HANDBOOK
FOR WELDING TRANSFORMERS
TBH 250
TBH 400
WELDING TRANSFORMERS TBH 250 TBH 400 TBH 700
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CONTENTS
| Unioral TBH 20 Transformer. Mains Switch Safety Unit (42 V) Power Factor Correction Capacitors TBH 400 and 700 Transformers Mains Switch Servomotor Remote Control Cable Direct Remote Control Safety Unit (42 V). Protection Power Factor Correction Combined Transformers. Maintenance. TDI 1260, 400 and 700 Maintenance Specification TBH 250. Specification TBH 250. Maintenance Specification TBH 250. Maintenance Open-circuit Voltage Power Pactor Correction Maintum Load Welding Current Range Open-circuit Voltage Primery Current and cos 9 for Type TBH 250. Without Capacitor Capacitor = 5 Wating Current Range Open-circuit Voltage Primery Current Range Open-circuit Voltage Power Factor (cos 7) burg tBH 400. Mains Connection Maximun Load Welding Current Range | ansformers TBH 250, TBH 400, TBH 700 |
Pag
3 |
|---|---|---|
| PBH 400 and 700 Transformers |
former
ch (42 V) for Correction |
4 |
| Safety Unit (42 V) |
0 Transformers
ch ntrol ntrol Cable iote Control |
5 |
| Combined Transformers, | (42 V) | 6 |
| Maintenance | sformers, | 7 |
|
Specification TBH 250, TBH 400, TBH 700
specification TBH 250 |
00 and 700 Maintenance
ntenance |
7 |
| Specification TBH 250 | ЗН 250, ТВН 400, ТВН 700 | 13 |
|
Primary Current and cos φ
0
for Type TBH 250.
Without Capacitor Capacitor = 2, 5 kVAr Capacitor = 5 kVAr Characteristic Curves for Type TBH 250. Specification TBH 400. Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Bificiency Measurements and Weight Power factor (cos φ ) using different sizes of capacitors at different loads, TBH 400. Without Capacitor Capacitor = 2, 5 kVAr Capacitor = 2, 5 kVAr Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor BH 700. Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Primary Current and Power Factor for various condensor capacities for Type TBH 400. Specification TBH 700. Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos φ ) using different sizes of capacitors at different loads, TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current and Cos φ for Type TBH 700. Primary Current a |
BH 250
nection load rrent Range it Voltage sipation ents and Weight |
15 |
| Characteristic Curves for Type TBH 250 |
nt and cos φ for Type TBH 250,
pacitor = 2,5 kVAr = 5 kVAr |
16 |
| Specification TBH 400 | Curves for Type TBH 250 | 17 |
|
Power factor (cos 9) using different sizes of capacitors
at different loads, TBH 400, Primary Current and cos 9 for Type TBH 400 Without Capacitor Capacitor = 2, 5 kVAr Capacitor = 7, 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 400 Primary Current and Power Factor for various condensor capacities for Type TBH 400 Specification TBH 700 Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos 9) using different sizes of capacitors at different loads, TBH 700 Primary Current and cos 9 for Type TBH 700 Without Capacitor Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor = 7, 5 kVAr |
an 400
Load Load rrent Range it Voltage sipation |
10 |
|
at different loads, TBH 400,
Primary Current and cos % for Type TBH 400. Without Capacitor = 2, 5 kVAr Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 400. Primary Current and Power Factor for various condensor Capacities for Type TBH 400. Primary Current and Power Factor for various condensor Capacities for Type TBH 400. Specification TBH 700. Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos %) using different sizes of capacitors at different loads, TBH 700. Primary Current and cos % for Type TBH 700. Without Capacitor Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Capacitor = 7, 5 kVAr |
os9) using different sizes of capacitors | |
|
Primary Current and cos φ for Type TBH 400
Without Capacitor Capacitor = 2, 5 kVAr Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 400 Primary Current and Power Factor for various condensor capacities for Type TBH 400 Specification TBH 700 Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos φ) using different sizes of capacitors at different loads, TBH 700 Primary Current and cos φ for Type TBH 700 Without Capacitor Capacitor = 5 kVAr Capacitor = 5 kVAr Capacitor = 7, 5 kVAr |
ls, TBH 400,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, | 19 |
| Characteristic Curves for Type TBH 400 Primary Current and Power Factor for various condensor capacities for Type TBH 400 Specification TBH 700 Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos?) using different sizes of capacitors at different loads, TBH 700 Primary Current and cos p for Type TBH 700 Without Capacitor Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 700 |
nt and cos $\overline{9} for Type TBH 400
pacitor = 2,5 kVAr = 5 kVAr = 5 kVAr = 7,5 kVAr |
20 |
|
Primary Current and Power Factor for various condensor
capacities for Type TBH 400 |
Curves for Type TBH 400 | 21 |
|
Specification TBH 700
Mains Connection Maximum Load Welding Current Range Open-circuit Voltage Power Dissipation Efficiency Measurements and Weight Power factor (cos P) using different sizes of capacitors at different loads, TBH 700 Primary Current and cos P for Type TBH 700 Without Capacitor Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 700 |
nt and Power Factor for various condensor
Ype TBH 400 |
22 |
|
Power factor (cos β) using different sizes of capacitors
at different loads, TBH 700 Primary Current and cos β for Type TBH 700 Without Capacitor Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 700 |
BH 700
nection Load Irrent Range hit Voltage sipation ents and Weight |
23 |
|
Primary Current and cos β for Type TBH 700
Without Capacitor Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 700 |
os () using different sizes of capacitors
is. TBH 700 |
24 |
|
Without Capacitor
Capacitor = 5 kVAr Capacitor = 7, 5 kVAr Characteristic Curves for Type TBH 700 |
nt and cos β for Type TBH 700 | 25 |
| Characteristic Curves for Type TBH 700 |
pacitor '
= 5 kVAr = 7, 5 kVAr |
|
| Curves for Type TBH 700 | 26 | |
|
Current Ratings for Rubber,P.V.C. or Polyethelene
Conductors and Insulated Cables |
s for Rubber, P.V.C. or Polyethelene
Insulated Cables |
27 |
|
Single-core Arc Welding Cables for Welding Transformers
TBH 250, TBH 400, TBH 700 |
e Welding Cables for Welding Transformers
400, TBH 700 |
28 |
| Connection Diagram Type TBH 250 | gram Type TBH 250 | 30 |
()
Handwelding Transformers TBH 250, TBH 400, TBH 700
General
Ch
C
The TBH series of ESAB welding transformers have been produced after a lengthy period of design and development. The resultant outcome has been a robust but easy-to-handle transformer with excellent welding qualities suitable for operation under the most arduous conditions. The transformers have been built in a modular form which offers the advantage of adapting the unit in total or part to other fields of welding activity should the need arise.
The transformers are air-cooled and are aluminium encased. By using inorganic and highly heat resistant insulation both welding efficiency combined with low weight has been obtained. The transformer windings are also resistant to moisture and acidic fumes and are well-suited for use in tropical conditions. The units are also equipped with a carriage with two rubber wheels and can consequently very easily be moved by hand. A lifting eye is provided for crane lifting. This lifting eye makes it also possible to move the transformer by means of a fork truck.
Welding current adjustment is carried out by a magnetic shunt regulator and the cable connections are made by means of Hameva couplings which ensure excellent connection and also protect against separation by inadvertant straining of the cables by the operator.
TBH 250 Transformer
This handwelding transformer, as is the TBH 400 and TBH 700, has a movable iron core. The core which is spindle-mounted is moved up or down by means of a wheel on the top of the housing, thus altering the circuit inductance and thus the welding current. The desired amperage is easily read from a scale placed on the front of the transformer.
The TBH 250 is supplied for 220 V, 380 V, 415 V, 500 V, 50 cycles and for 220 V, 440, 550, 60 cycles. Refer to "Specification" p. 15
The TBH 250 handwelding transformer can be supplied with the following additional equipment.
Mains Switch
For switching "ON/OFF" the transformer can be provided with a switch which is marked 0-1 and situated in the middle of the front plate.
( )
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Safety Unit (42 V)
When the TBH 250 is equipped with this unit it requires an auxiliary housing. The housing is the same as required when the transformer is fitted with capacitors. This safety unit should be used when welding in very narrow and confined spaces with little ventilation. This is generally compulsory for protection of the welder. The 42 V safety unit lowers the open-circuit voltage from 70 V to 42 V. The use of this unit in no way affects the standard of welding.
To show that the safety unit is functioning during operation (i.e. welding) a pilot lamp glows. This is at a voltage over 42 V no-load. Should a fault occur in the safety unit and the operator removes the electrode tip from the workpiece (i.e. not welding) the lamp will continue to glow. Under normal circumstances the lamp will go out informing him that the unit is operating and the open-circuit voltage of the transformer has been reduced to 42 V.
Power Factor Correction
The TBH 250 can come equipped with either a 2.5 kVAr or a 5 kVAr capacitor.
There are two reasons why welding transformers may require capacitors.
- (a) To keep the cable diameters and the fuse sizes small.
- (b) When there is a demand for a certain output factor (cos $\varphi$).
How the condensors influence the cable fuse and sizes can be seen in the table provided on page 16. In this table the values of the output factor (cos4) are also indicated. Note that these values refer to continuous load.
Capacitors
When using the TBH 250 with a 380 V capacitor the transformer can be connected to:-
380 V, 415 V, 500 V
This 380 V capacitor must always be connected to terminals S7 and S9 on the connection block inside the transformer. See Wiring Diagram on p. 34
Refer to the separate spare pants list for full details of spare parts obtainable.
TBH 400 and 700 Transformers
On the standard versions, as is the TBH 250, the welding current is adjusted by means of a handwheel on the top of the transformer housing. The required amperage can be easily read on from the scale on the front of the unit. These standard transformers can be supplied with the following ancillary equipment, listed below.
The TBH 400 and TBH 700 can be connected to the following mains networks, (see also "Specification" on 18 and 23).
- Type A: 380 V, 500 V, 50 cycles. This unit can also be connected to a 60 cycles mains. This type is then designated Type "E", 440 V and 550 V, 60 cycles.
- (`)
- Type B: 220 V, 380 V, 440 V, 50 cycles is the same as Type D, 220 V, 380 V, 440 V, 60 cycles. This means that a 50 cycles transformer can be connected to a 60 cycles mains.
Mains Switch
The transformers can be switched "ON/OFF" by means of a switch which is marked 0-1 and which can be fitted in the centre of the front plate.
Servomotor
This motor, with pushbuttons for adjustment of the welding current can be easily built into the transformers without any alteration in the standard housing. A three-pole socket for cable connection of a remote control is also included with this equipment.
Remote Control
For remote control of the welding current a cable is connected by means of a 3-pole plug and socket. The drive consists of a gear and a 42 V servo D.C. motor with a power rating of 55 W. The ratio of the gear is 55:1. By means of this motor, the drive spindle with iron core can be moved, altering the circuit inductance, and thus the welding current value.
Remote Control Cable
() A cable with socket and spring-loaded toggle switch can be delivered; the cable to any desired length. The switch is designated + and - and resets automatically to 0-position. See Fig. 7
Direct Remote Control
If the units are equipped with this type of remote control a larger housing is necessary as a transductor and extra relay are necessary. This remote control which is patented by ESAB makes it possible to adjust the welding current without resorting to a separate control cable or switch. The electrical variation necessary for the alteration and adjustment of current is transmitted via the welding cable itself. This control equipment consists of a tube or rod of bakelite which contains a 15 ohm resistance and a silicon diode. When the rod is held against the workpiece and the welding electrode (Fig. 8) an alteration in current occurs; this never exceeds 2A. The value of this current is determined by the resistance imposed by this special circuit and the current in the cable. The current direction is dependent in which direction the rod is held. This directional current which is fed via the transductor operates a relay. This relay starts the servomotor which shaft drives the core in the correct direction and automatically adjusts the welding current. The motor runs as the rod is held in position and current flows. So the operator can check which direction the current is intended to flow the control rod is marked + on one end and - on the other. For example if the workpiece is touched by the - (negative) end of the rod and the welding electrode touches the + (positive) end the iron core moves upwards, i, e, the welding current increases and if the rod is reversed, vice versa.
Safety Unit (42 V)
Should the TBH 400 and 700 be equipped with this unit a bigger housing is necessary. The 42 V safety unit should be used when welding in very narrow and confined spaces with little ventilation. This is generally compulsory for protection of the welder. The 42 V safety unit lowers the open-circuit voltage from 70 V to 42 V. The use of this unit in no way affects the standard of welding. The safety pilot lamp operates in the manner described for the TBH 250 on p. 4.
Protection
If requested the TBH 400 and 700 can be supplied with protection for the remote control switch "ON/OFF". This is especially important when the transformers are placed so that they are difficult to reach.
Power Factor Correction
The TBH 400 and 700 welding transformers can be equipped either with a 2.5 kVAr, 5 kVAr and 7.5 kVAr capacitor but the housing must be enlarged. As for the TBH 250 there are two reasons why transformers are equipped with capacitors.
- (1) To keep the cable diameter and the fuse sizes small.
- (2) When the electricity authorities demand that the output factor (cos$\varP$) is above a certain limit.
How the capacitors affect the cable diameters and the fuse sizes can be seen from the table on pages 20 and 25. Also from these tables the value of the output factors can be seen. These values refer to continuous load.
Using a normal duty cycle of approx. 30% the cos value as an average amounts on a TBH 700 transformer using a 7.5 kVAr capacitor and a TBH 400 with 5 kVAr capacitor to approximately 0.9.
When using TBH 400 or TBH 700 Type B with 220 V capacitor(s) as listed under Technical Data these can be connected to 220 V, 380 V, 440 V. The capacitor still provides the same power factor. The 220 V capacitor(s) must be connected to terminals 1 and 3 on the connection block in the transformer (See Wiring Diagram p. 31).
If using a TBH 400 or TBH 700 Type A as listed under Technical Data with 380 V capacitor(s) the transformer(s) can be connected to 500 V; 380 V capacitor(s) should also be connected to terminals 1 and 3 on the connection block (See Wiring Diagram p. 30).
N.B. When using any of the above transformers with a Safety Unit and capacitor(s) the voltage of the capacitor(s) must match the mains voltage or higher.
۲
Combined Transformers
Similar transformers can be built together to form a single unit. Such a unit has the advantage of being connectable to a 3-phase mains. See Fig. 11
Combined banks of transformers of the TBH 400 and 700 types, can be supplied with a servomotor for remote control for current adjustment. From a small control box, (see Fig. 13), the required current values for the weld to be undertaken can be finely adjusted by means of pushbuttons. The switching "ON/OFF" can also be made from this control box.
Fig. 12 shows the three servomotors of a multi-transformer unit and the connection clamps for the three mains phases.
Maintenance
(TBH 250, 400 and 700 Maintenance
The TBH transformers are designed to give consistent operation in conjunction with safe operation. A yearly check is sufficient and they virtually require no maintenance. They are naturally superior to rotating welding current sources as they do not consist of moving parts with their consequent wear. Therefore both servicing and expenditure are low. If for any reason spare parts are needed they can at any time be ordered by using the order numbers stated in the Spare Parts List. By using the correct numbers you will ensure a fast delivery of the spares you require.
Yearly Maintenance
()
- 1. Clean the transformer by removing accumulated dust by blowing with compressed air. This can be done more frequently if the conditions warrant it.
- 2. Clean the shaft and chain (i.e. servomotor control) with petrol or other agent. Grease with Industrial No Melt Grease, BINM (delivered by Bardahl), or a grease of equivalent type.
-
3. Check all electrical connections and cables with their connection for wear and fraving.
- 4. When the transformers are frequently moved from location to location grease the bearings of the carriage wheels with ball bearing grease.
- 5. Check fixing screws on the housing and aluminium casing are tight.
- N.B. At three yearly intervals fill up the shaft bearing of the core shaft and the gear of the servomotor with BINM hrease.
Fig. 1. Handwelding Transformer Type TBH 250,
Fig. 2. Inside of a handwelding transformer Type TBH 250 equipped with primary switch.
Fig. 3. Handwelding Transformer Type TBH 400.
Fig. 4. Inside of a handwelding transformer Type TBH 400 equipped with capacitors; con-- trol motor; remote control device and primary switch.
Fig. 5. Handwelding Transformer Type TBH 700.
Fig. 6. Inside of a handwelding transformer Type TBH 700 equipped with capacitors; control motor; remote control device and primary switch.
ig.8a. Remote control circuit for Type TBH 400 and TBH 700 Transformers.
Fig. 9. 42 V Safety Unit for TBH Transformers.
Fig. 9a. Transformer with capacitors equipped with a 42 V Safety Unit.
( :
Fig. 9b. Transformer without capacitor equipped with a 42 V Safety Unit.
Fig. 11. Multi-transformer TBH 700.
Fig. 12. Inside of a Multi-transformer .
Fig. 13. Remote control box for Multi-transformer.
SPECIFICATION TBH 250, TBH 400 and TBH 700
Ĺ
Specification TBH 250
1. Mains Connection
Voltage: 220/380/415/500 V 50 cycles 220/440/550 V 60 cycles Welding Current: 50/29/25/22 A (without capacitor) Efficiency: 11 kVA
2. Maximum Load
At 50 cycles 150 Amps, 28 - 58 V, 100% Duty Cycle 200 ", 30 - 50 V, 60% """ 250 ", 33 - 40 V, 35% """
At 60 cycles 150 Amps, 28 - 53 V, 100% Duty Cycle 200 '', 30 - 40 V, 60% '' '' 250 '', 24 V, 35% '' ''
3. Welding Current Range
40 Amps, (23 V) to 260 Amps, (37 V). Refer to the diagrams on page 17.
4. Open-circuit Voltage
69 V (with 440 V and 550, 60 c/s, 78 V).
5. Power Dissipation
100 W.
6. Efficiency
80 - 85%.
7. Measurements and Weight
Width 17 1/2 ins. (446 mm) Depth 11 1/2 ins. (545 mm) Height 30 7/8 ins. (784 mm) Weight 220 lbs (100 kgs)
N.B. The measurements are inclusive of carriage and lifting eye.
Primary Current and cos of for Type TBH 250
Without Capacitor
| Prim | ary Current a | t different Lo | ads | |||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 150A - 28V | 250A - | 33∨ | Fuses | Cable | |||
| V | I 1 (A) | cos 4 | I 1 (A) | cos₽ | А |
2
|
||
| 220 | 50 | 0.45 | 83 | 0.56 | 63 | 16 | ||
| 380 | 29 | 0.45 | 48 | 0.56 | 35 | 10 | ||
| 440 | 25 | 0.45 | 42 | 0.56 | 25 | 6 | ||
| 500 | 22 | 0.45 | 37 | 0.56 | 25 | 6 | ||
Capacitor = 2.5 kVAr
| Primai | y Current at | different loa | ds | |||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 150A - 28V | 250A - | 33V | Fuses | Cable | |||
| V | 1 1 (A) | cos q | 1 1 (A) | cosψ | А | mm 2 | ||
| 220 | 41 | 0.56 | 73 | 0.64 | 63 | 16 | ||
| 380 | 24 | 0.56 | 43 | 0.64 | 25 | 6 | ||
| 440 | 21 | 0.56 | 37 | 0.64 | 25 | 6 | ||
| 500 | 18 | 0.56 | 32 | 0.64 | 20 | 4 | ||
Capacitor = 5 kVAr
| Prim | ||||||
|---|---|---|---|---|---|---|
| Primary Voltage | 150A - | - 28V | 250A - | 33V | Fuses | Cable |
| v | i, (A) | cosq | 1, (A) | cos 4 | А | 2 |
| 0.70 | 15 | 0.70 | 10 | |||
| 220 | 32 | 0.72 | 60 | 0.72 | 35 | |
| 380 | 19 | 0.72 | 38 | 0.72 | 20 | 4 |
| 440 | 16 | 0.72 | 33 | 0.72 | 20 | 4 |
| 500 | 14 | 0.72 | 29 | 0.72 | 16 | 2.5 |
Specification TBH 400
1. Mains Connection
-
Version A 380/500 V, 50 c/s, single-phase. "B 220/380/440 V, 50 c/s, single-phase. "C 220 V, 400 V, 415 V, 440 V, 50 cycles single-phase. "D 220/380/440 V, 60 c/s, single-phase. "E 440/550 V, 60 c/s, single-phase.
2 Maximum Load
| Voncion | Maximum welding current and voltage at:- | |||||||
|---|---|---|---|---|---|---|---|---|
| Version | 100% Duty Cycle | 60% Duty Cycle | 35% Duty Cycle | |||||
|
A and B
C D E |
230 Amps - 60 V.
190 " - 70 V. 230 " - 56 V. 230 " - 60 V. |
300 Amps - 53 V.
250 '' - 60 V. 300 '' - 46 V. 300 '' - 53 V. |
400 Amps - 43 V.
325 " - 42 V. 350 " - 37 V. 400 " - 43 V. |
|||||
3. Welding Current Range
| Version | A and B | 60 | - | 430 | Amps |
|---|---|---|---|---|---|
| 17 | С | 40 | - | 350 | - 11 |
| п | D | 40 | - | 350 | 11 |
| 11 | ы | 60 | _ | 430 | п |
4. Open-circuit Voltage
| Version | ıs A, | B and D | 70 V. |
|---|---|---|---|
| п | Ċ | 85 V. | |
| п | Е | 80 V. |
5. Power Dissipation
135 W
6. Efficiency
84% at 300 Amps on load.
7. Measurements and Weight
| Area with small housing |
21 1/4 ins. x 19 11/16 ins. (540 mm x 500 mm)
23 27/64 ins. x 19 11/16 ins. (595 mm x 500 mm) |
|---|---|
| Height | 39 39/64 ins. (1025 mm) |
| Weight | 300 lbs (150 kgs) |
( ,
Power factor (cos φ) using different sizes of capacitors at different loads
TBH 400
| Weldin | g Current | 100 Amps | 200 Amps | 300 Amps |
|---|---|---|---|---|
| 0 kVAr | 0.37 | 0.50 | 0.57 | |
| Single transformer | 2.5 " | 0.52 | 0.57 | 0.63 |
| Single indistonate | 5 " | 0.79 | 0.67 | 0.69 |
| 7.5 " | 1.0 | 0.79 | 0.76 | |
| Several | 0 kVAr | 0.33 | 0.47 | 0.55 |
| transformers | 2.5 " | 0.66 | 0.62 | 0.66 |
| 50% Duty Cycle | 5 " | +0.98 | 0.86 | 0,80 |
| Several | 0 kVAr | 0,30 | 0.44 | 0.53 |
| transformers | 2.5 " | 0.85 | 0,69 | 0,70 |
| 33% Duty Cycle | 5 " | +0.47 | 1.0 | 0.92 |
. )
Primary Current and cos $\varphi$ for Type TBH 400
Without Capacitor
| Primary C | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 230 A - | - 31 V | 300 A | - 35 V | 400 A · | - 40 V | Fuses | Cable |
| V | i 1 (A) | cos 4 | ו ן (A) | cosΨ | 1, (A) | cos IP | А |
2
mm |
| 220 | 76 | 0.51 | 99 | 0.57 | 135 | 0.66 | 80 | 25 |
| 380 | 44 | 0.51 | 58 | 0.57 | 78 | 0.66 | 63 | 16 |
| 415 | 48 | 0.43 | 63 | 0.48 | 63 | 16 | ||
| 440 | 38 | 0.51 | 51 | 0.57 | 67 | 0.66 | 36 | 10 |
| 500-550 | 33 | 0.51 | 44 | 0.57 | 60 | 0.66 | 36 | 10 |
Capacitor = 2.5 kVAr
| Primary Voltage |
Primary Co
230 A - 31 V |
orrent at c
300 A |
lifferent loo
- 35 V |
ads
400 A |
- 40 V | Fuses | Cable | |
|---|---|---|---|---|---|---|---|---|
| · · | ι 1 (A) | cosφ | 1 1 (A) | cosψ 1 | I 1 (A) | cos₽ 1 | А | ກາກົ |
| 220 | 68 | 0.57 | 93 | 0.62 | 128 | 0.70 | 80 | 25 |
| 380 | 40 | 0.57 | 53 | 0.63 | 72 | 0.71 | 63 | 16 |
| 415 | 42 | 0.50 | 57 | 0.53 | 63 | 16 | ||
| 440 | 34 | 0.57 | 46 | 0.63 | 63 | 0,71 | 36 | 10 |
| 500-550 | 30 | 0.57 | 40 | 0.63 | 55 | 0.71 | 36 | 10 |
Capacitor = 5 kVAr
| Primary C | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 230 A - | · 31 V | 300 A | - 35 V | 400 A | - 40 V | Fuses | Cable |
| V | I, (A) | cos | ۱ ۱ (A) | cos 1 | I, (A) | cos 1 | А | 2 |
| 220 | 64 | 0.61 | 90 | 0.67 | 125 | 0.70 | 80 | 16 |
| 380 | 35 | 0.65 | 48 | 0.68 | 68 | 0.74 | 36 | 10 |
| 415 | 38 | 0.57 | 51 | 0.57 | 63 | 10 | ||
| 440 | 30 | 0.65 | 44 | 0.68 | 59 | 0.74 | 36 | 10 |
| 500-550 | 27 | 0.65 | 37 | 0.68 | 52 | 0.74 | 36 | 10 |
Capacitor = 7.5 kVAr
| Primary Current at different loads | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 230 A - | 31 V | 300 A | - 35 V | 400 A · | • 40 V | Fuses | Cable |
| і , (А) | cos φ 1 | ו ן (A) | cos q | 1 (A) | cos$ | А |
2
|
|
| 220 | 56 | 0.69 | 79 | 0.72 | 120 | 0.77 | 63 | 16 |
| 380 | 31 | 0.74 | 44 | 0.75 | 64 | 0.80 | 36 | 10 |
| 415 | 35 | 0.64 | 47 | 0.64 | 36 | 10 | ||
| 440 | 26 | 0.74 | 38 | 0.75 | 58 | 0.80 | 36 | 6 |
| 500-550 | 24 | 0.74 | 34 | 0.75 | 4 49 | 0,80 | 25 | 6 |
Primary Current and Power Factor for various condensor capacities for Type TBH 400
Specification TBH 700
1. Mains Connection
-
-380/500 V, 50 c/s single-phase 220/380/440 V, 50 c/s single-phase 415 V, 50 c/s single-phase 220/380/440 V, 60 c/s single-phase 440/550 V, 60 c/s single-phase Version A
- R
- п
- Ц Т
2. Maximum Load
| Version | Maximum welding current and voltage at | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| V et 81011 | 100% Duty Cycle | 60% Duty Cycle | 35% Duty Cycle | ||||||
|
A and B
C D E |
425 Amps - 57 V
350 " - 70 V 425 " - 56 V 425 " - 57 V |
550 Amps ~ 51 V
450 '' ~ 60 V 550 '' ~ 48 V 550 '' ~ 31 V |
700 Amps - 42 V
600 '' - 42 V 630 '' - 40 V 700 '' - 42 V |
||||||
3. Welding Current Range
| Version | A and B | 100 - 730 Amps |
|---|---|---|
| н | С | 85 - 630 " |
| 11 | D | 85 - 630 " |
| п | Э | 100 - 730 " |
4. Open-circuit Voltage
| Version | A, B and D | 70 V |
|---|---|---|
| 11 | C | 85 V |
| 11 | न | 80 V |
5. Power Dissipation
200 W.
5. Efficiency
88% at 425 Amps on load
6. Measurements and Weight
| Floor area for small housing |
25 ins. x 21 1/4 ins. (635 x 540 mm).
26 1/2 ins. x 21 1/4 ins. (675 x 540 mm). |
|---|---|
| Height | 40 23/64 ins. (1025 mm). |
| Weight | 506 lbs (230 kgs). |
Power factor (cos \varphi) using different sizes of capacitors at different loads
| Welding Cu | rrent | 300 A | 400 A | 500 A |
|---|---|---|---|---|
| . | 0 kVAr | 0.50 | 0.61 | 0.61 |
| Single Transformer | 5 " | 0.60 | 0.69 | 0.67 |
| ·7,5 " | 0.67 | 0.73 | 0.70 | |
| Several | 0 kVAr | 0.46 | 0.57 | 0.57 |
| Transformers | 5 " | 0.67 | 0.73 | 0.70 |
| 50% Duty Cycle | 7.5 " | 0.80 | 0.83 | 0.78 |
| Several | 0 " | 0.42 | 0.54 | 0.54 |
| Transformers | 5 " | 0.73 | 0.78 | 0.76 |
| 33% Duty Cycle | 7.5 " | 0.94 | 0.92 | 0.86 |
( ·
TBH 700
Primary Current and cos \u03c6 for Type TBH 700
Without Capacitor
| Primary Current at different loads | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 425 A - 40 V | 550 A - 40 V | 700 A - 40 V | Fuses | Cable | |||
| V | ۱ ۱ (A) | cos 4 | I 1 (A) | cos ψ 1 | ۱ ۱ (A) | cos₽₁ | А |
2
|
|
220
380 415 440 500-550 |
146
84 90 73 64 |
0.62
0.62 0.53 0.62 0.62 |
189
109 117 94 83 |
0.62
0.62 0.53 0.62 0.62 |
240
138 120 105 |
0.62
0.62 0.62 0.62 |
160
100 100 80 80 |
70
25 25 25 25 25 |
Capacitor = 5 kVAr
| Primary Cu | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 425 A - 40 V | 550 A - 40 V | 700 A - 40 V | Fuses | Cable | |||
| V | ן (A) | cos 41 | I 1 (A) | cosφ 1 | I 1 (А) | cos Ψ 1 | А |
2
|
| 220 | 123 | 0.69 | 163 | 0.67 | 210 | 0.66 | 125 | 50 |
| 380 | 70 | 0.70 | 93 | 0.68 | 120 | 0,67 | 80 | 25 |
| 415 | 76 | 0.60 | 104 | 0.59 | 80 | 16 | ||
| 440 | 60 | 0.70 | 80 | 86.0 | 104 | 0.67 | 63 | 16 |
| 500-550 | 53 | 0.70 | 71 | 0.68 | 92 | 0.67 | 63 | 16 |
( )
(
Capacitor = 7.5 kVAr
| Primary Cu | ||||||||
|---|---|---|---|---|---|---|---|---|
| Primary Voltage | 425 A - 40 V | 550 A - 40 ∨ | 700 A - 40 V | Fuses | Cable | |||
| V | I 1 (A) | cosΨ | 1 1 (A) | cosψ | ۱ ۱ (A) | cos q | A . |
2
mm 2 |
| 220 | 116 | 0.72 | 158 | 0.68 | 203 | 0.68 | 125 | 35 |
| 380 | 65 | 0.75 | 90 | 0.71 | 115 | 0.70 | 80 | 16 |
| 415 | 71 | 0.65 | 96 | 0.62 | 80 | 16 | ||
| 440 | 56 | 0.75 | 77 | 0.71 | 100 | 0.70 | 63 | 16 |
| 500-550 | 50 | 0.75 | 68 | 0.71 | 88 | 0.70 | 63 | 16 |
ه آ 8 Ę. SEN 8301 8 õ 2 8 Characteristic Curves for Type TBH 700 cose at 7.5 kVAr cos de at 0 kVAI .8 200 00 1 . 00 - 02 00 ì 52 Į | | ់ л cos ф ۲ ب 0,5 --------------------------------------1 120 l õ 80 8 न २ 20 20
connected into a Aains Connection 5 S S ß õ 50 50 150 150 lug in socket. Vominal Voltage ব 4.B. Must be Zo. of oles а 4 4 a 4,6 ۳, 4 4 3,4 :00 <. voltage of 750 V/ 1000 V. nsulated cores vith a nominal 2,3,4 × 1.5 Heavy Rubber 4 × 70 2,3,4 × 4 2,3,4 × 6 4 × 10 4 × 16 t x 25 4 × 35 4 × 50 ?//4 × 35 No. of cable cores multiplied oy cross-sectional area Cables ,2,3,4,5 × 1.5 ,2,3,4,5 × 2.5 Voltage of 400 V. ,3,4,5 × 4 l × 35 I × 50 1 × 70 ,3,4,5 × 6 1,4 × 10 1,4 × 16 ,4 × 25 2//1 × 35 nsulated Cores Normal Rubber vith a normal which limits values given Fuses in series with other Nominal Current for overload protection Highest Permissable 2 អ្ល ប្ល ß 8 8 60 0 250 315 ∢ 4 n column 11 other than in column 4 for fuse arrangements Highest Permissable Nominal Current 2 • õ S 35 63 8 8 25 ô 200 ∢ Highest Permissable Continous Current 4 20 27 ж 51 2 96 120 155 195 240 ∢ 2 Cross-sectional , mm 2 ς, Γ Area of Conductor 2.5 2///35 4 $ 0 20 R 16 25 35
Current Ratings for Rubber, P.V.C. or Polyethelene Conductors and Insulated Cables
27
witchbox
2//4 × 50
2//1
ŝ
280
2//50
315
325
2//70
2//4 × 70
0/ × 1//2
Single-core Arc Welding Cables for Welding Transformers TBH 250, TBH 400, TBH 700
| Transformer |
Cable Cross-sectional
Area |
|---|---|
| ТВН 250 | 35 mm 2 |
| TBH 400 | 50 mm 2 |
| твн 700 | 95 mm 2 |
N.B. Cross-sectional area is same irrespective of cable lengths.
CONNECTION DIAGRAM
( )
()
CONNECTION DIAGRAM TYPE TBH 250
Part List: Transformer, Insulator, Capacitor, Connection terminal
220 V condensors to be connected to S 7 and S 8 380 V condensors to be connected to S 7 and S 9
CONNECTION DIAGRAM TYPE TBH 400 AND 700 Type A 380/500 V, 50 c/s Type E 440/550 V, 50 c/s
Part List: Transformer, Insulator, Condensor, Connection Terminal
A3i
()
()
500 V 50 c/s condensors to be connected to 1 and 3 for a mains voltage 60 c/s
380 V 50 c/s condensors to be connected to 1 and 3 for a mains voltage of 50 and 60 c/s
CONNECTION DIAGRAM TYPE TBH 400 AND 700 Type B 220/380/440 V, 50 c/s Type C 220/400/415/440 V, 50 c/s Type D 220/380/440 V, 60 c/s
Part List: Transformer, Insulator, Capacitor, Connection terminal
220 V 50 c/s condensors to be connected between 1 and 3 for 220 V 50 c/s and 60 c/s Mains Network
380 V 50 c/s condensors to be connected between 1 and 2 for 380 V, 415 V 50 c/s Mains Network
500 V 50 c/s condensors to be connected between 1 and 4 for 440 V 60 c/s Mains Network
CONNECTION DIAGRAM TYPE TBH 400 AND 700
Type A 380/500 V, 50 c/s Type E 440/550 V, 50 c/s
500 V 50 c/s condensors to be connected to 1 and 5 for a mains voltage 500 V 50 c/s, 440 V 60 c/s
500 V 50 c/s condensors to be connected to 1 and 3 for a mains voltage 550 V 60 c/s
380 V 50 c/s condensors to be connected to 1 and 3 for a mains voltage of 50 and 60 c/s
CONNECTION DIAGRAM TYPE TBH 400 AND 700 Type B 220/380/440 V, 50 c/s Type C 220/400/415/440 V, 50 c/s Type D 220/380/440 V, 60 c/s
Part List: Transformer, Insulator, Capacitor, Limit Switch, Limit Switch, Motor, Pushbutton, Pushbutton, Socket for remote control, Operation transformer, Connection terminal.
220 V 50 c/s condensors to be connected to 1 and 3 for 220 V 50 c/s and 60 c/s Mains Voltage
380 V 50 c/s condensors to be connected to 1 and 2 for 380 V, 415 V 50 c/s 500 V 50 c/s condensors to be connected to 1 and 4 for 440 V 60 c/s Mains Voltage
CONNECTION
DIAGRAM
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