GB

LAF 1001 /
LAF 1001M

Instruction manual

0449 503 001 GB 2010-08-02 Valid for serial no. 0935-xxx-xxxx

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 1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LIST OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CONNECTION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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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 pre­
cautions. 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 oper­
ation 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. Note! Do not use safety
gloves when replacing wire.
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
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR
EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU­
FACTURER'S 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 keep fumes and gases 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 inflam­
mable materials nearby.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MAN­

UAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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CAUTION!
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.

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

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!

CAUTION!
The welding power source and control box PEH can't be used together.

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2 INTRODUCTION

2.1 General
LAF 1001/ LAF 1001M are remote-controlled 3-phase welding power
sources intended for highly productive mechanised gas metal arc welding
(MIG/MAG) or submerged arc welding (SAW). They can be used together with
ESAB's control box A2 Welding Control Unit (PEI).
The welding power sources are fan-cooled and are monitored by a thermal cutout
against overload. When the thermal cutout is deployed the yellow lamp on the front
panel illuminates automatically. The reset is carried out automatically when the
temperature has decreased to a permitted level.

2.2 Technical data

LAF 1001 LAF 1001M
Mains connection: 400/415/500 V, 350 Hz 230/400/415/500 V, 350 Hz
400/440/550 V, 360 Hz 230/400/440/550 V, 360 Hz
Primary current Imax 80 A Imax 138 A
Permissible load at:
100 % duty cycle 800 A/44 V 800 A/44 V
60 % duty cycle 1000 A/44 V 1000 A/44 V
Setting range
SAW 100-1000 A /24-44 V 100-1000 A /24-44 V
MIG/MAG 100-1000 A /19-44 V 100-1000 A /19-44 V
No-load voltage 53 V 53 V
No-load power 130 W 130 W
Effiency 88% 88%
Power factor 0,92 0,92
Weight 330 kg 330 kg
Dimensions L x W x H 646 x 552 x 1090 646 x 552 x 1090
Insulation class H H
(transformer):
Enclosure class IP 23 IP 23
Application class

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.

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 GB

3 INSTALLATION

3.1 General
The installation must be executed by a professional.

Note!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.

3.2 Location

WARNING - TIPPING RISK!

Fasten the equipment - particularly if the ground is uneven or sloping.

S Place the welding power source on a level foundation.

S Make sure there is nothing to prevent the cooling.

Lifting instructions

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3.3 Connections
S On delivery the welding power source is connected
for 400 V.
S For other supply voltage:
Remove the left side plate.
Perform the switchings on the main and control
transformer in accordance with the connection
instruction on page 14.
S Select the mains cable with the correct cable area
and fuse the cable with the correct fuse in accordance
with local regulations (see the table on page 9).
S Remove the front plates (x 2).

S Connect the ground cable to the screw marked .

S Tighten the cable clamp (1).
S Connect the mains cables to the main connection terminals L1, L2 and L3 (5).
S Connect the control cable between the welding power source and the control
box to the 28-pin connector (2) on the inside of the welding power source.
S Connect the 1-pin measuring cable (4) for measuring the arc voltage to the
return cable/welding head.
S Connect a suitable welding and return cable in the connectors (3) marked + and
- on the front of the welding power source.
S Fit the side/ front plates.

Mains connection
LAF 1001 50 Hz 60 Hz

Voltage (V) 400 415 500 400 440 550

Phase current I1eff (A) 64 64 52 64 64 52

Cable area (mm2) 4 x 16 4 x 16 4 x 16 4 x 16 4 x 16 4 x 16

Fuse, slow (A) 63 63 63 63 63 63

LAF 1001M 50 Hz 60 Hz

Voltage (V) 230 400 415 500 230 400 440 550

Phase current I1eff (A) 111 64 64 52 111 64 64 52

Cable area (mm2) 4x50 4 x 16 4 x 16 4 x 16 4x50 4 x 16 4 x 16 4 x 16

Fuse, slow (A) 125 63 63 63 125 63 63 63

Note:
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. They may not be applicable in other countries: make sure
that the cable area and fuse sizes comply with the relevant national regulations.

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4 OPERATION

4.1 General
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
Note! Never use the welding power source without side plates.

4.2 Controls
The front panel contains:

1. Main circuit-breaker for switching the mains voltage and the fan on
and off in the welding power source.

S Position "1" On
S Position "0" Off

2. S The indicator lamp (white) illuminates when the main switch is

switched on.

3. Indicator lamp for overheating (yellow)

S The indicator lamp illuminates when the thermal cutout is

deployed due to excess temperature in the welding power
source.
S The indicator lamp goes out when the temperature in the
welding power source has decreased to a permitted level.
4. Pushbutton resetting the automatic fuse FU2 for 42 V supply
voltage.

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5 MAINTENANCE

5.1 General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the welding power source during the warranty
period.

5.2 Cleaning
5.2.1 Welding power source

WARNING!
Blocked air inlets or outlets will lead to overheating.

S Clean the welding power source as necessary.

Dry compressed air is recommended for the purpose.

5.2.2 Contactor

WARNING!
Never use compressed air to clean the contactor without first taking it apart
completely.
Note:
To ensure the reliable operation of the contactor, the magnetic parts must be kept
clean.
If the contactor has to be cleaned it must be taken apart, and all the pieces be
cleaned.
Alternatively, the contactor can be replaced.

6 ORDERING OF SPARE PARTS

LAF 1001 / LAF 1001M 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 are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig­
nation and spare part number as shown in the spare parts list on page 17.
This will simplify dispatch and ensure you get the right part.

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 DIAGRAM

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LIST OF COMPONENTS

C = Component designation in the circuit diagram

C Denomination Remarks

AP1 Circuit board

AP2 Circuit board, insulation
AP3 Circuit board, EMC-filter
C1, C2, C3, C4 Capacitor
FU1 Automatic fuse 16 A
FU2 Automatic fuse 20 A
FU3 Fuse 1,25 AT
FU4 Fuse 1,25 AT
FU5 Fuse 3,15 AT
HL1 Indicating lamp (white)
HL2 Indicating lamp (yellow)
KM1 Contactor
KM2 Contactor
L1 Inductor
M1 Fan
QF Main switch
R1, R2, R3, R4 Resistor
RS1 Shunt
ST1 Thermal guard
TC1 Control transformer 42 V, 900 VA
TM1 Transformer
THY1, THY2, THY3 Thyristor
V2 Silicon diode
V3 Diode bridge
V4 Diode bridge
XT2, XT3, XT4 Connection block
RC1 - RC5 Contact protection
XS1 Socket 1 pole
XS2 Socket 1 pole
XS3 Socket 1 pole
XS4 Sleeve socket 28 pole

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CONNECTION INSTRUCTION

LAF 1001

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LAF 1001M

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SPARE PARTS LIST

Edition 2010-08-02

Ordering no. Denomination Notes

0460513880 Welding power source LAF 1001
0460513881 Welding power source LAF 1001M

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

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Item Qty Ordering no. Denomination Notes C

0460513880 Welding power source LAF 1001

1 1 0469844882 Transformer TM1
2.1 1 0469841884 Transformer coil
2.2 1 0469841885 Transformer coil
2.3 1 0469841886 Transformer coil
4 1 0318060001 Capacitor C4
5 1 0318022001 Fan M1
6 1 0321003881 Resistor R3
7 2 0040894001 Connection block XT2
8 1 0551202980 Shunt RS1
9 1 0319445001 Thermal guard ST1
10 1 0320116882 Thyristor bridge
11 2 0490600606 Silicon diode V4
12 5 0455748884 Contact protection RC1-RC5
13 3 0320946001 Thyristor THY1- THY3
14 1 0158115880 Cable inlet
15 1 0162772001 Connection block X1
16 1 0320746002 Main switch Black QF
17 2 0194077008 Automatic fuse 16 A FU1
18 1 0192576004 Indicating lamp (white) HL1
19 1 0192576304 Indicating lamp (yellow) HL2
20 1 0193586104 Automatic fuse 20 A FU2
22 2 0467176001 Handle
23 1 0487399880 Circuit board From serial no. 0935-xxx-xxxx AP1
The circiut board must be configured
when installed
1 0487399884 Circuit board From serial no. 0935-xxx-xxxx AP1
Circuit board configured for LAF 1001
version.
24 1 0805586131 Contactor KM2
25 1 0193358102 Contactor KM1
26 1 0460092002 Control transformer 42 V, 900 VA TC1
27 1 0486224880 Circuit board, EMC filter AP3
28 3 0321468003 Silicon diode V3
29 1 0321489880 Base current bridge
30 1 0318040883 Inductor L1
31 6 0490600626 Silicon diode V2
32 1 0567900129 Fuse 315 mA FU3
33 1 0487068880 Circuit board, insulation AP2
0368544006 Sleeve socket 28-pole, Burndy XS4
34 1 0191093135 Resistor 680R R4
35 1 0523300201 Measure terminal
36 1 0320266880 Diode bridge

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Item Qty Ordering no. Denomination Notes C

0460513881 Welding power source LAF 1001M

1 1 0469844882 Transformer TM1
2.1 1 0469841884 Transformer coil
2.2 1 0469841885 Transformer coil
2.3 1 0469841886 Transformer coil
4 1 0318060001 Capacitor C4
5 1 0318022001 Fan M1
6 1 0321003881 Resistor R3
7 2 0040894001 Connection block XT2
8 1 0551202980 Shunt RS1
9 1 0319445001 Thermal guard ST1
10 1 0320116882 Thyristor bridge
11 2 0490600606 Silicon diode V4
12 5 0455748884 Contact protection RC1-RC5
13 3 0320946001 Thyristor THY1- THY3
14 1 0158115880 Cable inlet
15 1 0040894001 Connection block X1
16 1 0320746002 Main switch Black QF
17 2 0194077008 Automatic fuse 16 A FU1
18 1 0192576004 Indicating lamp (white) HL1
19 1 0192576304 Indicating lamp (yellow) HL2
20 1 0193586104 Automatic fuse 20 A FU2
22 2 0467176001 Handle
23 1 0487399880 Circuit board From serial no. 0935-xxx-xxxx AP1
The circiut board must be configured
when installed
23 1 0487399884 Circuit board From serial no.0935-xxx-xxxx AP1
Circuit board configured for LAF 1001
version.
24 1 0805586131 Contactor KM2
25 1 0442849880 Contactor KM1
26 1 0460092002 Control transformer 42 V, 900 VA TC1
27 1 0486224880 Circuit board, EMC filter AP3
28 3 0321468003 Silicon diode V3
29 1 0321489880 Base current bridge
30 1 0318040883 Inductor L1
31 6 0490600626 Silicon diode V2
32 1 0567900129 Fuse 315 mA FU3
33 1 0487068880 Circuit board, insulation AP2
0368544006 Sleeve socket 28-pole, Burndy XS4
34 1 0191093135 Resistor 680R R4
35 1 0523300201 Measure terminal
36 1 0320266880 Diode bridge

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ESAB subsidiaries and representative offices

Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
Larvik CHINA
ESAB Ges.m.b.H Shanghai ESAB A/P ESAB Representative Office
Vienna-Liesing Tel: +47 33 12 10 00 Sofia
Fax: +47 33 11 52 03 Shanghai
Tel: +43 1 888 25 11 Tel: +86 21 2326 3000 Tel/Fax: +359 2 974 42 88
Fax: +43 1 888 25 11 85 Fax: +86 21 6566 6622
POLAND EGYPT
BELGIUM ESAB Sp.zo.o. INDIA ESAB Egypt
S.A. ESAB N.V. Katowice ESAB India Ltd Dokki-Cairo
Brussels Tel: +48 32 351 11 00 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 32 351 11 20 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 745 11 28 Fax: +91 33 468 18 80
PORTUGAL ROMANIA
THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
ESAB VAMBERK s.r.o. Lisbon P.T. ESABindo Pratama Bucharest
Vamberk Tel: +351 8 310 960 Jakarta Tel/Fax: +40 1 322 36 74
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 0188
Fax: +420 2 819 40 120 Fax: +62 21 461 2929 RUSSIA
SLOVAKIA LLC ESAB
DENMARK ESAB Slovakia s.r.o. JAPAN Moscow
Aktieselskabet ESAB Bratislava ESAB Japan Tel: +7 095 543 9281
Herlev Tel: +421 7 44 88 24 26 Tokyo Fax: +7 095 543 9280
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +81 45 670 7073
Fax: +45 36 30 40 03 Fax: +81 45 670 7001 LLC ESAB
SPAIN St Petersburg
FINLAND ESAB Ibérica S.A. MALAYSIA Tel: +7 812 336 7080
ESAB Oy Alcalá de Henares (MADRID) ESAB (Malaysia) Snd Bhd Fax: +7 812 336 7060
Helsinki Tel: +34 91 878 3600 USJ
Tel: +358 9 547 761 Fax: +34 91 802 3461 Tel: +603 8023 7835
Fax: +358 9 547 77 71 Fax: +603 8023 0225 Distributors
SWEDEN For addresses and phone
FRANCE ESAB Sverige AB SINGAPORE numbers to our distributors in
ESAB France S.A. Gothenburg ESAB Asia/Pacific Pte Ltd other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Singapore home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Tel: +65 6861 43 22
www.esab.com
Fax: +33 1 30 75 55 24 ESAB international AB Fax: +65 6861 31 95
Gothenburg
GERMANY Tel: +46 31 50 90 00 SOUTH KOREA
ESAB GmbH Fax: +46 31 50 93 60 ESAB SeAH Corporation
Solingen Kyungnam
Tel: +49 212 298 0 SWITZERLAND Tel: +82 55 269 8170
Fax: +49 212 298 218 ESAB AG Fax: +82 55 289 8864
Dietikon
GREAT BRITAIN Tel: +41 1 741 25 25 UNITED ARAB EMIRATES
ESAB Group (UK) Ltd Fax: +41 1 740 30 55 ESAB Middle East FZE
Waltham Cross Dubai
Tel: +44 1992 76 85 15 North and South America Tel: +971 4 887 21 11
Fax: +44 1992 71 58 03 Fax: +971 4 887 22 63
ARGENTINA
ESAB Automation Ltd CONARCO
Andover Buenos Aires
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313
BRAZIL
HUNGARY
ESAB S.A.
ESAB Kft
Contagem-MG
Budapest
Tel: +55 31 2191 4333
Tel: +36 1 20 44 182
Fax: +55 31 2191 4440
Fax: +36 1 20 44 186
CANADA
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20
Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
MEXICO
THE NETHERLANDS ESAB Mexico S.A.
ESAB Nederland B.V. Monterrey
Amersfoort Tel: +52 8 350 5959
Tel: +31 33 422 35 55 Fax: +52 8 350 7554
Fax: +31 33 422 35 44
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48

ESAB AB
SE-695 81 LAXÅ
SWEDEN
Phone +46 584 81 000

www.esab.com

081016