LORCH Saprom S Service Manual Download Page 2 | Manualshive

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2

Contents

Subject

Page

Machine

3

Machine Elements

3

Safety precautions

4

Common Logic Functions

5

Schematic S-Series

6

Troubleshooting guide

7

Pc-board DP-MAPRO

8

Pc-board DMR

11

Pc-board DS20BF

13

Pc-board DK-DCDRV / DK-S3DRV

16

Pc-board DK-PWRUP

18

Pc-board PWRUP04

19

Pc-board DP-S3NEFI

20

Pc-board DK-GLCL

21

Pc-board DP-UFI

22

Pc-board DP-UFI-BO

23

Pc-board DP-EMV

23

Pc-board LSW

24

Pc-board DS-VA

24

Pc-board PP-90R

25

Pc-board DS-ERW

26

Control Transformer

27

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Summary of Contents for Saprom S

Page 1: ...Service Manual Saprom S 909 0620 1 01 ...

Page 2: ...ing guide 7 Pc board DP MAPRO 8 Pc board DMR 11 Pc board DS20BF 13 Pc board DK DCDRV DK S3DRV 16 Pc board DK PWRUP 18 Pc board PWRUP04 19 Pc board DP S3NEFI 20 Pc board DK GLCL 21 Pc board DP UFI 22 Pc board DP UFI BO 23 Pc board DP EMV 23 Pc board LSW 24 Pc board DS VA 24 Pc board PP 90R 25 Pc board DS ERW 26 Control Transformer 27 ...

Page 3: ... air intake 2 pressure reducer 10 transport wheels 3 gas cylinder 11 main switch 4 tray area 12 display current voltage 5 facility for transport 13 ground clamp 6 handle 14 connector for ground cable 7 front panel 15 display cover 8 connections ...

Page 4: ...evention by working with this machine Only qualified workers who are knowledgeabel and have been trained to work safely with test instruments and equipment on energized circuits shall be permitted to perform testing work on electrical circuits or equipment were there is danger of injury from accidental contact with energized parts or improper use of the test instru ments and equipment Use only ori...

Page 5: ... their default values if Tiptronic is active the settings of the current job are reset to their programmed values all adjustments of the Extras menu remain unchanged Master reset press the buttons arrow up and Mode together for about five sec the display shows Master Reset the machine is reset completely to factory settings CAUTION all Tiptronic jobs are deleted component function associated event...

Page 6: ...6 Schematic S Series ...

Page 7: ...torch socket cable short circuit of torch control cables or between torch switch wires and welding potential check torch control cables and torch interface E 11 remote control conn short circuit between remote control cables check remote control and wiring of remote control socket E 12 Communication Process Process is not responding to Master switch the machine off and on again optionally exchange...

Page 8: ...parameters CAN bus LED displays If the LEDs are indicating a malfunction which can not be relieved by switching the machine off and on again it is recommended that the pc board DP MAPRO is exchanged normal LED state designation 1 green flashing half freq of LED5 CPLD processor ok 2 red off Digital Signal Processor DSP ok 3 green on supply voltage 3 3V DC ok 4 red off micro controller ok 5 green fl...

Page 9: ...point result solenoid valve X10 1 X10 2 GND 24V DC supply voltage control transformer X6 1 X6 3 230V AC supply voltage fan group 1 X7 1 X7 2 230V AC supply voltage fan group 2 X25 1 X25 2 230V AC supply voltage cooling pump X13 1 X13 2 230V AC supply voltage control transformer X2 1 X2 2 18V AC X2 3 X2 4 42V AC supply voltage flow meter X9 1 X9 3 GND 15V DC supply voltage CAN bus X8 1 X8 2 GND 15V...

Page 10: ...10 Picture Pc board DP MAPRO X5 X6 X7 X25 X9 X18 X13 X19 LED4 LED6 LED 3 X1 X4 X14 X17 X20 X8 X3 X10 X11 X16 X23 X21 X22 LED1 LED5 LED2 X2 ...

Page 11: ... ok 2 green on supply voltage 5V ok malfunction LED state designation 1 red is lit weak microcontroller not programmed flashes malfunction CAN bus 2 green off supply voltage 5V not ok Measuring points designation measure point result solenoid valve X6 1 X6 2 GND 24V DC supply voltage Tacho X5 1 X5 3 GND 5V DC drive level for pc board PP90R Push Pull X7 1 X7 3 GND 24V DC wire insert button when but...

Page 12: ...12 Picture Pc board DMR ...

Page 13: ... panel with all buttons rotary impulse encoder and all displays Functions operating setup the machine display of all welding parameters display error messages display machine parameters version operating system actual values etc Picture Pc board DS20BF ...

Page 14: ...14 At a machine with separated front panels the pc boards DS21BF and DS22BF are used ...

Page 15: ...t all buttons are checked by pressing all 12 buttons one after another The button which is to be pressed is indicated by a lit LED After that the rotary impulse encoders are checked The LCD Display shows a cursor which can be moved by the rotary impulse encoders At first the cursor has to be moved to the left with the left rotary impulse encoder then to the right After that the cursor has to be mo...

Page 16: ...ontact closed If DIP switches are used instead of jumper 0 OFF 1 ON LED displays jumper J1 jumper J2 setting machine type 0 0 240 A S5 0 1 270 A S3 1 0 300 A S8 1 1 reserved normal LED state designation 1 red off primary overcurrent shut down 2 green on drive level of low side is ok 4 green on DC link voltage max is ok 5 green on drive level of high side is ok 6 green on DC link voltage min is ok ...

Page 17: ...Picture Pc board DK DCDRV DK S3DRV designation Messpunkt Messergebnis supply voltage pc board LSW X2 1 X2 6 GND 15V DC supply voltage pc board LSW X2 3 X2 6 GND 15V DC thermal sensor X3 1 X3 2 GND 10kΩ at 25 C about 2V DC ...

Page 18: ...ransformer Measuring Points Picture Pc board DK PWRUP Fuses Safeguarding the control transformer via Si1 Si2 each 4A idle Beschreibung Messpunkt Messergebnis mains input L1 mains input L2 mains input L3 X5 X6 X7 400V AC mains output L1 mains output L2 mains output L3 X1 X2 X3 400V AC supply voltage control transformer X10 1 X10 2 400V AC drive level relay X4 1 3 X4 2 4 24V DC ...

Page 19: ...rol transformer Measuring Points Picture Pc board PWRUP04 Fuses Safeguarding the control transformer via Si1 Si2 each 4A idle designation measure point result mains input L1 mains input L2 mains input L3 X5 X6 X7 400V AC mains output L1 mains output L2 mains output L3 X1 X2 X3 400V AC supply voltage control transformer X10 1 X10 2 400V AC drive level relay X4 1 3 X4 2 4 24V DC ...

Page 20: ...S3NEFI Fuses Safeguarding the control transformer via Si3 Si4 each 4A idle designation measure point result mains input L1 LP1 400V AC mains input L2 LP2 400V AC mains input L3 LP3 400V AC drive level power up relais X4 1 X4 3 X4 2 X4 4 24V DC GND supply control transformer X10 1 X10 2 400V AC mains output L1 LP4 400V AC mains output L2 LP5 400V AC mains output L3 LP6 400V AC X4 X10 SI3 SI4 LP1 LP...

Page 21: ...21 Pc board DK GLCL The pc board DK GLCL is for wiring the secondary rectifier diodes Functions wiring pulse smoothing Picture pc board DK GLCL ...

Page 22: ...ing serial no the pc board DP UFI was replaced by the boards DP UFI BO and DP EMV designation measure point result secondary output voltage nm MMA mode X3 X2 GND ca 81V DC socket socket GND ca 81V DC X1 1 X1 2 GND ca 81V DC machine serial no date Saprom S3 405 1525 001 22 06 2005 Saprom S5 403 1525 001 22 06 2005 Saprom S8 404 1525 001 22 06 2005 Saprom S3 mobile 406 1524 001 24 06 2005 ...

Page 23: ...wiring welding sockets providing output voltage Picture Pc board DP UFI BO Pc board DP EMV Functions EMC filter Picture Pc board DP EMV X3 X2 X1 650 5311 x DP UFI BO RP393 2 D00 0107 2 00 X3 X2 650 5316 x DP EMV RP399 2 D00 0107 1 00 ...

Page 24: ...e Pc board LSW Pc board DS VA Digital display Functions display nominal and actual values of welding voltage and welding current hold function of the last welding values LED displays Picture Pc board DS VA designation measure point result supply voltage X1 1 X1 3 30V DC normal LED state designation 41 green on hold function active ...

Page 25: ...h Pull torches Functions supply Push Pull motor managing start signal Measuring points Picture Pc board PP 90R designation measuring point result supply voltage X1 2 X1 5 42VAC motor voltage X1 4 X1 1 60VDC drive level relay X1 7 X1 6 GND 24VDC ...

Page 26: ... driving solenoid valve driving water valves LED displays Measuring Points Picture Pc board DS ERW normal LED state designation 1 green off wire feed unit 1 active on wire feed unit 2 active designation measuring point result solenoid valve 1 X5 1 X5 2 GND 24V DC solenoid valve 1 X6 1 X6 2 GND 24V DC water valve 1 X7 1 X7 2 42V AC water valve 2 X8 1 X8 2 42V AC ...

Page 27: ...S3 mobile 655 8023 0 400V 3 2 0 400V 1 0 18V 0 18V 0 18V 42V 4A 0 42V 18V 1A 18V 0 4A 18V 0 4A 0 400V 1 0 42V 42V 3 5A 400V 2 Pos 4 3 7 8 Pos 20V 3A 0 20V 5 6 primary secondary 5 11 655 8021 0 3 1 2 10 4 8 9 12 13 14 15 5 9 12 10 11 13 15 14 4 8 Pos 230V 2 5A 19V 3A 0 19V 1 2 3 4 5 6 7 8 primary secondary Secondary primary secondary 1 2 3 4 ...

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