LUA 400

Bruksanvisning Manuel d’instructions

Brugsanvisning Gebruiksaanwijzing
Bruksanvisning Instrucciones de uso
Käyttöohjeet Istruzioni per l’uso
Instruction manual Manual de instruções
Betriebsanweisung

0456 053 001 020311 Valid from serial no. 535--xxx--xxxx

SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INLEDNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TEKNISK BESKRIVNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TILLBEHÖR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TECHNICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Schema -- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Reservdelsförteckning -- Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . 94

Rätt till ändring av specifikationer utan avisering förbehålles.

Rights reserved to alter specifications without notice.

 ENGLISH

ENGLISH

INTRODUCTION
LUA 400 is a welding rectifier built on the inverter principle and designed for welding
with coated electrodes, TIG welding, semi--automatic welding and arc air gouging.
Advanced electronics permit rapid control, low energy consumption, excellent weld-
ing characteristics and compensation for mains voltage fluctuation.
Inverter technology contributed to the low weight and compact dimensions of the
unit. The rating plate and connection information are located at the rear of the LUA.
LUA is supplied with two handles, connecting bolts, Allen key and cable couplings.

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 pre-
cautions.

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.

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 inflammable 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 -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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 ENGLISH

Applications
LUA 400 is the ideal choice for those who require a single power source that permits
the use of all welding methods.
The basic unit, the LUA 400 power source, can be combined with ESAB standard
components to create a complete system for MIG/MAG, manual or TIG welding. This
instruction manual only describes the LUA 400 power source. (Order numbers for
complementary equipment can be found in the ”Accessories” section).

Manual welding
The high open circuit voltage and a carefully chosen ”start puff” at the beginning of
welding ensure a smooth start to the welding cycle and easy striking of electrodes.
The ”anti--freeze feature” of LUA greatly reduces the risk of the electrode sticking to
the work piece. If however the electrode does stick then the welding current is auto-
matically reduced so that the electrode can be freed without damage and welding
can continue immediately. This feature facilitates the welding of root beads in par-
ticular and saves electrodes.

MIG/MAG welding
In the case of semi--automatic welding the power source must be combined with a
wire feed unit, welding gun and gas bottle.
The latest electronics have been used to produce a compact, manageable and reli-
able semi--automatic supply with first class characteristics for MIG/MAG welding.
By using ESAB’s wide selection of semi--automatic components (wire feed units, re-
mote controls, welding guns, counterbalance arms and cooling units) you can cus-
tomise equipment to suit your welding requirements. ESAB’s special brochures de-
scribe the wide selection of semi--automatic equipment and accessories.

TIG welding
When combined with ESAB’s TIG--AID and BTD TIG gun the LUA 400 is an excellent
unit for professional TIG welding.
Low current operation is essential for welding thin sheet metal. The LUA 400 sat-
isfies this requirement, with a minimum welding current of just 15 A.
During TIG welding the ”start puff” and ”anti-- freeze” features should be switched off.
This is done by turning the rotary switch on the front panel to the ”TIG” setting.

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 ENGLISH

TECHNICAL DESCRIPTION
This is how the LUA inverter works.
The incoming 3 phase AC current is rectified. Then it is converted back into AC using
a much higher frequency than mains frequency. After transformation the current is
again rectified to give a DC supply for welding. The entire cycle is controlled by a
control circuit that gives the power source the desired static characteristic and dy-
namic performance.
LUA is divided into four main sections:

S The control section on top, comprising the circuit card, controls and electronics.
S The fan compartment, containing the fan and power resistor.
S The remaining components are mainly divided into mains components and weld-
ing components.

Control system
The LUA control system used modern electronics to create a power source that has
excellent static and dynamic welding characteristics, high efficiency, high power fac-
tor, low minimum current, start puff, anti--freeze, foldback, electrically insulated re-
mote control, compensation for mains fluctuations, etc.

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 ENGLISH

TECHNICAL DATA

Current setting range 15 A/20 V -- 400 A/36 V

TIG welding 15--400 A
Manual welding 20--400 A
Semi--automatic welding 45--400 A

Maximum load
Manual welding
-- at 35% duty cycle 400 A/36 V
-- at 60% duty cycle 315 A/32.6 V
-- at 100% duty cycle 150 A/26 V
TIG welding
-- at 35% duty cycle 400 A/26 V
-- at 60% duty cycle 315 A/22.6 V
-- at 100% duty cycle 250 A/20 V
Semi--automatic welding
-- at 35% duty cycle 400 A/34 V
-- at 60% duty cycle 315 A/30 V
-- at 100% duty cycle 200 A/24 V

Open circuit voltage 65--75 V

Open circuit power 0.06 kW
Power factor λ 0.94
Efficiency η 0.80
Enclosure class IP 23
Application class
Weight 48 kg

Mains supply
Voltage (V) 3x230 3x400 3x415 3x440 3x500 3x550
Frequency (Hz) 50/60 50/60 50 60 50 60
Primary current (A) 40 26 25 18 19 15
Fuse, slow (A) 35 20 20 20 20 20
Cable (mm2) 4x6 4x2.5 4x2.5 4x2.5 4x2.5 4x2.5

This welding power source complies with IEC 974--1

Mains cable complies with Swedish regulations.

The symbol indicates the power source is designed for use in area of increased
electrical hazard.
The IP code indicates the degree of protection the casing provides against penetra-
tion of solid objects and water.
Equipment marked IP 23 is designed for indoor and outdoor use.

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 ENGLISH

INSTALLATION
Check that the welding power source is set up for the available main voltage before
connecting it to the supply.
The voltage is indicated on the rating plate at the rear of the power source.
LUA must be connected to a three phase mains supply.
LUA is supplied with a mains cable. The cable is connected to the terminals L1, L2
and L3 on terminal block K11. The phase sequence is not important. The cable
grommet and cable grip are located on the bottom right at the rear of the rectifier.
The equipment must be earthed in accordance with regulations.
Suitable welding and return cables for the LUA 400 are 50 mm2.

Controls on front panel of LUA:

1. Power switch
2. White lamp which lights up when rectifier
is switched on
3. Yellow lamp which lights up if power
source overheats
4. Rotary switch for selecting between
MIG/MAG, manual, or TIG welding
5. Knob for adjusting welding current.
Equipped with planetary gear to allow
fine adjustment. A sliding clutch prevents
damage caused if the knob is turned past
the min. or max. settings.
6. Toggle switch for selecting between cur-
rent control on front panel or remote con- bu07d001

trol
7. Socket for remote control

Controls at rear of LUA:

8. Automatic fuse which protects against
overloading and high current spikes
9. Socket for connecting wire feed unit and
MIG/MAG remote control
10. Socket for connecting OCD1 cooling unit
or TIG--AID (220 V)
11. Fuses

bu07d002

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 ENGLISH

OPERATION
1. LUA must be placed upright.
2. Set the automatic fuse on the rear to setting I.
3. Set the power switch to setting I. The power lamp will light up and the fan will
start.
4. Check that there is no restriction in the flow of air.
5. Set the rotary switch to MIG/MAG, manual or TIG, as required. There are three
different MIG/MAG settings. A gives the ”coldest” weld and C gives the ”hottest”
weld.
6. In the case of MMA or TIG welding, set the toggle switch on the front panel to
allow direct or remote control of the welding current, as required.
7. In the case of MIG/MAG welding the remote control must also be connected to
the socket on the wire feed unit and the toggle switches on the wire feed unit and
the front panel must both be set to the appropriate setting.
8. Fine adjust the welding current using the knob on the front panel or using the re-
mote control. See relevant instruction manual.
9. Check that the couplings on the welding cable and return cable are properly con-
nected to LUA.
10. LUA is now ready to start welding.
Operating instructions for the wire feed unit and TIG--AID are supplied with that
equipment.

Safety devices
As mentioned previously there is an automatic fuse unit on the rear of the LUA
power source.
In the event of overloading or a high current spike this fuse trips automatically and
switches off the power.
To continue operation the automatic fuse must be reset to setting I. If the fuse trips
repeatedly you should call in a service engineer.
LUA is also equipped with a thermal overload switch that automatically switches off
the power in the event of overload or overheating (yellow lamp lights up). This is
reset automatically once the components have cooled down to an acceptable tem-
perature.

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 ENGLISH

MAINTENANCE
Depending on the environment it is used in the power source should be blown clean
regularly using dry compressed air at reduced pressure. Otherwise blocked air in-
takes or vents may lead to overheating.

Ordering spare parts

When ordering spare parts please state the machine model, serial number plus the
name and spare part number as shown in the list of spare parts.
This makes dispatch easier and ensures correct delivery.

ACCESSORIES

LUA 400 multi--voltage version.

LUA 400 is supplied as standard for connection to 380--415 V mains supplies. By fit-
ting a voltage module the LUA 400 can also be connected to the following supply
voltages:
220/380/415/500 V -- 50 Hz and
220/380/440/550 V -- 60 Hz.

Remote control
Order no.

S PHB 1 remote control 367 317--880

S PHB 2 remote control 367 318--880
S PHC 2 remote control 367 620--880
S PHA 5 pulse unit
with Cannon connector 320 128--880
with Burndy connector 367 970--880
S PHA 2 hot--start unit 367 601--880

S Programmer unit PAB 6 367 308--880

S Crater filling unit PAC 8 367 305--880
S Short pulse unit PAD 3 367 502--880

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 ENGLISH

Connection and extension cables

PHB 1, PHB 2, PHC 2, PHA 5 och PHA 2.
Order no.

S 5 m connecting cable 367 144--881

S 10 m connecting cable 367 144--882
S 25 m connecting cable 367 144--883
S 25 m extension cable 367 662--880

Remote control cable PAB 6, PAC 8, PAD 3.

S 5 m, 367 144--884
S 10 m, 367 144--885
S 16 m, 367 144--886

Switching unit

S For permanent connection. 321 170--880

S For cable connection. 321 170--881

Optional accessories for LUA include:

Order no.

S Trolley for power source 365 187--880

S LUA semi--trolley (Basic)
for power source and wire feed 367 360--882
S LUA semi--trolley (water)
for power source and wire feed 367 360--880
S LUA maxi--trolley ”JUMBO”
with space for cooling unit
and TIG--AID 367 360--881
S TIG--MAID I trolley 365 075--880

bu07d12e -- 45 --
Schema Skema Skjema Johdotuskaavio Diagram Schaltplan Schéma
Schema Esquema Schema Esquema

bu07e001

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LUA 400 Edition 020311

Reservdelsförteckning Reservedelsfortegnelse Reservedelsliste

Varaosaluettelo Spare parts list Ersatzteilliste Liste de pièces détachées
Reserveonderdelenlijst Lista de repuestos Elenco ricambi Lista de peças
sobressalentes

Valid for serial no. 535--xxx--xxxx

Ordering numbers for LUA 400

0367 044 880 Welding power source 380 V, 50 Hz
0367 044 881 Welding power source 220/380 V, 50/60 Hz
0367 044 882 Welding power source 220/380/415/440/500/550 V, 50/60 Hz
0367 044 883 Welding power source 380/415 V, 50/60 Hz
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.

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

101 0365 452 001 Side panel

102 0365 451 001 Cover plate

103 0318 113 001 Knob

104 0192 576 004 Lamp

105 0193 666 003 LED Yellow

106 0319 187 001 Indicator

107 0191 510 104 Knob

108 0147 866 001 Switch

109 0368 544 003 Socket

110 0468 883 001 Front sign

111 0192 296 104 Control knob

112 0367 240 881 Front plate

113 0160 362 881 Cable connection

114 0320 787 001 Cover

115 0467 290 001 Automatic cut out

116 0368 544 005 Socket Burndy

117 0567 901 116 Fuse 10 A

118 0567 900 113 Fuse 4A

119 0156 388 001 Handle

120 0367 098 002 Rear plate

121 0319 455 002 Foot

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LUA 400 Edition 020311

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

201 0191 309 107 Clamp

202 0341 609 880 Filter

203 0320 689 101 Resistor

204 0320 688 002 Diode

205 0367 030 880 Welding diode filter

206 0320 704 002 Capacitor

207 0367 577 880 Resistor

208 0320 870 880 Inductor

209 0367 033 880 Inductor

210 0365 348 880 Control transformer

211 0320 655 001 Thermostat

212 0320 729 001 Current transformer

213 0367 168 880 Diode bridge

214 0320 795 001 Fan

215 0320 558 880 Shunt

216 0320 655 002 Thermostat

217 0367 032 880 Mains transformer

218 0192 903 501 Capacitor

219 0367 020 880 Thyristor module filter

220 0193 542 001 Connection block

221 0367 127 880 Choke

222 0193 545 107 Capacitor

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LUA 400 Edition 020311

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

301 0191 870 212 Potentiometer 2,5 KÙ

302 0192 576 004 Lamp

303 0367 105 002 Switch

304 0467 356 880 Automatic fuse

305 0481 190 880 Circuit board

306 0320 724 001 Transformer

307 0191 085 102 Capacitor

308 0481 255 880 Circuit board

309 0481 343 882 Main circuit board

310 0192 927 102 Spacer

311 0147 866 001 Switch

0367 234 883 Autotransformer Contains items 312, 313, 314 and 315b

312 0365 551 002 Rear panel

313 0365 001 003 Cover

314 0365 000 881 Rear plate

315a 0367 235 001 Transformer 220/380V

315b 0365 134 002 Transformer 220/380/415/440/500/550 V,

315c 0368 175 001 Transformer 415/380 V

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LUA 400 Edition 020311

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

0365 187 880 Carriage

401 0365 255 880 Handle compl.

402 0320 939 002 Brakcet left

403 0320 939 001 Bracket right

404 0321 001 001 Ring

405 0365 255 881 Handle compl.

406 0218 801 202 Rubber handle Included in item 405 and 401

407 0365 066 001 Support

408 0366 451 001 Chassis

409 0365 068 003 Shaft

0215 701 019 Grooved ring D25x1,2

410 0366 516 001 Wheel

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

0367 360 882 Carriage semi

501 0278 300 401 Insulating bushing

502 0318 170 001 Bracket

503 0321 173 001 Chain L=700

504 0365 388 001 Handle

505 0365 068 003 Shaft

506 0215 701 019 Grooved ring D25x1.2

507 0366 516 001 Wheel

508 0159 932 004 Swivel castor

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

0367 360 880 Semi carriage

601 0278 300 401 Insulating bushing

602 0318 170 001 Bracket

603 0321 173 001 Chain L=700

604 0365 388 001 Handle

605 0365 068 003 Shaft

606 0366 516 001 Wheel

607 0215 701 019 Grooved ring D25x1.2

608 0159 932 004 Swivel castor

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

0367 360 881 Semi carriage

701 0156 388 001 Handle

702 0156 389 001 Bar

703 0278 300 401 Insulating bushing

704 0318 170 001 Bracket

705 0321 173 001 Chain L=700

706 0366 516 001 Wheel

707 0215 701 019 Grooved ring D25x1.2

708 0365 068 003 Shaft

709 0159 932 004 Swivel castor

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LUA 400 Edition 020311

Item Qty Ordering no. Denomination Notes

0365 075 880 Trolley Tigaid 1

801 0321 173 001 Chain L=700

802 0159 932 001 Swivel castor

803 0365 038 001 Wheel

804 0365 046 001 Shaft

0215 701 019 Circlips

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ESAB subsidiaries and representative offices

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SE-- 695 81 LAXÅ
SWEDEN
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