ESAB TBH 400, TBH 700 Instruction manual

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Instruction Book

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The TBH 400 and TBH 700 are single operator transformers intended for handwelding. They are of a rugged construction, are easy to handle and have excellent welding characteristics.

The main feature of the two transformers is that the welding current is steplessly set by altering the magnetic field flux by a leakage core. This core is moved manually or by means of a motor.

Three motor-operated transformers can be assembled into a multi-transformer. This multi-type transformer is then designated TBH 400/3 and TBH 700/3.

The TBH 400 and TBH 700 transformers are supplied for two voltages:

1. 380/500 V, 50 Hz – 440/550 V, 60 Hz 2. 220/380/440 V, 50 – 60 Hz

Based on these voltages the following basic models are available. All models can be complemented with a component system of accessories.

	Voltage	Order No.
TBH 400 Hand Operated	1	158384-880
TBH 400 Hand Operated	2	158384-891
TBH 400 Motor Operated	1	158384-884
TBH 400 Motor Operated	2	158384-895
TBH 700 Hand Operated	1	158383-880
TBH 700 Hand Operated	2	158383-891
TBH 700 Motor Operated	1	158383-884
TBH 700 Motor Operated	2	158383-895
TBH 400/3 Multi-transformer	1	159456-880
TBH 400/3 Multi-transformer	2	159456-889
TBH 700/3 Multi-transformer	1	159455-880
TBH 700/3 Multi-transformer	2	159455-889

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1.1 TBH 400 and TBH 700 (Hand Operated)

See Figs 1 and 2 and Diagrams Figs 17 and 20.

Both transformers are built from a system of components. All components are easily accessible for both service and reconnection. The transformers can easily be fitted with complementary components.

The transformer unit is a single-phase transformer connected between two phases. The supply cable is connected to a coupling plinth, which can be coupled up for various mains voltages. From this coupling plinth the current passes via switch A2'to the primary side of the main transformer A1. From the secondary side of the main transformer A1 the current developed is taken and then led to the welding current outlets to which welding and return cables are connected.

The welding current is steplessly set by means of a leakage core which is moved in or out. The amount of leakage depends on the position of the core in the magnetic field. In turn, this position affects the magnetic field strength on the secondary side and consequently the secondary current, i.e. the welding current. This leakage core is lifted or lowered by means of a worm drive turned by a handwheel mounted on the top casing (Fig. 1). The welding current set (approximate value) can be read on an easily discernible scale (Fig. 1) on the front of the welding transformer.

The transformer is contained in a strong steel sheet cabinet. The cabinet is of an attractive design, has easily removable panels and is designed so that it can encase any accessory equipment.

Two solid rubber-tyred wheels and a handlebar makes for easy movement of the unit. Also included is a large lifting eye allowing ready transport by a crane or forklift truck.

Complementary equipment is available as follows:

1. Limiter for Open-circuit Voltage.
2. Phase Compensation Capacitor, 5 kVAr, 380 V.
3. Phase Compensation Capacitor, 5 kVAr, 220 V.
4. Phase Compensation Capacitor, 7.5 kVAr, 380 V.
5. Phase Compensation Capacitor, 7.5 kVAr, 220 V.

Refer to heading – 2. Accessories

Fig. 1 TBH 400

Fig. 2 TBH 400 with 7,5 kVAr Phase Compensation Capacitors.

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Fig. 3 TBH 700

Fig. 4 TBH 700 with Remote Control and 7.5 kVAr Phase Compensation Capacitors,

1.2 TBH 400 and TBH 700 (Motor Operated)

See Figs 3, 4 and Diagram Figs 18 and 21.

The leakage core in this type is moved by an electric motor.

The transformer A10 provides an operating voltage of 36 V. The servo motor A6 then obtains its drive voltage via pushbuttons A7, "Increase", and A8 "Decrease". These are situated on the primary side of the transformer and make the motor rotate in either direction dependent on the pushbutton which is pressed. Via a worm gear and a chain drive the leakage core is then moved in or out. The current to the servo motor is automatically broken by contacts A4 and A5 when the core reaches either limit position.

The advantage with the motor-operated model is that the welding current can be remotely set and adjusted from the workpiece during welding. Two types of remote control are offered as accessory components (see under heading - 2, Accessories).

On the front plate of the transformer there is a connection A9 for the cable of the remote control unit.

The following complementary components can be obtained:

1. Remote Control Unit with Separate Cable and Plug.
Built-in Remote Control Unit for Setting from the Workpiece with a Remote Control Rod.
3. Open-circuit Voltage Limiter,
4. Phase Compensation Capacitor, 5 kVAr, 380 V.
5. Phase Compensation Capacitor, 5 kVAr, 220 V.
6. Phase Compensation Capacitor, 7.5 kVAr, 380 V.
7. Phase Compensation Capacitor, 7.5 kVAr, 220 V.

Refer to heading – 2. Accessories.

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1.3 TBH 400 and TBH 700 Multi-transformer

See Figs 5 and 6.

The TBH 400 and the TBH 700 can be obtained in self-contained units of three transformers built in a common cabinet. For shipbuilding and other industries where the transformer often has to be moved and where long connection cables are necessary, the multi-transformer is especially suitable, as only one mains supply cable is necessary. Phase balance is also better for the three-phase supply is more evenly loaded, as each unit is divided over all three phases. Welding current is set by means of remote motor-operated units.

The equipment and its operation is identical to that of the TBH 400 and TBH 700 motor-operated model. However, these multi-transformer types can be equipped with a circuit breaker for the mains voltage. This is of great advantage when the transformers are placed so that they are not easily accessible, e.g. on shelves, frames, etc. For multi-transformers fitted with circuit breakers an operating box is offered as an accessory. This has current positions for all the three contactors and pushbuttons for all the three motor-operated units. The TBH 400 and TBH 700 multi-transformers can be equipped with complementary components of the same type as for motor-operated models.

The components available are as follows:

1. Separate Operating Box for Remote Control and Remote Setting of all Three Transformers.
2. Remote Control with Separate Cable and Plug.
3. Built-in Remote Control Unit for Setting from the Workpiece with a Remote Control Rod.
4. Open-circuit Voltage Limiter.
5. Phase Compensation Capacitor, 7.5 kVAr, 380 V.
6. Phase Compensation Capacitor, 7.5 kVAr, 220 V.

Refer to heading – 2. Accessories.

2. Accessories

All the transformers of this series can easily be equipped with various additonal components. This makes it possible to build a large number of variants which can have remote control, open-circuit limitation, or voltage and phase compensation. The components can be fitted before delivery from the factory, or later by the customer. In the latter case, complete instructions, all attachments and cable connectors are supplied.

The following are the additional components which are available:

Fig. 5 Multi-transformer TBH 700.

Fig. 6 Multi-transformer Interior.

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2.1 Remote Control with Cable

See Figs 7, 18 and 21. Order No.: 4727 088-81.

The remote control consists of a box which has two pushbuttons: "Increase" and "Decrease", 25 m rubber cable with a plug to connect it to the outlet A9 on those transformers, which are motor-operated. The pushbuttons on the box are connected in parallel with pushbuttons A7 and A8 on the transformer and cause the servo motor to rotate in either direction, consequently moving the leakage core in and out thus increasing or decreasing the welding current. This allows the weldor to easily set and adjust the welding current from the workpiece during welding.

Fig. 7 Remote Control, Pushbutton Control Connection Cable and Fuse,

2.2 Built-in Remote Control with Remote Control Rod

See Figs 8, 11 and Diagram Fig. 23. Order No.: 158400-880.

This component is designed for the TBH transformer motor-operated units. With long distances between the transformer and workpiece the welding current can in an easy and speedy manner be set with the built-in remote control (ESAB patent pending). There is no requirement for a special operating cable. Welding current is set or adjusted by means of a remote control rod, which contains a resistor and a silicon diode. When this rod is placed between the workniece and the welding cable (see fig 8) a control current flows through the welding cable the strength of which depends on the resistance. The direction of the control current depends in which direction the rod is held and placed. This control current activates a transductor unit, which via transmitters and relays causes the servo motor to rotate in one direction or the other varying the leakage field and thus the welding current.

The servo motor works as long as operating current flows through the control rod, and, consequently, by reversing this between the workpiece and electrode welding current can be increased or decreased. The ends of the rod are marked with plus and minus symbols. When the plus end is placed towards the electrode, welding current is increased. When the negative end is set towards the electrode welding current is then decreased.

When ordering the rod only, the order number is 4923 000-80.

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2. Accessories

2.3 Voltage Limiting Unit

See Fig. 9 and Diagram Fig. 24. Order No.: 0304 649-80

The voltage limiting unit is especially suitable when welding in confined, damp or warm places, where a voltage of over 50 V is considered to be excessive and possibly dangerous, and where special measures for weldor protection are laid down.

The voltage limiting unit automatically reduces open-circuit voltage to 42 V without any deterioration in the welding characteristics of the transformer. Laid down instructions prescribe that the voltage limitation unit is easily observed to be in operation. This requirement is filled by the use of an indicating lamp, which is on during welding and which goes out as soon as welding stops. If the lamp is on with an open-circuit, i.e. not welding, a fault has developed in the unit. The system ensures that if the limiting unit does not work, it will not go unnoticed by the weldor.

2.4 Remote Control Box for Multi-transformers

See Fig. 10. Order No.: 5759 017-80.

For multi-transformers with a contact operated ON-OFF switch, there is a separate control box, which is useful when the multi-transformer unit is placed on shelves, in a frame, or where it is not easily accessible.

This control box has a current switch for switching ON and OFF each of the three transformers and pushbuttons for all the three motor-operated drive units for the welding current setting.

2.5 Phase Compensation Capacitors

See Fig. 11 and Diagram Figs 17, 18 and 20, 21.

Order Nos:

5 kVAr, 380 V	158395-880
7.5 kVAr, 380 V	158395-881
5 kVAr, 220 V	158395-882
7.5 kVAr. 220 V	158395-883

Transformers can be fitted with capacitors for phase compensation:

a) to reduce the cable area and fuse size, or,

b) if the electricity supplier requires the power factor (cos \varphi) to be held within a certain value.

From the curves and tables under heading – 3. Technical Data, it can be seen how power factor affects the cable area and the fuse size using different capacitor values for specific loads.

All basic TBH transformers can be equipped with capacitors of 5 and 7.5 kVAr, except the multi-transformers. These can only be fitted with capacitors of 7.5 kVAr.

Fig. 9 Limiter for Open-circuit Voltage.

Fig. 10 Multi-transformer Control Box,

Fig. 11 TBH Transformer with built-in Remote Control and Phase Compensation Capacitors,

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3. Technical Data

Fig. 13 Static Characteristic 22013801440 V. 50 Hz

Fig. 14 Efficiency and Power Factor 380 V. SO Hz.

3.1 Handwelding Transformer TBH 400

Voltage: 1) 380/500 V, 50 Hz – 440/550 V, 60 Hz 2) 220/380/440 V, 50 and 60 Hz

Operating Range:

60 A, 21 V – 400 A, 36 V

Duty Cycle:

100 % 230 A, 29 V

60 % 300 A, 32 V

35 % 400 A, 36 V

Cross-sectional Area of Welding and Return Cables: 50 mm²

Open-circuit Voltage: 64 - 70 V 74 - 83 V on connection to 440 V, 60 Hz 72 - 79 V on connection to 550 V, 60 Hz Power Dissipation (off-load): 250 W (without capacitors) Dimensions: Height = 1035 mm Breadth = 550 mm Depth = 685 mm Weight: 153 kg

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Primary	Frequency	Canacitor	Danuar	Primary Current for Various Permitted Loads						Stow-blow	Connece
Voltage Voltage		Capacitor	rowei	Intermittency: 100 % 230 A - 29 V		Intermittency: 60 % 300 A - 32 V		Intermittency: 35 % 400 A - 36 V		Fuses	tion Cable
v	Hz	kVAr	kVA	А	cosφ	A	cosφ	А	cos φ	A	mm ²
380 500 440 550	50 50 60 60	Without	17	44 34 44 34	0.47	58 44 58 44	0.53	77 58 77 58	0.60	50 35 50 35	3 x 16 3 x 10 3 x 16 3 x 10
380 500 440 550	50 50 60 60	5	12.5	23 25 35 22	0.63	47 36 49 34	0,62	68 51 68 42	0.68	35 25 35 25	3 x 10 3 x 6 3 x 10 3 x 6
380 500 440 550	50 50 60 60	7.5	11	28 21 30 19	0.74	43 32 44 40	0.69	63 48 64 38	0.73	35 25 35 25	3 x 10 3 x 6 3 x 10 3 x 6

TBH 400 Mains Connection Voltage 1 (380/500 V, 50 Hz-440/550 V, 60 Hz)

TBH 400 Mains Connection Voltage 2 (220/380/440 V, 50-60 Hz)

Primary	Frequency	Capacitor	Power	Primary Current for Various Permitted Loads						Slow-blow	Connec-
Voltage	I requency	cupitorior	10wei	Intermitter 230 A	ncy: 100 % - 29 V	Intermitte 300 A -	ncy: 60 % - 32 V	Intermitto 400 A	ency: 35 % 36 V	Fuses	tion Cable
v	Hz	kVAr	kVA	A	cos φ	А	cos φ	А	cos φ	А	mm ²
220 380 440 220 440	50 50 50 60 60	Without	17	77 44 38.5 77 38.5	0.48	102 58 51 102 51	0.53	134 77 67 134 67	0.60	80 50 50 80 50	3 x 25 3 x 16 3 x 16 3 x 25 3 x 16
220 380 440 220 440	50 50 50 60 60	5	13	57 33 28.5 53 26.5	0.63	82 47 41 80 40	0,61	117 68 58.5 113 56.5	0.68	63 35 35 63 35	3 x 16 3 x 10 3 x 10 3 x 16 3 x 10
220 380 440 220 440	50 50 50 60 60	7.5	11	49 28 24.5 45 22.5	0.75	74 43 37 68 34	0.69	110 63 55 106 53	0.74	50 35 25 50 25	3 x 16 3 x 10 3 x 6 3 x 16 3 x 6

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3. Technical Data

Fig. 15 Static Characteristic 220/380/440 V, 50 Hz.

3.2 Handwelding Transformer TBH 700	Open-circuit Voltage:
Voltage:	65 – 70 V
1) 380/500 V, 50 Hz – 440/550 V, 60 Hz	74 – 81 V on connection to 440 V, 60 Hz, Voltage 1
2) 220/380/440 V, 50 - 60 Hz	70 – 77 V on connection to 550 V, 60 Hz, Voltage 1
Operating Range:	Power Dissipation (off-load):
100 A, 24 V – 730 A, 44 V	400 W (without capacitors)
Duty Cycle:	Dimensions:
100 % 420 A, 37 V	Height = 1035 mm
60 % 550 A, 42 V	Breadth = 550 mm
35 % 700 A, 44 V	Depth = 685 mm
Cross-sectional Area of	Weight:
Welding and Return Cables:	240 kg
95 mm ²

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Primary	Frequency	Canacitor	Power	Primary Current for Various Permitted Loads						Stow-blow	Connece
Voltage		Cup at the		Intermittency: 100 % 425 A - 37 V		Intermittency: 60 % 550 A – 42 V		Intermittency: 35 % 700 A - 44 V		Fuses	tion Cable
v	Hz	kVAr	kVA	A	cos φ	А	cos φ	А	cos φ	А	nım ²
380 500 440 550	50 50 60 60	Without	32	84 64 84 64	0.57	108 82 108 82	0.64	140 106 140 106	0.67	80 63 80 63	3 x 25 3 x 16 3 x 25 3 x 16
380 500 440 550	50 50 60 60	5	28	73 60 76 59	0.64	98 78 101 77	0.71	131 103 133 102	0.74	80 63 80 63	3 x 25 3 x 16 3 x 25 3 x 16
380 500 440 550	50 50 60 60	7.5	27	68 58 73 57	0.69	94 76 97 75	0.75	127 101 130 99	0.74	63 63 80 63	3 x 16 3 x 16 3 x 25 3 x 16

TBH 700 Mains Connection Voltage 1 (380/500 V, 50 Hz-440/550 V, 60 Hz)

TBH 700 Mains Connection Voltage 2 (220/380/440 V, 50-60 Hz)

Primary	Frequency	Capacitor	Power	Primary Current for Various Permitted Loads						Slow-blow	Connec-
Voltage		-		Intermitte 425 A	ency: 100 % - 37 V	Intermitte 550 A -	ncy: 60 % 42 V	Intermitte 700 A	ency: 35 % – 44 V	Fuses	tion Cable
V	Hỵ	kVAr	kVA	A	cos φ	А	cos φ	А	cos φ	А	mm ²
220 380 440 220 380 440	50 50 50 60 60 60	Without	32	146 84 73 146 84 73	0.57	185 108 93 185 108 93	0.64	242 140 121 242 140 121	0.67	160 80 80 160 80 80	3 x 70 3 x 25 3 x 25 3 x 70 3 x 25 3 x 25 3 x 25
220 380 440 220 380 440	50 50 50 60 60 60	5	28	128 74 64 124 71 62	0.65	168 98 84 165 95 82	0.68	227 131 113 223 129 112	0.72	160 80 63 160 80 63	3 x 70 3 x 25 3 x 16 3 x 70 3 x 25 3 x 16
220 380 440 220 380 440	50 50 50 60 60 60	7.5	26	119 69 60 114 66 57	0.70	160 93 80 156 90 78	0.71	218 126 109 212 123 106	0.75	160 63 63 160 63 63	3 x 70 3 x 16 3 x 16 3 x 70 3 x 16 3 x 16 3 x 16

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Fig. 17 Wiring Diagram, Motor Operated Model 380/500 V 50 Hz 440/550 V 60 Hz

Components

A1 Transformer
A2 Circuit Breaker
A3 Capacitor
A4 Limit Position Switch
A5 Limit Position Switch
A6 Motor
A7 Pushbutton
A8 Pushbutton
A9 Remote Control Connection
A10 Auxiliary Transformer
A11 Coupling Plinth

Fig. 19 Coupling Plinth A11. Coupling Bar Positions.

Fig, 18 Wiring Diagram, Hand Operated Model 380/500 V 50 Hz 440/550 V 60 Hz

Connection

The welding transformers can be connected to various mains supplies.

Check that the coupling plinth A11 is connected for the mains supply desired. Correct connection can be seen from Figs 19 and 22.

If the transformer is equipped with a voltage limiter, it should be connected for the required mains voltage in accordance with Fig. 25.

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Fig. 20 Wiring Diagram, Motor Operated Model 220/380/440 V 50-60 Hz

Fig. 21 Wiring Diagram, Hand-Operated Model 220/380/440 V 50-60 Hz

Fig. 22 Coupling Plinth A11. Coupling Bar Positions.

Components

A1 Transformer
A2 Circuit Breaker
A3 Capacitor
A4 Limit Position Switch
A5 Limit Position Switch
A6 Motor
A7 Pushbutton
A8 Pushbutton
A9 Remote Control Connection
A10 Auxiliary Transformer
A11 Coupling Plinth

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Fig. 23 Wiring Diagram.

Components

F1	Transformer	F13 Condenser
F2	Transductor	F14 Relay
F3	Transductor	F15 Relay
F4	Resistor	F16 Relay
F5	Resistor	F17 Resistor
F6	Capacitor	F18 Resistor
F7	Silicon Rectifier	F19 Resistor
F8	Silicon Rectifier	F20 Resistor
F9	Silicon Rectifier	F21 Resistor
F10	Silicon Rectifier	F22 Zener Diode
F11	Silicon Rectifier	F23 Zener Diode
F12	Condenser	F24 Coupling Plinth

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Fig. 24 Wiring Diagram.

Components

A3	Capacitor	B5	Resis
A11	Coupling Plinth	B6	Capac
B1	Transformer	B7	Relay
B2	Pilot Lamp	B8	Resis
B3	Resistor	B9	Silico

B4 Contactor
eitor
n Diode
B10 Silicon Diode

Fig. 25 Coupling Plinth A11 and Transformer B1. Coupling Bar Positions,

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5. Maintenance and Service

5.1 Maintenance

Once a year the following should be carried out:

1. Clean the transformer by blowing with compressed air.
2. In case of any abnormal vibration in the transformer, which could have arisen due to the fact that the leakage core has been moved out of its position, the adjusting screws on the coils should be tightened. The adjusting screws to the leakage core have springs, which are self-adjusting. This is the reason why resetting is seldom necessary. If, however, this has to be done, it is important that the screws are not overtightened as then the leakage core could become too tight to move, and if the transformer is motor-operated, the servo motor then could be

overloaded and damaged. To prevent this, the current to the motor and therefore the load, which must not exceed 4.5 A, can be checked.

The guides of the leakage core must be cleaned. Note! Do not grease!
The worm drive of the leakage core and, if motoroperated, the chain from the unit is to be cleaned with paraffin and greased with: Industrial No-Melt Grease BINM.
The needle bearings of the wheels to be greased with ball-bearing grease.
6. The thrust bearing of the drive to the leakage core and the gearbox of the motor to be filled with grease: Industrial No-Melt Grease BINM.

5.2 Service

The TBH 400 and the TBH 700 are designed for hard, intensive welding and are very safe in operation. They have few moving parts, which are exposed to heavy wear. This is the reason why they need little service.

Should, however, spare parts be needed these can be ordered from the nearest branch office or representative.

When ordering, please state the order numbers given in the spare parts list and the production number of the transformer, which can be found engraved in the data plate. Use of the correct numbers will prevent any errors in delivery.

BOX 8850, S 402 71 GÖTEBORG 8, SWEDEN Phone: 22 80 20, Tgm: Esabsales, Telex 206 25