LHF250 LHF400 LHF630 LHF800
LHF250 LHF400 LHF630 LHF800
LHF 400
LHF 630
LHF 800
Service manual
TOCe -- 2 --
READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.
Use the connection diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation.
This manual contains details of all design changes that have been made to LHF machines
with serial no. 906--xxx--xxxx up to and including March 2002.
The LHF 250, LHF 400, LHF 630 and LHF 800 are designed and tested in accordance
with international and European standard IEC/EN 60974--1 and EN 50199.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure that the product does not depart from the requirements
of the above standard.
INTRODUCTION
The LHF 250/400/630/800 are thyristor--controlled welding power sources incorporating
mains voltage compensation and intended for MMA welding, TIG welding and air--arc
gouging. The mains voltage compensation ensures that the arc voltage and welding current
remain stable even though supply voltage may vary. Electronic control ensures that the
welding current maintains its set value at all times. A single knob regulates the welding
current over its entire range.
TECHNICAL DATA
LHF 250 LHF 400 LHF 630 LHF 800
Maximum load
35 % duty cycle 250 A/30 V 400 A/36 V 630 A/44 V 800 A/44 V
60 % duty cycle 200 A/28 V 315 A/33 V 500 A/40 V 630 A/44 V
100 % duty cycle 160 A/26 V 250 A/30 V 400 A/36 V 500 A/40 V
Setting range 8A/20V--250A/30 8A/20V--400A/36 8A/20V--630A/44 8A/20V--800A/44
(33)V V (49)V (50)V
Open circuit volt. 78--84 V 80--87 V 65--72 V 65--72 V
Open circuit output
at 400 V 300 W 340 W 615 W 640 W
Power factor
(max current) 0,88 0,90 0,87 0,82
clhf1de1 -- 3 --
LHF 250 LHF 400 LHF 630 LHF 800
Efficiency
(max current) 68 % 74 % 77 % 78 %
Enclosure class IP 23 IP 23 IP 23 IP 23
Application class
Weight 160 kg 195 kg 260 kg 295 kg
Dimens. lxwxh 1310/765/705 1310/765/705 1310/765/705 1310/765/705
Duty cycle
The duty cycle refers to the time in per cent of a ten--minute period that you can weld at a certain
load without overloading the welding power source.
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.
COMPONENT DESCRIPTION
This component description referres to the connection diagrams on pages 6 to 9.
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic
sensitive devices.
ESD S Use proper static--proof bags and boxes.
K1 Main transformer.
K2.1 Main thyristors.
K2.2 Main diodes.
K2.3 Base current diodes.
K2.4 Freewheel diode.
K6 Mains switch.
K11 Mains terminal block.
K12 Inductor.
K13 Welding current terminals.
K14 Base current resistor, 8.6 τ ±5%.
K18.1 Shunt -- 120 mV at 250 A (LHF 250), at 400 A (LHF 400), at 630 A (LHF 630)
and at 800 A (LHF 800).
K18.2 Additional shunt for ampere meter, only LHF 630 and LHF 800.
K19 Ampere meter.
clhf1de1 -- 4 --
K20 Volt meter.
K24 Remote control socket
K25 Current relay. Activates contactor K62.2 during welding.
K27.1 Transient protection.
K27.3 Capacitor 0.1←F.
K27.4 Capacitor 5←F.
K27.5 Capacitor, reduces the supply voltage to the fan. See K51.
K28 Fan.
K30 Terminal block.
K30.1 Terminal block.
K31.1 Thermal switch: breaks at 68˚C, resets at 59˚C, tolerance ±3˚C.
Fitted on the thyristor heatsink.
K31.2 Thermal switch: LHF 250: breaks at 140˚C, LHF 400: breaks at 160˚C, LHF
630: breaks at 150˚C, LHF 800: breaks at 130˚C.
Fitted in the winding of the main transformer, K1.
K33 LOCAL/REMOTE control selector switch
K38.1 Indicating lamp, 28 V.
K38.2 LED, yellow. On when the thermal overload is activated, i.e. when one or both
of the thermal switches K31.1 and K31.2 are open.
K45.1 Contact, 15 pole, male.
K45.2 Contact, 15 pole, female.
K45.3 Contact, 12 pole, male.
K45.4 Contact, 12 pole, female.
K45.5 Contact, 6 pole, male.
K45.6 Terminal block.
K47 Starting capacitor for cooling fan.
K50 Terminal block.
K51 Time relay. The fan runs at a reduced idle speed of 300 rpm. When welding
with currents greater than 30 A the fan speed increases to its working speed of
around 1350 rpm. Timer relay K51 maintains the higher speed setting for 6 1/2
minutes after welding has stopped.
K52.1 Control power supply transformer, supplied at 35 V from K1s3. The secondary
winding supplies 19 V AC to circuit board K70.
K52.2 Control power supply transformer for the time relay (K51).
K57 Potentiometer (2 kτ) for controlling the welding current. Fine--resolution type,
fitted with planetary reduction gear.
K62.1 Relay, controlling LED K38.2.
K62.2 Contactor. When K62.2 is activated the runs at working speed, see K51.
K69 Filter board (interference suppression).
K70 Main control circuit board.
K79 Selector switch, TIG/MMA/Air--arc gouging. Only LHF 630 and LHF 800.
clhf1de1 -- 5 --
CONNECTION DIAGRAM LHF 250, LHF 400
Primary side
clhf1de1 -- 6 --
Secondary side
clhf1de1 -- 7 --
CONNECTION DIAGRAM LHF 630, LHF 800
Primary side
clhf1de1 -- 8 --
Secondary side
clhf1de1 -- 9 --
FUNCTION DESCRIPTION, CIRCUIT BOARD K70
This description refers to the connection diagrams on pages 6 to 9 and to the block
diagram on page 16.
clhf1de1 -- 10 --
K70:3 Remote control
clhf1de1 -- 11 --
K70:4 D/A converter
The D/A converter, which recreates the mean value of the reference signal from the
pulse train from the A/D converter. The input signal is first amplified and filtered:
trimming potentiometer R87 adjusts the output signal from IC4:1 to 0 V when the
remote control potentiometer is at its minimum position and to +11.5 V when the
potentiometer is at its maximum position. The signal is then passed to analog
switch IC1, which is controlled by the LOCAL/REMOTE selector switch.
The control power supply is obtained from winding K1s3 on the main transformer,
which is connected in star. The voltage between the star point and the respective
phase terminals is about 19 V, and the star point is connected to B5, which is the
neutral in the electronic circuitry.
Resistors R125--127 are film resistors that protect the synchronising winding
against any short circuits on the circuit board.
Voltage regulator VR2 produces a +15 V stabilised voltage: trimming
potentiometer R129 provides fine adjustment. Resistors R128 and R130 restrict
the range over which the voltage can be adjusted to a maximum voltage of +18 V,
which is the maximum permissible supply voltage for the CMOS circuits.
D21 stabilises the negative voltage to --15 V. The power rating of R131 is such as
to allow the circuit to supply a load current of 30 mA.
clhf1de1 -- 12 --
K70:6 Thyristor trigger circuits
The trigger unit converts the DC signal from the control amplifier to ignition pulses
that fire the thyristors at the correct point in the cycle.
The unit consists of three identical sections, one for each thyristor. A synchronising
winding K1s2, provides synchronising information for correct firing. The voltage
between B13/B14/B15 is approximately 35 V.
The ignition pulses are connected to each thyristor. The gate connections are
twisted together with the associated neutral connections in order to minimise the
risk of interference in the gate circuit.
The thermal overload switches K31.1 and K31.2 interrupts the power supply to
output transistors Q9, Q12 and Q15 in the trigger unit in the event of excessive
temperature. The switches resets automatically when the temperature has fallen.
Switch K31.1 is fitted on the thyristor heatsink. Switch K31.2 is fitted in the winding
of the main transformer. See page 5 for information on switch temperatures.
Operation of the thermal overload switch prevents the thyristors from receiving any
trigger pulses. The current flowing in the main welding circuit is then limited to the
basic current of 8 A.
clhf1de1 -- 13 --
K70:8 Shunt amplifier
The shunt amplifier amplifies the voltage signal from the shunt.
The shunt provides an output voltage signal of 120 mV for the maximum welding
current of each power source. (250 A, 400 A, 630 A and 800 A respectively.)
Changeover between MMA and TIG welding modes is controlled by transistor Q16,
which is controlled by switch K79.
In the MMA welding mode, the control voltage at A1 is about --25 V (switch K79
open), while in the TIG welding mode it is 0 V (K79 closed).
This function is only avilable in the LHF 630 and LHF 800.
A contact on switch K79 links contacts A9--A12 in the galvanically isolated remote
control circuit to change the operating mode to air--arc gouging. (Switch K79 also
selects MMA or TIG welding modes.)
Optocoupler IC11 is activated in the air--arc gouging mode, and in turn activates
the air--arc gouging control circuits.
clhf1de1 -- 14 --
clhf1de1 -- 15 --
K70 Block diagram
clhf1de1 -- 16 --
clhf1de1 -- 17 --
K70 Component positions
cmva2eba
clhf1de1 -- 18 --
cmva2ebb
clhf1de1 -- 19 --
REPLACEMENT OF THYRISTORS
LHF 400 Offshore, LHF 630 and LHF 800
When fitting replacement thyristors, it is extremely important that they are correctly secured,
i.e. with a clamping force of 4500 N (450 kp) ±10% for LHF 400 Offshore and LHF 630.
For the LHF 800 the claming forc is: 5490--5530 N.
Clean the flat surfaces of the thyristors and heat sinks carefully, and remove any burrs or
traces of grease or oil. Apply a very thin film of silicone grease to the contact surfaces of
the heat sink, and position the thyristor between the surfaces with the symbol on the
thyristor facing in the direction as shown in the diagram below. Centre the thyristor by
locating the pin projecting from the pressure cap in the depression in the thyristor body.
Start by finger--tightening the nuts enough to remove play between the nuts and washers.
Then, using a dial gauge or depth gauge, measure the distance from the plate to the spring
as shown in the diagram below.
Tighten the nuts alternately with a spanner until the distance has decreased by 0.9 ±0.05
mm for LHF 400 Offshore and LHF 630. For the LHF 800 the measure is 1.0 ±0.05 mm.
Fitting of thyristors
cmja2p02
clhf1de1 -- 20 --
INSTRUCTIONS LHF 250--800
This chapter is an extract from the instructions for the LHF 250, LHF 400, LHF 630 and
LHF 800.
SAFETY
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
INTRODUCTION
LHF 250/400/630/800 are thyristor controlled welding rectifiers designed for welding with
coated electrodes, TIG welding and arc air gouging.
The welding rectifiers can be used with the following remote control devices:
PHA 1, PHA 2, PHA 5, PHB 1, PHB 2, och PHC 2.
An auxiliary control unit is required for TIG welding with high frequency arc ignition.
clhf1de2 -- 21 --
INSTALLATION
The installation shall be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
Connecting to mains
LHF 250 LHF 400 LHF 630 LHF 800
Frequency 50 Hz 50 Hz 50 Hz 50 Hz
Voltage 230/400/ 230/400/ 230/400/ 230/400/
415/500 V 415/500 V 415/500 V 415/500 V
Current at
100% duty cycle 20/11/11/9A 34/19/19/16 A 65/38/38/30 A 86/49/49/40 A
60% duty cycle 25/14/14/11 A 42/24/24/20 A 81/47/47/38 A 107/62/60/50A
35% duty cycle 31/18/18/14 A 53/31/31/25 A 102/59/59/47A 136/79/79/63A
Fuse, slow 25/16/16/16 A 63/25/25/20 A 80/50/50/35 A 100/63/63/50A
Cable area (4xmm2) 4/1.5/1.5/1.5 10/4/4/2.5 25/10/10/6 35/10/10/10
clhf1de2 -- 22 --
OPERATION
S Set switch (1) to position ”I”. The white lamp (2) will light and the fan will start.
S Select the welding method using the toggle switch (3).
S Adjust the welding current using the knob (7) on the front, and set the toggle switch (8)
to the position nearest the socket.
S Select suitable earth and return cables and connect them to the terminals marked +
and -- on the front of the rectifier. Connect the return cable to the work piece.
S The rectifier is now ready for welding.
1. On/Off
2. White lamp (power on)
3. Method selector switch
4. Arc air gouging
5. MMA
6. TIG
7. Current setting bh10d001
8. Remote switch
9. Remote socket
10. Yellow lamp (thermal cut--out)
clhf1de2 -- 23 --
MAINTENANCE
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
Cleaning
Check regularly that the power source is free from dirt.
How often, and to what extent, cleaning should be carried out depends on the
welding process, arc time, disposition and the surrounding environment. It will
normally suffice to blow the power source clean using compressed air (reduced
pressure) once a year.
If the power source is very dirty, brushing and vacuuming are recommended.
S Disconnect the welding power source from the mains current supply.
S Remove the adapter from the socket. Lock the socket to prevent unauthorised
connection.
At fixed installations, the safety switch should be set to the off position. Lock the
switch.
S Remove the power source’s safety plates for best access.
After cleaning, all safety plates must be mounted before you connect the power
source to the mains supply.
LHF 250, LHF 400, LHF 630, LHF 800 is designed and tested in accordance with the in-
ternational an European standards IEC/EN 60 974--1 and EN 60 974--1.
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 27.
This will simplify dispatch and ensure you get the right part.
clhf1de2 -- 24 --
Assembly instructions
bh10d002
bh10a12a -- 25 --
page -- 26 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
Ordering numbers for LHF 250, LHF 400, LHF 630, LHF 800
0319 782 882 LHF 250, 230/400/415/500V 50Hz, 230/440/550V 60Hz
0319 783 882 LHF 400, 230/400/415/500V 50Hz, 230/440/550V 60Hz
0319 783 886 LHF 400 Offshore, 230/400/415/500V 50Hz, 230/440/550V 60Hz
0319 950 882 LHF 630, 230/400/415/500V 50Hz, 230/440/550V 60Hz
0319 950 882 LHF 630 Offshore, 230/400/415/500V 50Hz, 230/440/550V 60Hz
0319 951 884 LHF 800 Offshore, 230/400/415/500V 50Hz, 230/440/550V 60Hz
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the
cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to
the spare parts list.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.
bh10s11a -- 27 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
Item
Qty Ordering no. Denomination Notes C
no.
bh10s11a -- 28 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
104
105
107
106
108
114
115
116
117
109
110 113
121
120
122
123
124
125
bh10s11a -- 29 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
Item
Qty Ordering no. Denomination Notes C
no.
bh10s11a -- 30 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
206
204
227--233 211
220--226 213
212
219
215
bh10s11a -- 31 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
Item
Qty Ordering no. Denomination Notes C
no.
bh10s11a -- 32 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
bh10s11a -- 33 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
Item
Qty Ordering no. Denomination Notes C
no.
bh10s11a -- 34 --
LHF 250, LHF 400, LHF 630, LHF 800 Edition 020328
401 405
407
402
408
406
403
411
409 412
410
404 413
414
415
416
417 422
418 421 423
420
419
424 427
428
425, 426
433
431 430
437
438
436 439
440 429
bh10s11a -- 35 --
LHF 400 Offshore, LHF 630, LHF 800 Edition 020328
Item
Qty Ordering no. Denomination Notes C
no.
Rectifier bridge
501 1 0319 690 884 Thyristor bridge LHF 400 Offshore K2.1
502 1 0319 690 882 Thyristor bridge LHF 630 K2.1
503 1 0319 932 880 Thyristor bridge LHF 800 K2.1
504 1 0319 904 880 Diode bridge LHF 400 Offshore, LHF 630 K2.2
505 1 0319 923 880 Diode bridge LHF 800 K2.2
506 3 0320 028 002 Thyristor LHF 400 Offshore, LHF 630 K2.1
507 3 0320 946 001 Thyristor LHF 800 K2.1
508 1 0490 600 606 Diode LHF 400 Offshore, LHF 630 K2.4
2 0490 600 606 Diode LHF 800 K2.4
509 3 0041 051 606 Contact protection K27.1
510 3 0319 690 883 Tensioning device LHF 400 Offshore, LHF 630
511 3 0319 932 881 Tensioning device LHF 800
512 1 0319 999 001 Thermal Relay LHF 400 Offshore, LHF 630 Offshore, K31.1
LHF 800
513 1 0368 020 001 Thermal Relay LHF 630 K31.1
514 1 0319 911 880 Shunt LHF 630 K18
515 1 0319 911 881 Shunt LHF 800 K18
516 0163 139 001 Bushing
517 0162 414 002 Insulating tube
bh10s11b -- 36 --
LHF 400 Offshore, LHF 630, LHF 800 Edition 020328
510
511
509
506, 507
508
501--503
514--515
517
516
504--505 512--513
bh10s005
bh10s11b -- 37 --
LHF 250, LHF 400 Edition 020328
Rectifier bridge for LHF 250, LHF 400 From serial No. 906.
C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Notes C
no.
0458 219 880 Rectifier bridge compl.
001 1 0458 219 001 Thermal cutout K31.1
002 1 0458 219 002 Filter K27.1
003 1 0458 219 003 Diode K2.4
004 3 0458 219 004 Rectifier bridge K2.2
005 3 0320 028 008 Thyristor K2.1
006 1 0320 558 880 Shunt LHF 400 K18
007 1 0320 558 881 Shunt LHF 250 K18
6, 7
bh10s11c -- 38 --
NOTES
notes -- 39 --
ESAB subsidiaries and representative offices
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
020314