LHF 405 PIPEMASTER.pdf

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LHF 405 PIPEMASTER
Service manual
0349 300 057
051219
Valid for serial no. 522−xxx−xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LHF 405 PIPEMASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0 control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0:1 Current setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0:2 Functional control circuit ANTISTICK, HOTSTART, ARCFORCE . . . . . . . . . . . . . .
LH21/0:3 Regulator and current shunt amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0:4 Synchronisation and thyristors firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0:5 Thermal overload circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0:6 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH21/0
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Components layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CALIBRATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMA welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Air Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 wiring 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. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and
including December 2005.
The LHF 405 PIPEMASTER is designed and tested in accordance with international
and European standard IEC/EN 60974−1.
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
LHF 405 PIPEMASTER
is thyristor controlled welding rectifier designed for welding
with coated electrodes and arc air gouging.
The welding rectifiers can be used with the following remote control devices:
AT1, AT1 Coarse Fine.
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TECHNICAL DATA
LHF 405 PIPEMASTER
Maximum load
35 % duty cycle
60 % duty cycle
100 % duty cycle
Setting range
Open circuit volt.
Open circuit output
at 400 V
Power factor
(max current)
Efficiency
(max current)
Enclosure class
Application class
Weight
Dimens. lxwxh
400 A/36 V
310 A/33 V
240 A/30 V
10A/20V−400A/36V
75 V
330 W
0,80
70 %
IP 23
194 kg
915/515/630
Duty cycle
The duty cycle refers to the time as a percentage of a ten−minute period that you can weld at a cer-
tain 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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WIRING DIAGRAM
Component description
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
S
Observe precautions for handling electrostatic
sensitive devices.
Use proper static−proof bags and boxes.
B1
B2
C1
C2,C3
H1
H2
L
LH21/0
M1
Q01
R01
R03
R1
RB
S1
T1
T2
V1,V3,V5
V2,V4,V6
Thermal switch: breaks at 68_C, resets at 59_C; fitted on the thyristor
heatsink
Thermal switch: breaks at 160_C
Capacitor 2µF, for cooling fan
Capacitor 0,1µF
Indicating lamp, white
LED, yellow; on when thermal overload is activated, i.e. when one or both
of thermal switcjes B1 and B2 are open
Inductor
Circuit board
Fan
Mains switch
Potentiometer 2kΩ, for controling the welding current
Potentiometer 10kΩ, for ARC FORCE
Base current resistor, 100Ω
Shunt, 120mV@400A
Selector switch, MMA/Air−Arc Gouging
Main transformer
Control transformer, supplied at 35V from X45, secondary 19V supplies
circuit board LH21/0
Main diodes
Main thyristors
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