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Service Manual
PowerMaster
320SP / 400SP / 500 SP

999.9997.9-97

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Summary of Contents for POWERMASTER 320SP

Page 1: ...Service Manual PowerMaster 320SP 400SP 500 SP 999 9997 9 97...

Page 2: ...Pc board DP EMV 22 Pc board LSW 23 Current Sensor VAC 23 Pc board DS VA 24 Pc board PP 90R 24 Control Transformer 25 Temperature Monitoring 26 Supply Voltages 27 Monitoring Welding Current 28 Cooling...

Page 3: ...nstruments 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 part...

Page 4: ...pe again to end the test manually Pump test press the buttons arrow up and material type at the same time the cooling pump is activated for one minute a countdown is shown in the display press button...

Page 5: ...ltage is rectified first and with electronic power switches MOSFETs or IGBTs chopped into a frequency of 80 kHz This allows a very small construction of the welding transformer because it s driven at...

Page 6: ...value and wiring of the sensor E 14 Op voltages error supply voltage is too low 24V supply 17V check mains voltage and control transformer 2 E 16 primary overcurrent protection1 power consumption of p...

Page 7: ...mal 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 flas...

Page 8: ...de normal operation 3 mode serial programming mode normal operation 4 configuration 320SP configuration 400SP 500SP Measuring points designation measure point result solenoid valve X10 1 X10 2 gnd 24V...

Page 9: ...X7 connector fan group 1 X8 CAN connector X9 connector flow meter X10 connector gas valve only used when TIG option is installed X11 connector front panel X13 connector cooling unit X14 CAN connector...

Page 10: ...n 1 red off microcontroller 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...

Page 11: ...ignation X1 torch trigger switch X2 front panel X3 volt amp display X4 wire insert button X5 tacho X6 gas valve X7 pc board PP90R Push Pull option X8 Interpass hose package X10 wire feed motor minus X...

Page 12: ...s display machine parameters version operating system actual values etc Picture Pc board DS20BF X1 LED10 LED11 S2 LED12 LED13 LED16 LED17 LED18 LED7 LED8 LED9 LED1 LED4 LED3 LED2 S1 LED5 LED6 LED14 LE...

Page 13: ...ernately The LC Display shows LEDs on Backlight off Press any button to go to the next test In this test all buttons are checked by pressing all 12 buttons one after another The button which is to be...

Page 14: ...P switch DIP 1 DIP 2 setting machine type OFF OFF 240 A 400SP OFF ON 270 A 320SP ON OFF 300 A 500SP ON ON reserved LED displays normal LED state designation 1 red off primary overcurrent shut down 2 g...

Page 15: ...page 15 Picture Pc board DK DCDRV DK S3DRV X3 X2 X1 S1 LED6 LED4 LED1 LED2 LED5 T T T T T T T T D D00 0050 6 01 T MOSFET power transistor D diode...

Page 16: ...connector temperature sensor Primary Driver The pc board DCDRV is the primary driver board for the transformer It is a classical half bridge design The sup ply is provided via pins 1 2 and 3 of the fl...

Page 17: ...y DCDR 01 and DCDR 03 Since December 2007 additional diodes had been added to the pc boards change from DCDR0x to DCDR1x Since April 2008 a new driver circuit was used change from DCDR1x to DCDR2x typ...

Page 18: ...x E812001 A W1000201 E812001 A W1000301 E812001 A W1000401 12 03 2008 new yes yes new 500SP pc board part no serial no date identification MOSFET toroidal core diode driver ic DK DCDRV 650 1274 x old...

Page 19: ...asure point result mains input L1 X1 400V AC mains input L2 X2 mains input L3 X3 mains output L1 X11 400V AC mains output L2 X12 mains output L3 X13 supply voltage control transformer X10 1 X10 2 400V...

Page 20: ...n measure point result mains input L1 LP1 400V AC mains input L2 LP2 mains input L3 LP3 drive level power up relays X4 1 and 3 X4 2 and 4 24V DC supply control transformer X10 1 X10 2 400V AC mains ou...

Page 21: ...GLCL is for wiring the secondary rectifier diodes Functions wiring secondary diodes pulse smoothing Picture pc board DK GLCL C1 C2 C3 D4 D5 D6 KK1 KK2 KK3 R1 R2 R3 R4 R5 R6 R7 U 1 U 2 ZD4 ZD5 ZD6 X1...

Page 22: ...s wiring welding sockets providing output voltage Picture Pc board DP UFI BO X3 X2 X1 650 5311 x DP UFI BO RP393 2 D00 0107 2 00 Pc board DP EMV Functions EMC filter Picture Pc board DP EMV X3 X2 650...

Page 23: ...0 Current Sensor VAC Since the following serial no the current sensor VAC is used instead of the pc board LSW machine Serial no date 320SP A727001 A W1000101 27 06 2007 400SP A713001 A W1000201 A71300...

Page 24: ...d DS VA C2 C5 C6 C7 C8 H4 H5 H6 H7 H8 H9 IC1 R1 R3 R4 R5 R42 C10 X1 650 1228 0 DS VA RP260 2 D0000138 01 LED41 Pc board PP 90R management for Lorch Push Pull torches Functions supply Push Pull motor M...

Page 25: ...4 8 9 12 13 14 15 5 11 655 8021 0 1 2 3 4 5 6 7 8 655 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 5 9 12 10 11 13 15 14 4 8 Pos 230V 2 5A 19V 3A 0_19V 0_400V 1 0_...

Page 26: ...odule Tem peratures Maximum Temperatures Machine type Temperature 320SP 77 C 400SP 80 C 500SP 75 C If the temperature rises too fast too high the machine will stop and displays E04 air cooling error T...

Page 27: ...Master and the DSP Process If the 24V drops below 17V the machine will stop and displays E14 Op voltages error If the 24V are higher than 36V the machine will stop and displays E02 mains overvoltage S...

Page 28: ...at a welding current of 300A the sen sor output is 150mA The output current is measured via an internal shunt resistor by the Master and Process If the Master measures a current 120 of the maximum val...

Page 29: ...he higher the frequency If the flowrate is below 0 3 liter per minute the machines will stop and dislays E05 cooling system error Schematic The actual flowrate can be monitored via the front panel in...

Page 30: ...ng a voltage higher than 100V the machine will stop and displays E06 secondary overvoltage If the Process should detect a voltage higher that 100V the machine will stop and displays E20 Overvoltage se...

Page 31: ...n and the tacho signal of the motor is monitored by the microcontroller If the current con sumption of the motor is too high e g if wire feed unit is blocked mechanically or if the tacho signal is mis...

Page 32: ...analog input for setting the weld energy e g with an potentiometer 0V minimum setting of the actual welding program 15V maximum setting of the actual welding program CAUTION this analog input is only...

Page 33: ...power unit 1 is broken hardware defect like broken MOSFET power unit 2 is not active if driver signals for the second power unit are missing or the DCDRV pcb of power unit 2 is malfunctioning In this...

Page 34: ...the mains fuses to break The current limitation is made by the PWRUP pcb where each phase is conducted via resistors to the mains rectifier After the bus voltage reached a certain voltage 250V DC the...

Page 35: ...ltage 1 E23 Mains overvoltage E30 Mains undervoltage 2 Should the mains voltage be too low at both power units only at 400SP and 500SP only the error message with the highest number is displayed E30 S...

Page 36: ...are connec ted The identification of the power units is made by a DIP switch at the DCDRV pcbs Should the MAPRO detect that configuration is not valid it will stop and displays E25 Power module detec...

Page 37: ...S GS G D S GS G D S GS G D 9V Batterie 9V battery use a 9V battery to switch on the drain source path drain source path is low resistant short circuit between gate and source to switch off the drain s...

Page 38: ...page 38 Inside Diagram Diodes...

Page 39: ...page 39...

Page 40: ......

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