number and connection data is located on the rear panel of the LHH.
On delivery, LHH includes two handles with connection bolts, Allen key and cable connectors.
Optional LHH accessories:
Convenient cart for those, who frequently move their equipment from one work area to another. After sliding the holding rings upwards, the handle which is provided with support hooks for mains and welding cables is simply folded back. Order no. 320 845-880
Remote control
When the rectifier is inaccessible or when exact, continuous current control is required, for instance during pipe welding, remote control is a must.
Remote control unit PHB1 is a lightweight, easy to use single-hand unit featuring planetary gear for accurate setting.
Order no. 317 937-880
Remote control unit PHB2 is a robust unit featuring infinitely variable coarse and fine welding adjustment. Order no. 317 920-880
Remote control unit PHC2 another robust unit featuring 10 coarse setting ranges and infinitely variable fine adjustment within each coarse range. Order no. 320 902-880
Pulsed current with pulse unit PHA5 for TIG or stainless steel welding requiring pulsed current. The current pulses are adjustable from 0.03 to 4 secs. PHA5 can also be used as a regular remote control or hot-start unit. Order no. 320 128-880
Hotstart with hot-start unit PHA2 will enable you to select two independent current levels for removal of possible welding defects, which may occur as soon as welding is interrupted during welding from one side. Order no. 154 675-880
Connection and extension cables – PHB1, PHB2, PHC2, PHA5 and PHA2: Connection cable, length 10 m (33 ft) Order no. 317 922-881 Connection cable, length 25 m (82 ft) Order no. 317 922-882 Extension cable, length 25 m (82 ft) Order no. 317 576-880
Welding station equipment
U1H for LHH 250 and U2H for LHH 400. These sets include 5 m (16,5 ft) welding and return cable, electrode holder, return clamp, welding shield, chipping hammer, wire brush and welding gloves. Order no. UIH: 160 302-881, U2H: 160 302-882
SEIRION DC TIG add-on unit – For optimal TIG welding results, the Seirion DC add-on unit is used. Order no. 154 298-880
TIG welding torch BTB 200 Order no. 156 842-881
Application
LHH is designed for welding in all weldable metals using all types of covered electrodes as well as TIG welding.
The LHH 250 welding current range 5–250 Amps permits welding with covered electrodes up to Ø 5 mm.
The current range of the LHH 400 is 9--400 Amps. Applicable electrode dimensions for LHH 400 are Ø 1,6-6 mm. The LHH 400 can also be used for gouging with carbon rods up to Ø 8 mm.
Hand and TIG welding
High open-circuit voltage and a well balanced start surge ensure reliable striking and restriking action. And, the anti-stick action of the LHH considerably reduces the risk of electrode stick. Should electrode stick occur in spite of this, the welding current is automatically reduced enabling separation of the undamaged electrode from the workpiece. Immediate re-striking can commence. This antistick action greatly facilitates root bead welding, and – it is a great electrode "saver".
When TIG welding, the start surge and antistick action are disconnected with the switch on the front panel.
The low minimum current makes it possible to TIG weld very thin materials.
Installation
Make sure that the proper mains voltage is available. Correct voltage is indicated on the rating plate on the rear panel of the LHH, which requires three-phase mains connection.
The mains cable, which is ordered separately, is connected to connection block K 11 marked R, S and T. Phase sequence is not important. Cable leadin and stress relief clamp to be attached bottom right inside the rear panel of the rectifier. Earth connection according to local regulations: Earth should be connected to the bolt marked () next to the mains connection block.
| Mains connection | LHH 250 | LHH 400 | LHH 400 | ||
|---|---|---|---|---|---|
| Voltage (V) | 380 V | 415 V | 380 V | 415 V | |
| Frequency (Hz) | 50–60 | 50 | 50–60 | 50 | |
| Primary current (A) | 14 | 13 | 21 | 20 | |
| Fuse, slow (A) | 16 | 16 | 20 | 20 | |
| Cable area (mm²) | 4×1,5 | 4×1,5 | 4×2,5 | 4×2,5 | |
| Fuse, fast (A) | 20 | 20 | 25 | 25 | |
| Cable area (mm²) | 4×2,5 | 4×2,5 | 4×4 | 4×4 | |
Cable and fuse dimension comply with Swedish regulations.
The above primary current refers to load at 60% duty factor.
Operation
LHH is semi-protected and drip-proof according to the IP 23 AF protection criteria, i.e. it will withstand exposure to rain or water at 60% angle.
Front panel controls
- Combined mains switch and coarse range selector
- Indicator lamp, which lights up when the rectifier is live.
- Toggle switch for covered electrode welding or TIG welding.
- Fine setting potentiometer for adjustment of welding current featuring planetary gear for accurate setting. Slip coupling prevents damage, which may be caused when turning to min. or max. setting position.
- Toggle switch for adjustment of welding current by means of the LHH setting knob or remote control, pulse or hot-start unit.
- Terminal for remote control, pulse or hot-start unit connection.
Rear panel controls
-
Automatic short-circuiting and high current peak cut-out
- 1. The LHH is to be used in an upright position.
- 2. Set the automatic cut-out on the rear panel in position I.
- 3. Set the main/coarse setting switch in position I or II, the indicator lamp lights up and the fan starts.
|
LHH
250 |
LHH
400 |
|
|---|---|---|
|
Position I –
coarse range |
560 | 9-130 |
|
Position II –
coarse range |
45-250 | 75-400 |
- 4. Make sure that the flow of cooling air is not obstructed.
- Set the toggle switch in its pertinent position – hand or TiG welding.
- Set the welding current toggle switch in position welding current setting – with or without remote control, pulse or hot-start unit.
- 7. When using remote control, pulse or hot-start unit, connect the connection cable to the terminal below the toggle switch.
- 8. For fine setting of welding current, use the potentiometer on the front panel of the rectifier or the remote control, pulse or hot-start unit, whenever applicable. When using PHA 5, see separate manual.
- Make sure that the welding and return cable connectors are properly connected to the machine.
- 10. The LHH is ready for welding.
Safety devices
We have already mentioned the automatic cut-out at the back of the LHH. This cut-out will automatically reduce the current to 0 as soon as short-circuiting or a high current peak occurs. For continued welding, the automatic cut-out switch must be returned to position I. Frequent occurance of this cut-out action requires the services of a repair man.
LHH is provided with two thermal cutouts, which automatically cut the welding current when overload occurs. As soon as the components are sufficiently cooled, the thermal cut-outs are automatically re-set.
Galvanic separation of remote control prevents a short-circuited or damaged remote control unit from damaging the rectifier electronics.
TIG welding
When TIG welding, the following items should be added:
- SEIRION DC TIG add-on unit
- A cylinder of argon gas with regulator
- TIG torch with tungsten electrode
ESAB's TIG add-on unit, Seirion DC, provides high-frequency starting of the arc. In addition Seirion DC is provided with a current relay and automatic post-flow of gas, which prevents workpiece and tungsten electrode oxidation.
Electrode selection
ESAB has a wide selection of electrodes for DC welding.
Your local ESAB representative will gladly provide you with technical advice and help you solve your welding problems, including the appropriate electrode for the job at hand.
| TECHNICAL DATA | LHH 250 | LHH 400 |
|---|---|---|
| Setting range | 5A/20V-250A/30V | 9A/20V-400A/36V |
|
- Coarse range I
- Coarse range I |
5–60 Amps
45–250 Amps |
9–130 Amps
75–400 Amps |
| Permitted load | ||
|
– At 35% duty cycle
– At 60% duty cycle |
250A/30V
200A/28V |
400A/36V
315A/33V |
| Open-circuit voltage | 55–65V | 6575V |
| No-load rating | 0,06 kW | 0,06 kW |
|
Power factor
- At 150A (λ) - At max. A (λ) - Cos φ, approx Efficiency (η) |
0,72
0,75 0,99 0,78 |
0,83
0,91 0,99 - 0,80 |
| Weight, approx. | 38 kg (84 lbs) | 45 kg (99 [bs) |
| Weight, incl. cart, | 45 kg (99 lbs) | . 52 kg (115 lbs) |
Standards complied with: VDE 0542, SEN 8301, ISO R700 and NF A85-011
Technical description
The heaviest component of a conventional welding rectifier is the transformer, which steps down the primary input voltage to a suitable welding voltage.
The weight of the transformer depends on the primary current frequency.
By being able to increase the frequency, the weight is reduced. This interrelation was utilized in the LHH. We were able to reduce the weight of several main components by applying the inverter technique, which means that a frequency, many times higher than the mains frequency, is used in the power source itself. At the same
time, a number of additional advantages were gained, for instance high power factor as well as increased welding process control.
Function: The three-phase input AC current is rectified. The inverter then re-converts the current into a much higher frequency than the mains voltage. After transformation, rectification recurs and DC welding current is obtained. The whole process is controlled by a control circuit, which provides the power source with appropriate static characteristics and dynamic properties.
LHH is built in four sections:
- The control section in the upper part includes regulating circuits and control electronics.
- The ventilator space includes fan and resistors.
- One section includes the mains components.
- The fourth section includes the welding components.
Control system
The up-to-date electronics used in the LHH control system produce excellent static and dynamic characteristics, high efficiency and power factors, low min. current, start surge, anti-stick action, fold-back, galvanically separated remote control, mains voltage compensation, etc.
Maintenance and service
Normally, LHH requires no maintenance. It is sufficient to clean the unit with dry, compressed air under reduced pressure once a year. However, when used in dusty and dirty surroundings, this cleaning should be carried out more frequently.
LHH features easy component accessibility when the casing is removed.
Control and replacement of diodes and thyristors
NOTE! Bell or summer may not be used when checking diodes or thyristors.
When checking the diodes you do not need to remove them from the heat sink when using ESAB's diode tester ZPB. Order no. 160 115-880
The mains rectifier (K 87) includes 3 + and 3 – diodes, two heat sinks include 2 thyristors (K 91) and two back current diodes (K 92). The welding rectifier (K2) includes 2 diodes.
Diode or thyristor replacement
When replacing a faulty diode/thyristor or tightening a loose diode/thyristor, it is very important that the correct tightening torque is used. Insufficient tightening causes increased transition resistance and reduced thermal conductivity resulting in increased temperature and possible overheating. Mechanical damage to the semi-conductor element inside the diode/thyristor can be caused by excessive tightening.
| Tightening torque | Nm |
|---|---|
| Mains diodes in K 87 | 23-29 |
| Back current diodes | 14± 10% |
| K92 | 2,5±10% |
| Welding diodes K 2 | 28 ± 10% |
The mating surfaces between the bolt type diodes/thyristors and the heat sink, as well as plane surfaces, should be carefully cleaned and lubricated with silicon grease. This procedure improves heat transfer as well as prevents damage to and corrosion of threads.
Recommended types of silicon grease are:
- Midland silicon MS4 or DP2623
- Wacker silicon P4 or P12
- Dow Corning DC 200
On special request, ESAB will deliver Midland silicon DP 2623 grease in a 142 g (9,3 oz) tube or 1 kg (2,2 lbs) can. When ordering please specify order no 192 058-101 and quantity.
Diode tester control
Connect the pinplug of the diode tester ZPB to a 220 V AC wall socket. Check the diode tester by short-circuiting the two crocodile clips. Both indicator lamps should light up.
Diode control
Probable causes of faulty diodes are specified in the trouble-shooting instructions.
To find out which one or which diodes are faulty, using the ZPB tester, proceed as follows:
- 1. Loosen the diode top connection
-
2. Connect the two crocodile clips between the diode top connection and the heat sink.
- a) When one lamp lights up, the diode is in working order.
- b) When both lamps light up, there is a short in the diode.
- c) When no lamp lights up, the diode is defective.
Thyristor control
Probable causes of faulty thyristors, symptoms and remedies are specified in the trouble-shooting instructions.
Control and replacement of printed circuit
The printed circuit (K 70) is located in the upper part of the LHH.
The printed circuit is attached by means of 5 quick-action lockpins.
All electric printed circuit connections are made via three quick-action connection blocks:
K 45.1 (female) and K 45.2 (male) (15-pole)
K 45.3 (male) and K 45.4 (female) (15-pole)
K 45.5 (male) and K 45.6 (female) (12-pole)
K 45.1, K 45.3 and K-45.5 are connected to the printed circuit.
- K 45.2 leads to front panel controls and current transformer
- K 45.4 leads to auxiliary transformer (19 V), thermal cut-outs, shunt, main transformer and welding circuit
- K 45.6 leads to auxiliary transformer (3 V) and thyristors
For further information, see connection diagram on the inside of the LHH cover or on page 24 in this manual.
Three light diodes indicate whether specific main functions of the printed circuit are faulty or not. Green light diode is constantly on, when the input voltage to the galvanically separated remote control functions properly. The other green light diode is constantly on when the thyristor ignition input voltage is not faulty.
The red light diode indicates when the blocking circuit is switched in, which occurs if the open-circuit voltage exceeds 97 V.
Ordering spare parts
You can order LHH spare parts through your local ESAB representative, you will find a list of subsidiaries on the back cover. When ordering spare parts, please specify type designation (LHH 250 or 400), mains voltage variant (for ex. 380 V), serial number and description in accordance with the spare parts list. This will speed up handling of your order and ensure correct delivery.
Trouble-shooting instructions
Trouble-shooting to be carried out by trained electricians only.
Equipment
Connection diagram no. 320 798 (see page 24) Universal instrument with Ri≥kΩ/VDC
General
Check - that welding cables and connections are not damaged
- that all three phases are current-carrying (phase sequence of no importance)
- that control knobs and switches on the front panel are in the correct position, hand welding, TIG welding, respectively with or without remote control unit (internal/remote control)
All voltage to be measured relative to the electronic zero (welding terminal +) provided no other directions are given.
Warning! Be careful when measuring primary circuits. Normally, all capacitors should be discharged in 30 sec, however, certain faults may cause dangerous voltage to remain for a longer time.
Before proceeding with any trouble-shooting activity or repair, set the mains/coarse selector switch to position "Off". Certain capacitors will only discharge when the switch is in this position.
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