LHF 400, LHF 630

LHF 800

Instruction manual

0349 301 080

070108

Valid for serial no. 318, 318, 329

ENGLISH

1
2
3
4
5

DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
5
5
6

5.1 Connecting to mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
9

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

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1

DIRECTIVE

DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Lax, Sweden, gives its unreserved guarantee that welding
power source LHF 400 / LHF 630 / LHF 800 from serial number 318/318/329 complies with standard
IEC/EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and addendum
(93/68/EEC) and with standard EN 60974--10 in accordance with the requirements of directive
(89/336/EEC) and addendum (93/68/EEC).

--------------------------------------------------------------------------------------------------------------------------------------

Lax 31.08.2005

Henry Selenius
Vice President
ESAB Welding Equipment AB
695 81 LAX
SWEDEN

Tel: + 46 584 81000

Fax: + 46 584 411924

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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WARNING!
Read and understand the instruction manual
before installing or operating.

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!

ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Do not use the power source for thawing frozen pipes.

This product is solely intended for arc welding.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!

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3

INTRODUCTION

LHF 400/630/800 are thyristor controlled welding rectifiers designed for welding with
coated electrodes and TIG welding.
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.
LHF 400/630, versions with meters and timed cooling fan.
These welding rectifiers are equipped with a volmeter, ammeter and a circuit that
reduces the idle speed of the cooling fan.
The meters allow current and voltage settings to be read from the front of the
rectifier.
To minimise the amount of dust and dirt that is drawn into the rectifier 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. A timer relay
maintains the higher speed setting for 6 1/2 minutes after welding has stopped to
ensure adequate cooling of the rectifier.

TECHNICAL DATA

Maximum load
35 % duty cycle
60 % duty cycle
100 % duty cycle
Setting range

LHF 400

LHF 630

LHF 800

400 A/36 V
315 A/33 V
250 A/30 V
8A/20V--400A/36V

800 A/44 V
630 A/44 V
500 A/40 V
8A/20V--800A/44(50)
V
65--72 V

Open circuit volt.

Open circuit output
at 400 V
Power factor
(max current)
Efficiency
(max current)
Enclosure class
Application class

80--87 V

630 A/44 V
500 A/40 V
400 A/36 V
8A/20V--630A/44(49)
V
65--72 V

340 W

615 W

640 W

0,90

0,87

0,82

74 %
IP 23

77 %
IP 23

78 %
IP 23

Weight
Dimens. lxwxh

195 kg
1310/765/705

260 kg
1310/765/705

295 kg
1310/765/705

Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a certain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 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.

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5

INSTALLATION

The installation must be executed by a professional.

Note!
Connect the power source to the electricity mains with a network impedance of 0.256 (LHF 400), 0.127
(LHF 630) or lower. If the network impedance is higher, there is a risk of flicker in the illuminators.

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.

Lifting instructions
The power supply should be lifted by means of its lifting
eye. The handle is only intended for pulling it along the
ground.

Installation must be carried out by a qualified electrician.

Check that the welding rectifier is configured for the available mains supply before connecting it
to the mains.

See Connecting to mains for cable rating and fuse rating.

Connect the mains cable to the rectifier according to the relevant regulations and install a suitable
fuse in the main fuse box.

Make sure the welding rectifier is not covered or positioned so that cooling is obstructed.

5.1

Connecting to mains

Frequency
Voltage
Current at
100% duty cycle
60% duty cycle
35% duty cycle
Fuse, slow
Cable area (4xmm2)

Frequency
Voltage
Current at
100% duty cycle
60% duty cycle
35% duty cycle
Fuse, slow
Cable area (4xmm2)

LHF 400
50 Hz
400/415/500 V

LHF 630
50 Hz
400/415/500 V

LHF 800
50 Hz
400/415/500 V

19/19/16 A
24/24/20 A
31/31/25 A
25/25/20 A
4/4/2,5

38/38/30 A
47/47/38 A
59/59/47A
50/50/35 A
10/10/6

49/49/40 A
62/60/50A
79/79/63A
63/63/50A
10/10/10

LHF 400
60 Hz
440/550V

LHF 630
60 Hz
440/550V

LHF 800
60 Hz
440/550V

19/16 A

38/30 A

49/40 A

24/20 A
31/25 A
25/20 A
4/2,5

47/38 A
59/47 A
50/35 A
10/6

62/50 A
79/63 A
63/50 A
10/10

Cable areas comply with Swedish regulations.

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6

OPERATION

Set switch (1) to position I. The white lamp (2) will light and the fan will start.

Select the welding method using the toggle switch (3).

Adjust the welding current using the knob (7) on the front, and set the toggle
switch (8) to the position nearest the socket.

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.

The rectifier is now ready for welding.

6.1

Controls and connections

1. On/Off
2. White lamp (power on)
3. Method selector switch
4. Arc air gouging
5. MMA
6. TIG

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7. Current setting
8. Remote switch
9. Remote socket
10. Yellow lamp (thermal cut--out)

The yellow lamp comes on when the thermal cut--out trips.

When the rectifier has cooled down the thermal cut -- out is automatically reset.

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7

MAINTENANCE

Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
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.

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 sources safety plates for best access.

After cleaning, all safety plates must be mounted before you connect the power
source to the mains supply.

ORDERING OF SPARE PARTS

LHF 400, LHF 630, LHF 800 is designed and tested in accordance with the international
and European standards IEC/EN 60974--1 and EN 60974--10. 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 may be ordered through your nearest ESAB dealer, see the last page of
this publication.

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Assembly instructions

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Diagram

Prim. 400

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Sek. 400

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Prim. 630/800

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Sek. 630/800

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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 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
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: +49 212 298 218
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 2485 377
Fax: +31 30 2485 260

NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
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.
Alcal de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
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

ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313

Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 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 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 8027 9869
Fax: +60 3 8027 4754
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95

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
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060

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
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63

BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 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 57 48

ESAB AB
SE-- 695 81 LAX
SWEDEN
Phone +46 584 81 000
www.esab.com
061127