LAE 800/1000/1250/1600

LAF 800/1000/1250/1600
Conversion kit
104100

Monteringsanvisning

0457 566 126 2004--05--14

Assembly instruction

Valid for serial no. 310

SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rtt till ndring av specifikationer utan avisering frbehlles.

Rights reserved to alter specifications without notice.

-- 2 --

FRSKRAN OM VERENSSTMMELSE
Esab Welding Equipment AB, 695 81 Lax, Sweden, frskrar under eget ansvar att
svetsstrmklla LAH630/LAE800/1000/1250/1600 LAF630/800/1000/1250/1600
frn serienummer 751 r i verensstmmelse med standard EN 60974--1 enligt villkoren i direktiv (73/23/EEG) med tillgg (93/68/EEG) och standard EN 50199 enligt
villkoren i direktiv 89/336/ EEG med tillgg 93/68/ EEG.
-------------------------------------------------------------------------------------------------------------------------------------DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee
that welding power source LAH630/LAE800/1000/1250/1600
LAF630/800/1000/1250/1600 from serial number 751 complies with standard EN
60974--1, in accordance with the requirements of directive (73/23/EEA) and addendum (93/68/EEA) and standard EN 50199 in accordance with the requirements of
directive 89/336/ EEA and addendum 93/68/ EEA .
-------------------------------------------------------------------------------------------------------------------------------------Lax 98--02--16

Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAX
SWEDEN

Tel: + 46 584 81000

Fax: + 46 584 12336

SVENSKA

1 SKERHET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUKTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
7

2.1 Allmnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Tekniska data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7

3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1
3.2
3.3
3.4

Allmnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monteringsanvisning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Provning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anslutningar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
12
13

4 DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Allmnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

5 RESERVDELSBESTLLNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOMPONENTFRTECKNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESERVDELSFRTECKNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
28
30
31

TOCs

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SE
1

SKERHET

Anvndaren av en ESAB svetsutrustning har det yttersta ansvaret fr de skerhetstgrder som

berr personal i arbete med systemet eller i dess nrhet. Skerhetstgrderna skall uppfylla de
krav som stlls p denna typ av svetsutrustning. Innehllet i den hr rekommendationen kan ses
som ett tillgg till de normala regler som gller fr arbetsplatsen.
All manvrering mste utfras av utbildad personal som r vl insatt i svetsutrustningens funktion.
En felaktig manver kan skapa en onormal situation som skadligt kan drabba svl operatr som
den maskinella utrustningen.
1.

All personal som arbetar med svetsutrustningen skall vara vl insatt i:

S dess handhavande
S ndstoppens placering
S dess funktion
S gllande skerhetsfreskrifter
S svetsning

2.

Operatren skall se till:

S att ingen obehrig befinner sig inom svetsutrustningens arbetsomrde vid start
S att ingen person str oskyddad nr ljusbgen tnds

3.

Arbetsplatsen skall:
S vara lmplig fr ndamlet
S vara dragfri

4.

Personlig skyddsutrustning:
S Anvnd alltid freskriven personlig skyddsutrustning som t ex skyddsglasgon, flamskra
klder, skyddshandskar.
S Se till att inte anvnda lst sittande plagg ssom skrp, armband, ring etc som kan fastna,
eller ge brnnskador.

5.

vrigt
S Kontrollera att anvisade terledare r vl anslutna.
S Ingrepp i elektriska enheter fr endast gras av behrig personal.
S Ndvndig eldslckningsutrustning skall finnas ltt tillgnglig p vl anvisad plats.
S Smrjning och underhll av svetsutrustningen fr ej utfras under drift.

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SE

VARNING
BGSVETS OCH SKRNING KAN VARA SKADLIG FR ER SJLV OCH ANDRA. VAR DRFR
FRSIKTIG NR NI SVETSAR. FLJ ER ARBETSGIVARES SKERHETSFRESKRIFTER SOM
SKALL VARA BASERADE P TILLVERKARENS VARNINGSTEXT.
ELEKTRISK CHOCK -- Kan dda
S
Installera och jorda svetsutrustningen enligt tillmplig standard.
S
Rr ej strmfrande delar eller elektroder med bara hnder eller med vt skyddsutrustning.
S
Isolera Er sjlv frn jord och arbetsstycke.
S
Ombesrj att Er arbetsstllning r sker.
RK OCH GAS -- Kan vara farlig fr Er hlsa
S
Hll ansiktet borta frn svetsrken.
S
Ventilera och sug ut svetsrk och gas frn Ert och andras arbetsomrde.
LJUSBGEN -- Kan skada gonen och brnna huden
S
Skydda gonen och kroppen. Anvnd lmplig svetshjlm med filterinsats och br skyddsklder.
S
Skydda kringstende med lmpliga skyddsskrmar eller frhngen.
BRANDFARA
S
Gnistor (svetsloppor) kan orsaka brand. Se drfr till att brnnbara freml inte finns i svetsplatsens nrhet.
BULLER -- Starka ljud kan skada hrseln
S
Skydda ronen. Anvnd ronproppar eller andra hrselskydd.
S
Varna personer i nrheten fr riskerna
VID FEL -- Kontakta fackman
LS OCH FRST BRUKSANVISNINGEN FRE INSTALLATION OCH ANVNDNING
SKYDDA ER SJLV OCH ANDRA!

VARNING
Denna produkt r avsedd fr industriell anvndning. I hem-- och kontorsmilj
kan denna produkt orsaka radiostrningar. Det r anvndarens ansvar att vidta
lmpliga tgrder.

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SE
2

INTRODUKTION

2.1

Allmnt

Svetsstrmkllorna LAE (anpassade fr styrutrustning PEG--1) kan med en

ombyggnadssats byggas om s att de liknar LAF och drmed blir anpassade mot
ESABs manverlda A2--A6 Process Controller (PEH) eller
Welding Control Unit (PEI).
I ombyggnadssatsen finns allt ndvndigt material som krvs fr att ombyggnaden
ska ske s rationellt som mjligt.
S

Bruksanvisning A2--A6 Process Controller (PEH),

bestllningsnummer 0443 745 xxx

Bruksanvisning Welding Control Unit (PEI), bestllningsnummer 0449 375 xxx

2.2

Tekniska data

Tekniska data fr ombyggnaden av svetsstrmkllorna innehller fljande avvikelser

mot tidigare utgiven dokumentation:
S

Ndstopp r borttaget

0--10 V styrning i kontakt XS4

terkoppling av KM2 till plint X3

Strmshuntsignal i kontakt XS4

U+ och U-- kontakt XS4

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SE
3

INSTALLATION

3.1

Allmnt

Installationen skall utfras av behrig person.

VARNING
Roterande delar utgr klmrisk. Iakttag strsta frsiktighet!

3.2

Monteringsanvisning

3.2.1

Ombyggnad av LAE 800/1000

1. Demontera befintlig kabelstam men behll kablarna 034 och 035 fr matning av
manvertransformatorn.
2. Demontera samtliga elektronikkort med faststtningsdistanser.
3. Demontera manverpanelen.
4. Ta bort bygeln p vilken skringssocklarna r fstade.
5. Ta bort den nedre skringen (K21.2=avskring 42 V AC frn manvertransformatorn K9).
De tv vriga skringarna teranvnds tillsammans med underlggsbrickorna av
gummi, men de monteras p en annan plats i svetsstrmkllan.
6. Ta bort de tv mngpoliga kontaktdonen p den nedre plten och tck hlen
med tv plastpluggar ur monteringssatsen.

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SE
7. Demontera skyltarna (en klisterlapp och en fastskruvad skylt, mrkt 42 V) frn
den nedre plten.
8. Demontera plinten p manvertransformatorn.
9. Tck ver kontaktorn och manvertransformatorn innan nya fsthl borras.
10. Borra hl (enl. borrschema) fr faststtning av
S

skringssocklarna (FU1)

elektronikkortet (AP1)

kontaktorn (KM2)

11. Montera ett nytt kretskort (AP1) med lda p plten. Anvnd isoleringsbrickor
och sjlvgngande skruvar fr faststtningen (ingr i monteringssatsen).
12. Anslut avkopplingskondensatorn till jord.
13. Stll in de tv DIP switcharna (SW1 och SW2) p kortet enligt anvisning i
bruksanvisningen fr LAF.
14. Montera den nya uttagsplten.
15. Montera den 28--poliga kontakten (XS4) och isolerkortet p uttagsplten.
16. Koppla in en ny ledningsstam enl. kopplingsschemat.
17. Montera kablar till manverpanelen och anslut sedan manverpanelen till
ledningsstammen.
18. Ta bort (kapa) ledaren 077 mellan kortet K45.3 och strmskenan.
19. Montera tillbaka endast det RC--filter som sitter i den gamla strmkllan.
20. Ta bort det gamla elschemat som sitter p insidan av tckplten.

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SE
3.2.2

Ombyggnad av LAE 1250/1600

1. Demontera befintlig kabelstam men lmna kvar kablarna 034 och 035 ur
kabelstammen (anslutning till manvertransformatorn).
2. Klipp av anslutningen till synktransformatorernas ena sida (kablar mrkta 001,
002, 003) som ligger i kabelstammen.
3. Demontera samtliga elektronikkort med faststtningsdistanserna.
4. Demontera manverpanelen.
5. Ta bort skringshllaren K21.2 till hger och ovanfr manvertransformatorn.
Den nedre skringen (K21.2=avskring 42 V AC frn manvertransformatorn
K9) utgr helt och erstts av en automatskring p den nya manverpanelen.
6. Ta bort de tv mngpoliga kontaktdonen p den nedre plten och tck hlen
med tv plastpluggar ur monteringssatsen.
7. Demontera skyltarna (en klisterlapp och en fastskruvad skylt, mrkt 42 V) frn
den nedre plten.
8. Demontera plinten p manvertransformatorn.
9. Demontera shunt (1500 A, 60 mV). OBS! Gller endast fr LAE 1600.
10. Demontera strmrel (K25) som r fst p + skenan, till hger om
manvertransformatorn.
11. Demontera ledningarna (18, 47, 48) som r anslutna till strmrelet.
12. Tck ver kontaktorn och manvertransformatorn innan nya fsthl borras.
13. Borra hl (enl. borrschema) fr faststtning av
S

elektronikkortet (AP1)

kontaktorn (KM2)

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SE
14. Montera ett nytt kretskort (AP1) med lda p plten. Anvnd isoleringsbrickor
och sjlvgngande skruvar fr faststtningen (ingr i monteringssatsen).
15. Anslut avkopplingskondensatorn till jord.
16. Stll in de tv DIP switcharna (SW1 och SW2) p kortet enligt anvisning i
bruksanvisningen fr LAF.
17. Montera den nya uttagsplten.
18. Montera den 28--poliga kontakten (XS4) och isolerkortet p mellanplten samt
anslut avkopplingskondensatorn till jord.
19. Koppla in ny ledningsstam enligt kopplingsschemat
20. teranvnd de gamla ledarna 034 och 035 fr anslutning till manvertrans-formatorn (TC1).
21. Anslut ledarna 001, 002 och 003 till de tre synktransformatorernas ena sidor
(TC2).
22. Montera kablar till ndstoppsbrytaren p manverpanelen och anslut sedan
manverpanelen till ledningsstammen.
23. Ta bort (kapa) ledaren 077 mellan kortet K45.3 och strmskenan.
24. Montera tillbaka endast det RC--filter som sitter i den gamla strmkllan.
25. Ta bort det gamla elschemat som sitter p insidan av tckplten.
26. Montera shunt (2000 A, 60 mV). OBS! Gller endast fr LAE 1600.

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SE
3.3

Provning

1. Anslut svetsstrmkllan till ntet.

2. Kontrollera att matningsspnningen till kortet r p 19 V innan svetsstrmkllan
sls p.
3. Anslut manverlda PEH eller PEI med manverkabeln till den 28--poliga
kontakten (XS4) i svetsstrmkllan.
4. Sl p matningsspnningen till svetsstrmkllan med vridomkopplaren (QF) p
frontpanelen.
5. Kontrollera att matningsspnningen bryts nr ndstopp (QS) aktiveras.
6. Stll in svetsparametrar frn manverlda PEH eller PEI.
7. Starta svetsen genom att trycka p startknappen.
8. Kontrollera att relet i svetsstrmkllan aktiveras vid svetsstart.
9. Kontrollera att olika strm-- och spnningsvrden kan stllas in frn manverlda
PEH eller PEI.
10. Montera skyddspltar efter avslutat arbete.

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SE
3.4

Anslutningar

3.4.1

Generellt

Inkopplingen av manverldan till svetsautomaten skall ske enligt

bruksanvisningen fr A2--A6 Process Controller (PEH) eller
Welding Control Unit (PEI)

3.4.2

Svetsautomat (Pulverbgsvetsning, UP)

Anslut manverkabeln (4) mellan svetsstrmkllan (3) och manverldan

PEH eller PEI (2).

Anslut terledaren (7) mellan svetsstrmkllan (3) och arbetsstycket (8).

Anslut svetskabeln (6) mellan svetsstrmkllan (3) och svetsautomaten (1).

Anslut mtledningen (5) mellan svetsstrmkllan (3) och arbetsstycket (8).

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SE
3.4.3

Svetsautomat (Gasmetallbgsvetsning, MIG/MAG)

Anslut manverkabeln (4) mellan svetsstrmkllan (3) och manverldan

PEH eller PEI (2).

Anslut terledaren (7) mellan svetsstrmkllan (3) och arbetsstycket (8).

Anslut svetskabeln (6) mellan svetsstrmkllan (3) och svetsautomaten (1).

Anslut gasslangen (9) mellan reduceringsventilen (10) och svetsautomatens

gasventil (11).

Anslut slangar fr kylvatten (12) mellan kylaggregatet (13) och

svetsautomaten (1).

Anslut mtledningen (5) mellan svetsstrmkllan (3) och arbetsstycket (8).

in

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out

SE
4

DRIFT

4.1

Allmnt
Varning:
Har Du lst och frsttt skerhetsinformationen?
Om s ej r fallet fr maskinen inte tas i bruk!

Allmnna skerhetsfreskrifter fr handhavande av denna utrustning finns p

sidan 5. Ls dessa innan du anvnder utrustningen.

RESERVDELSBESTLLNING

Reservdelar bestlls genom nrmaste ESAB--representant, se sista sidan p denna

publikation. Vid bestllning var god ange maskintyp, serienummer samt benmningar och reservdelsnummer enligt reservdelsfrteckning p sidan 31.
Detta underlttar expedieringen och skerstller korrekt leverans.

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ENGLISH

1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19

3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1
3.2
3.3
3.4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20
20
24
25

4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

5 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27
28
30
31

TOCe

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GB
1

SAFETY

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.
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.

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GB

WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS 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 take fumes and gases away 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 inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interference. It is the users responsibility to take
adequate precautions.

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GB
2

INTRODUCTION

2.1

General

The welding power sources LAE (adapted to fit control equipment PEG--1) can be
converted to resemble LAF by way of a conversion kit, and by that be adapted to fit
ESABs control box A2--A6 Process Controller (PEH) or Welding Control unit (PEI).
For rational conversion all components necessary for the work are contained in the
conversion kit.
S

Instruction manual for A2--A6 Process Controller (PEH), order no. 0443 745 xxx

Instruction manual for Welding Control Unit (PEI), order no. 0449 375 xxx

2.2

Technical data

The conversion of the power sources results in the following divergencies with
regard to the technical data, compared to previously issued documentation.
S

The Emergency stop has been removed

0--10 V steering in contact XS4

Reconnection of KM2 to connection block X3

Current shunt signal in contact XS4

U+ , U-- contact XS4

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GB
3

INSTALLATION

3.1

General

The installation must be executed by a professional.

WARNING
Rotating parts can cause injury, take great care.

3.2

Assembly instructions

3.2.1

Conversion of LAE 800/1000:

1. Dismount the cable stem, excluding the cables 034 and 035 for the power supply
of the control transformer.
2. Dismount all electronics boards and their fittings.
3. Dismount the control panel.
4. Remove the support with the attached fuse--bases.
5. Remove the lower fuse (K21.2 = fuse for 42 V AC from the control transformer
K9).
The other two fuses are to be re--used together with the rubber spacers, but
fitted elsewhere in the power source.
6. Remove the multi--pole contact devices on the bottom plate and cover the holes
by way of two plastic plugs from the kit.

foe1i1ea

-- 20 --

GB
7. Remove the signs (a sticker and a screwed sign marked 42 V) from the bottom
plate.
8. Dismount the terminal block on the control transformer.
9. Cover the contactor and the control transformer before drilling new mounting
holes.
10. Drill the holes according to the drilling diagram for the attachment of
S

the fuse--bases (FU1)

the electronics board (AP1)

the contactor (KM2)

11. Fit a new (AP1) circuit board with box on the plate, using the insulating washers
and self--tapping screws which form part of the conversion kit.
12. Connect the discharge capacitor to earth.
13. Set the two DIP switches (SW1 and SW2) on the board according to the
instructions in the LAF manual.
14. Mount the new terminal plate.
15. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate.
16. Connect a new cable stem according to the connection diagram.
17. Mount the cables for the control panel. Then connect the control panel to the
cable stem.
18. Remove (cut off) the conductor 077 between the board K45.3 and the collector
rail.
19. Only remount the RC filter fitted in the old power source.
20. Remove the old connection diagram on the inside of the cover plate.

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GB
3.2.2

Follow the instructions below for the conversion of LAE 1250/1600:

1. Dismount the cable stem, excluding the cables 034 and 035 (for the connection
to the control transformer).
2. Cut off the connection to the synchronising transformers (cables marked 001,
002, 003) in the cable stem.
3. Dismount all electronics boards and their fittings.
4. Dismount the control panel.
5. Remove the fuse holder K21.2 fitted above the control transformer to the right.
The lower fuse (K21.2 = fuse for 42 V AC from the control transformer K9) is
replaced by an automatic fuse on the new control panel.
6. Remove the multi--pole contact devices on the bottom plate and cover the holes
by way of two plastic plugs from the kit.
7. Remove the signs (a sticker and a screwed sign marked 42 V) from the bottom
plate.
8. Dismount the terminal block on the control transformer.
9. Dismount the shunt (1500 A, 60 mV). N.B. Only for LAE 1600
10. Remove the current relay (K25) fixed to the +rail to the right of the auxiliary
transformer.
11. Remove the conductors (18, 47, 48) connected to the current relay.
12. Cover the contactor and the control transformer before drilling new mounting
holes.

foe1i1ea

-- 22 --

GB
13. Drill the holes according to the drilling diagram for the attachment of
S

the electronics board (AP1)

the contactor (KM2)

14. Fit a new (AP1) circuit board with box on the plate, using the insulating washers
and self--tapping screws which form part of the conversion kit.
15. Connect the discharge capacitor to earth.
16. Set the two DIP switches (SW1 and SW2) on the board according to the
instructions in the LAF manual.
17. Mount the new terminal plate.
18. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate
and connect the discharge capacitor to earth.
19. Connect a new cable stem according to the connection diagram.
20. Re--use the conductors 034 and 035 for the connection to the control
transformer (TC1).
21. Connect (by soldering) the conductors 001, 002 and 003 in the cable stem to the
three synchronising transformers (TC2).
22. Mount the cables for the control panel. Then connect the control panel to the
cable stem.
23. Remove (cut off) the conductor 077 between the board K45.3 and the collector
rail.
24. Only remount the RC filter fitted in the old power source.
25. Remove the old connection diagram on the inside of the cover plate.
26. Mount the shunt (2000 A, 60 mV). N.B. Only for LAE 1600

foe1i1ea

-- 23 --

GB
3.3

Testing

1. Connect the welding power source to the mains.

2. Before switching on the welding power source, check that the power supply to
the board is 19 V.
3. Connect control box PEH or PEI to the 28--pole contact (XS4) in the welding
power source by way of the control cable.
4. Switch on the power supply for the welding power source using the rotary switch
(QF) on the front panel.
5. Make sure the power supply is interrupted when the emergency stop (QS) is
activated.
6. Set the welding parameters over either the PEH or PEI control box.
7. Start welding by pressing the START key.
8. Make sure the relay in the welding power source is activated when the welding
starts.
9. Check that different current and voltage values can be set from either control box
PEH or PEI.
10. Mount the protective shields after finished work.

foe1i1ea

-- 24 --

GB
3.4

Connections

3.4.1

General

The connection of the control box to the automatic welding machine is to be

done according to the A2--A6 Process Controller (PEH) instruction manual or the
Welding Control Unit (PEI) instruction manual.

3.4.2

Automatic welding machine (Submerged Arc Welding, SAW)

Connect the control cable (4) between power source (3) and control box PEH or
PEI (2).

Connect return cable (7) between power source (3) and workpiece (8).

Connect welding cable (6) between power source (3) and

welding machine (1).

Connect measuring cable (5) between power source (3) and workpiece (8).

foe1i1ea

-- 25 --

GB
3.4.3

Automatic welding machine (Gas Metal Arc Welding, MIG/MAG)

Connect control cable (4) between power source (3) and control box
PEH or PEI (2).

Connect return cable (7) between power source (3) and workpiece (8).

Connect welding cable (6) between power source (3) and welding machine (1).

Connect gas hose (9) between reducing valve (10) and gas valve (11) on the
welding machine.

Connect the cooling water hoses (12) between cooling unit (13) and welding
machine (1).

Connect measuring cable (5) between power source (3) and workpiece (8).

in

foe1i1ea

-- 26 --

out

GB
4

OPERATION

4.1

General
Caution:
Have you read and understood the safety information ?
You must not operate the machine beforehand !

General safety regulations for the handling of the equipment can be found on
page 17. Read through before you start using the equipment!

ORDERING OF SPARE PARTS

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 31.
This will simplify dispatch and ensure you get the right part.

foe1o1ea

-- 27 --

Schema Diagram

dia3e11a

-- 28 --

dia3e11a

-- 29 --

Komponentfrteckning List of components

C = Component designation in the circuit diagram

C

LAE/LAF
800/1000

Denomination

LAE/LAF
Remarks
1250/1600

AP1 (K70.1)

Circuit board

AP2

Circuit board EMC--filter

C1

Capacitor

C2

Capacitor

C4

Capacitor

FU1 (K.35)
FU2 (K21.2)

Fuse
Fuse

X
X

X
X

20 A

HL1

Indicator lamp, white

42--48 V

HL2

Indicator lamp yellow

28 V

KM1 (K8)

Contactor

KM2
L1

Contactor
Inductor

X
X

X
X

M1

Fan

QF (K6)

Main switch (black)

R1

Power resistor

R2

Power resistor

R3

Power resistor

RS1 (K18)

Shunt

ST1

Thermal relay

TC1

Control transformer

TC2

Control transformer

TM1
V1

Transformer
Thyristor

X
X

X
X

V2

Thyristor

V3

Thyristor

V4

Thyristor

XS4

Burndy socket

XT1

Connection block

XT2

Connection block

XT3

Connection block

XT4

Connection block

Z1, Z2
Z3, Z4

Contact protection
Contact protection

X
X

X
X

compdok

-- 30 --

28--pole

Reservdelsfrteckning Spare parts list

Conversion kit
Edition 2003--08--19

Ordering no.

Denomination

0456 795 880

LAE 800

0456 795 881

LAE 1000

0456 796 880

LAE 1250

0456 796 881

LAE 1600

Notes

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

foespare

-- 31 --

Item
no.

Qty

Ordering no.

Denomination

0456795880

LAE 800

Notes

0456433881

Cable harness conversion kit

0805586131

Contactor

0805586113

Contact block

LAF 800
KM2

0456361882

Cable set

0193260155

Connector

7--pol.

0193260152

Connector

4--pol.

0193260150

Connector

2--pol.

0368544003

Sleeve socket Burndy

28--pol.

0456361883

Cable set

10
11

0193260154

Connector

6--pol.

12

0193260151

Connector

3--pol.

13

0486466880

Circuit board, insulation card

0456348880

Front panel complete

14

AP1.H

XS4

15

0320746001

Main switch

16

0192576004

Indicating lamp white

42--48 V

HL1

17

0192576303

Indicating lamp yellow

28 V

HL2

18

0567200610

Fuse

16 A 500 V

FU1

19

0193586104

Automatic fuse

20 A

FU2

20

0486368880

Circuit board

AP1

21

0486224880

Circuit board EMC--filter

AP2

22

0193358102

Contactor

23

0319470016

Control transformer

f456795s

QF

KM1
42 V 900 VA

-- 32 --

TC1

Item
no.

Qty

Ordering no.

Denomination

0456795881

LAE 1000

Notes

0456423881

Cable harness conversion kit

0805586131

Contactor

0805586113

Contact block

LAF 800
KM2

0456861882

Cable set

0193260155

Connector

7--pol.

0193260152

Connector

4--pol.

0193260150

Connector

2--pol.

0368544003

Sleeve socket Burndy

28--pol.

0456361883

Cable set

10
11

0193260154

Connector

6--pol.

12

0193260151

Connector

3--pol.

13

0486466880

Circuit board, insulation card

0456348881

Front panel, complete

14

AP1.H

XS4

15

0320746001

Main switch

16

0192576004

Indicating lamp white

42--48 V

HL1

17

0192576303

Indicating lamp yellow

28 V

HL2

18

0567200610

Fuse

16 A 500 V

FU1

19

0193586104

Automatic fuse

20 A

FU2

20

0486368880

Circuit board

AP1

21

0486224880

Circuit board EMC--filter

AP2

22

0193358102

Contactor

23

0319470016

Control transformer

f456795s

QF

KM1
42 V 900 VA

-- 33 --

TC1

Item
no.

Qty

Ordering no.

Denomination

0456796880

LAE 1250

Notes

0456434881

Cable harness conversion kit

0805586131

Contactor

0805586113

Contact block

LAF 800
KM2

0456373882

Cable set

0193260155

Connector

7--pol.

0193260152

Connector

4--pol.

0193260150

Connector

2--pol.

0368544003

Sleeve socket Burndy

28--pol.

0456373883

Cable set

10
11

0193260154

Connector

6--pol.

12

0193260151

Connector

3--pol.

13

0486466880

Circuit board insulation card

0456322880

Front panel complete

14

AP1.H

XS4

15

0320746001

Main switch

16

0192576004

Indicating lamp white

42--48 V

HL1

17

0192576303

Indicating lamp yellow

28 V

HL2

18

0567200610

Fuse

16 A 500 V

FU1

19

0193586104

Automatic fuse

20 A

FU2

20

0486368880

Circuit board

AP1

21

0486224880

Circuit board EMC--filter

AP2

22

0442849880

Contactor

23

0319470016

Control transformer

24

0319828001

Transformer

f457796s

QF

KM1
42 V 900 VA

TC1
TC2

-- 34 --

Item
no.

Qty

Ordering no.

Denomination

0456796881

LAE 1600

Notes

0456434881

Cable harness conversion kit

0805586131

Contactor

0805586113

Contact block

LAF 800
KM2

0456373882

Cable set

0193260155

Connector

7--pol.

0193260152

Connector

4--pol.

0193260150

Connector

2--pol.

0368544003

Sleeve socket Burndy

28--pol.

0456373883

Cable set

10
11

0193260154

Connector

6--pol.

12

0193260151

Connector

3--pol.

13

0486466880

Circuit board insulation card

0456322881

Front panel complete

14

AP1.H

XS4

15

0320746001

Main switch

16

0192576004

Indicating lamp white

42--48 V

HL1

17

0192576303

Indicating lamp yellow

28 V

HL2

18

0567200610

Fuse

16 A 500 V

FU1

19

0193586104

Automatic fuse

20 A

FU2

20

0486368880

Circuit board

AP1

21

0486224880

Circuit board EMC--filter

AP2

22

0442849880

Contactor

23

0319470016

Control transformer

24

0319828001

Transformer

f457796s

QF

KM1
42 V 900 VA

TC1
TC2

-- 35 --

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 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
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: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60

NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibrica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55

North and South America

Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 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 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39

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-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85

Distributors

For addresses and phone

numbers to our distributors in
other countries, please visit our
home page
www.esab.com

SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29

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 3369 4333
Fax: +55 31 3369 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 44 58

ESAB AB
SE-- 695 81 LAX
SWEDEN
Phone +46 584 81 000
www.esab.com
031021