LORCH P-Basic Service Manual Download

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Lorch Schweisstechnik GmbH
Im Anwaender 24 - 26
D-71549 Auenwald

Telephone: +49 7191 503-0
Fax:

+49 7191 503-199

Website: www.lorch.eu
Email: [email protected]

909.2710.1-06

Service manual

S-Pulse/S-SpeedPulse XT

P-Basic/-Synergic XT

Summary of Contents for P-Basic

Page 1: ...weisstechnik GmbH Im Anwaender 24 26 D 71549 Auenwald Telephone 49 7191 503 0 Fax 49 7191 503 199 Website www lorch eu Email info lorch eu 909 2710 1 06 Service manual S Pulse S SpeedPulse XT P Basic Synergic XT ...

Page 2: ... Copyright 2020 LORCH Schweisstechnik GmbH This documentation including all its parts is protected by copyright Any use or modification outside the strict limits of the copyright law without the permission of LORCH Schweisstechnik GmbH is prohibited and liable to prosecution This particularly applies to reproductions translations microfilming and storage and processing in electronic systems Techni...

Page 3: ...Pc board DCDR21 DCDR23 32 7 12 Pc board DK PWRUP DK PWRUP02 35 7 13 Pc board DK PWRUP04DKL DK PWRUP05 DKL 36 7 14 Pc board DP S3NEFI 37 7 15 Pc board DK GLCL3 39 7 16 Pc board DP UFI BO 40 7 17 Pc board DP EMV 40 7 18 Pc board DS ERW 41 7 19 Pc board TC21 43 8 Electrical Components 44 8 1 Current Sensor VAC 44 8 2 Control transformer 46 8 3 TIG Option 47 9 Troubleshooting 48 9 1 Monitoring tempera...

Page 4: ...Machine elements 4 02 20 909 2710 1 06 1 Machine elements 19 18 17 16 15 14 11 4 28 1 27 17 20 21 24 17 26 25 12 13 10 9 2 8 7 6 5 3 22 23 Fig 1 Machine elements S P driveable ...

Page 5: ...12 TIG torch socket control line optional 13 TIG torch gas connection optional 14 Hand grip 15 Display welding current voltage indicator 16 Control panel 17 Hoisting points 18 Protective cover operating console option al 19 Torch 20 Pressure reducer 21 Gas bottle 1 1 Accessories 22 Gas hose 23 Chain 24 Tray area 25 Mains plug 26 Ground clamp 27 Main switch 28 Transport rollers 29 Socket for WUK 5 ...

Page 6: ...nt were there is danger of injury from accidental contact with energized parts or improper use of the test instruments and equipment Use only original spare parts Replace any components that are not in perfect condition immediately Carry out the safety inspection after every repair or hardware change of the machine Norms IEC 60974 4 In service inspection and testing 2 2 Testing Lorch machines acco...

Page 7: ...ied 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 this high frequency The basic structure of a welding inverter is always the same at Lorch power sources mains filter power up circuit mains rectifier primary inverter transformer secondary rectifier mains filter 3 p...

Page 8: ...1 L2 L3 F4 F3 L1A L2A L3A A2 1 2 3 A3 F2 A T2 A4 A X2 A5 L1 A6 X3 X8 2 3 4 5 6 A7 A10 M1 M A11 X4 G XT 4 XT 3 XT 1 M2 M Y1 A13 15 F1 3 4 2 1 X5 1 X10 2 X10 1 X4 1 X4 2 X1 X1 X2 3 X2 2 X2 1 X1 2 X1 3 X1 1 X10 1 X10 2 X17 1 X17 2 X8 X5 X2 6 X2 5 X3 1 X3 2 X2 1 X2 2 X2 3 X6 1 X2 4 X6 3 X13 1 X13 2 X9 1 X9 2 X9 3 X9 4 X8 1 X8 2 X8 3 X8 4 X5 4 X5 1 X5 2 X5 3 X11 X6 1 X10 X6 2 X4 1 X4 2 X1 1 X1 2 X1 1 X...

Page 9: ... 1 2 3 A3 F2 A T2 A4 A X2 A5 L1 A6 X3 A7 A10 A11 X4 G XT 4 XT 3 XT 1 M3 M Y1 A13 15 F1 3 4 2 1 X5 X10 2 X10 1 X4 1 X4 2 X1 X1 X2 3 X2 2 X2 1 X1 2 X1 3 X1 1 X7 1 X7 2 X17 1 X17 2 X8 X5 X2 6 X2 5 X3 1 X3 2 X2 1 X2 2 X2 3 X2 4 X9 2 X9 3 X9 1 X11 X16 X8 1 X8 2 X8 3 X8 4 X5 4 X5 1 X5 2 X5 3 X11 X6 1 X10 X6 2 X4 1 X4 2 X1 1 X1 2 X1 1 X1 2 X12 2 X3 X2 X2 X3 X3 X2 S1 S2 F5 1 2 3 A8 A9 X1 X1 M1 2 1 M F6 X1...

Page 10: ...L1 A6 X3 A7 A10 A11 X4 G XT 4 XT 3 XT 1 M3 M Y1 A13 15 F1 3 4 2 1 X5 X10 2 X10 1 X4 1 X4 2 X1 X1 X2 3 X2 2 X2 1 X1 2 X1 3 X1 1 X7 1 X7 2 X17 1 X17 2 X8 X5 X2 6 X2 5 X3 1 X3 2 X2 1 X2 2 X2 3 X2 4 X9 2 X9 3 X9 1 X11 X16 X8 2 X8 3 X8 4 X5 4 X5 1 X5 2 X5 3 X11 X6 1 X10 X6 2 X4 1 X4 2 X1 1 X1 2 X1 1 X1 2 X12 2 X3 X2 X2 X3 X3 X2 S1 S2 F5 1 2 3 A8 A9 X1 X1 M1 2 1 M F6 X8 1 X9 4 2 3 1 L1 L2 L3 X6 3 X6 1 0...

Page 11: ...A5 L1 A6 X3 A7 A10 A11 X4 G XT 4 XT 3 XT 1 M3 M Y1 A13 15 F1 3 4 2 1 X5 X10 2 X10 1 X4 1 X4 2 X1 X1 X2 3 X2 2 X2 1 X1 2 X1 3 X1 1 X7 1 X7 2 X17 1 X17 2 X8 X5 X2 6 X2 5 X3 1 X3 2 X2 1 X2 2 X2 3 X2 4 X9 2 X9 3 X9 1 X11 X16 X8 2 X8 3 X8 4 X5 4 X5 1 X5 2 X5 3 X11 X6 1 X10 X6 2 X4 1 X4 2 X1 1 X1 2 X1 1 X1 2 X12 2 X3 X2 X2 X3 X3 X2 S1 S2 F5 1 2 3 A8 A9 X1 X1 M1 2 1 M F6 X8 1 X9 4 2 3 1 L1 L2 L3 X6 3 X6 ...

Page 12: ...tons arrow up 1 and gas type 2 at the same time the gas valve is activated for 30 sec a countdown is shown in the display press button gas type 2 again to end the test manually Pump fan test press the buttons arrow up 1 and material type 4 at the same time the cooling pump and the fans of the power unit are activated for one minute press button material type 4 again to end the test manually Reset ...

Page 13: ... jobs using the PC software JobTool Menu Extras press both buttons arrow up and arrow down 1 at the same time use the buttons material type 4 and gas type 2 to switch between the menu items forth and back press both buttons up and down 1 again to go into the selected menu item press the middle button wire diameter End to go back to the previeous menu level Menu Customizing press the buttons arrow ...

Page 14: ...trigger switch the gas valve is switched on for 30 sec Pump test press the button operating mode 6 and program selection 7 together at the same time the water pump is switched on for one minute press both buttons again to switch off the pump manually Reset keep the buttons program selection 7 and the button main parameter 8 pressed for about five sec all parameters are reset to factory settings ...

Page 15: ...ding current on arc established managing communications between PC and machine managing and storage of all welding parameters LorchNet communication CAN bus LEDs LED state meaning 1 green blinking CPLD in function off CPLD not working 2 red off Digital Signal Processor DSP Process ok on DSP detected a malfunction 3 green on supply voltage 3 3V ok off supply voltage 3 3V missing 4 red off Microcont...

Page 16: ...PRO05 measuring point X2 control transformer earth screw LED4 X17 X4 X1 X26 X2 X14 X20 X8 X3 X10 X16 X11 X15 X18 X9 X13 X6 X25 X7 X5 X19 X21 X23 X22 LED1 LED5 LED2 LED3 LED6 LED5 DSP LED2 DSP LED4 Master LED6 Master LED3 3 3V 4A 1A Fig 6 pc board MAPRO05 ...

Page 17: ...DIP switches Measuringpoints designation measuring point result supply voltage from control transformer primary X6 1 X6 3 230V AC driveable housing 42V AC S mobile P mobile supply voltage fans group 1 X7 1 X7 2 230V AC supply voltage fans group 2 X25 1 X25 2 230V AC supply voltage cooling unit X13 1 X13 2 230V AC supply voltage from control transformer secondary X2 1 X2 2 18V AC X2 3 X2 4 42V AC s...

Page 18: ...onnector flow meter X10 connector gas valve only used when TIG option is installed X11 connector front panel X13 connector cooling unit X14 LorchNet connector CAN bus X15 connector TIG torch button X16 connector volt amp display X17 connector output voltage to pc board DP UFI BO X18 connector remote control X19 connector gas test button X20 LorchNet connector CAN bus X21 connector JTAG interface i...

Page 19: ...Pc Boards 19 02 20 909 2710 1 06 ...

Page 20: ...rol and monitoring of operating elements DS20BF PowerMaster torch button monitoring wire inching button supply pc board PP90R Push Pull LEDs LED state meaning 1 red blinking normal operation lit weak microprocessor not programmed 2 green on internal supply voltage 5V DC ok off internal supply voltage 5V missing Tab 7 LEDs DMR Picture pc board DMR LED2 5V LED1 operation Fig 8 Pc board DMR ...

Page 21: ...nnectors DMR connector designation 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 X11 wire feed motor plus X12 welding potential X18 remote control interface CAUTION only the start contact pins 1 and 2 is available There is no analog input or a digital outp...

Page 22: ...pc board DMR Functions supply for PushPull motor Meauring points designation measuring point result supply voltage X1 2 X1 5 42V AC motor supply X1 1 X1 4 60V DC relay voltage X1 6 X1 7 24V DC Tab 10 Measuring points PP90R Picture pc board PP90R R2 GLR1 X1 RE1 C1 R1 650 6271 0 PP 90R RP87 2 D0000139 00 1 7 Fig 9 Pc board PP90R Schematic M X1 7 X1 6 X1 2 X1 5 X1 3 X1 1 X1 4 PP90R DMR X7 1 X7 3 X7 2...

Page 23: ...gas valve control and monitoring operating elements front panel remote control torch button PowerMas ter LEDs LED state meaning 1 red off DSP ok on brigth pc board is in programming flash mode DIP switch1 ON on weak DSP is not programmed 2 green on 5V internal supply voltage ok off 5V supply voltage is missing 3 green blinking DSP in function on no intermediate feeder present if DIP switch2 ON Tab...

Page 24: ...Pc Boards 24 02 20 909 2710 1 06 Picture pc board DMRPP04 X2 X14 X3 X18 X11 X10 X12 LED2 LED1 LED1 LED2 LED3 DIP S1 X4 X5 X1 X20 X6 X8 X9 X16 X13 X17 X15 LED3 S1 X2 X1 Fig 11 Pc board DMRPP04 ...

Page 25: ...X11 wire feed motor plus X12 welding potential PowerMaster signal compensation X13 control cable PushPull X14 flat ribbon connector motor wires X15 flat ribbon connector PWM control X16 wire end sensor X17 PushPull motor X18 remote control interface X20 LorchNet CAN bus Tab 14 Connectors DMRPP04 Overview PushPull Intermediate Feeder NanoFeeder DMRPP M M DMRPP M DMRPP M M M DMRPP M M DMRPP M DMRPP ...

Page 26: ...ting instruction Digital PushPull with auxiliary drive E00 0320 1 Please note the first rear DMRPP04 pc board requires special software special firmware the DMRPP04 pc board in the intermediate feeder front has the standard PushPull firmware Since the push pull software version 1 24 from 14 03 2019 the special software is no longer required 7 5 Pc board ZVP The pc board ZVP is the additional power...

Page 27: ...3 2 1 8 7 6 5 X2 4 3 2 1 8 7 6 5 X5 4 3 2 1 8 7 6 5 Fig 14 Schematic pc board ZVP connector designation X1 control cable to MAPRO X5 X2 control cable to DMRPP X3 60V DC X4 connection input 42V AC control transformer X5 parallel connection to DMRPP Tab 15 connections pc board ZVP ...

Page 28: ...f the operating system Press any button to start the first test where all LEDs and the LCD Display are turned on and off alternately The LCD 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 pressed is indicated by a lit LED After that the rotary impulse en coders a...

Page 29: ...02 20 909 2710 1 06 7 7 Pc board DS21BF S2 LED7 LED8 LED1 LED4 LED3 LED2 S1 LED5 LED6 X1 LED9 LED10 LED11 LED12 LED13 LED14 LED15 Fig 16 Pc board DS21BF 7 8 Pc board DS22BF X1 LED10 LED11 LED9 Fig 17 Pc board DS22BF ...

Page 30: ...oard MAT BF The pc board MAT BF is the front panel of the P Basic machines Fig 18 Pc board MAT BF Front panel test function The display test at the P Basic machines is activated by pressing the two outer buttons mode TA1 and main parameter TA4 ...

Page 31: ...unction codes Picture pc board DS VA C2 C5 C6 C7 C8 H4 H5 H6 H7 H8 H9 IC1 R1 R3 R4 R5 R42 C10 X1 LED41 Fig 19 Pc board DS VA Display test DS VA There is an internal display test for the pc board DS VA To carry out the test a PowerMaster torch or RC20 is necessary Pressing the mode button and the rocker switch left at the same time and keep them pressed all segments and LEDs of the pc board DS VA a...

Page 32: ...2 setting type OFF OFF 240A S5 P4500 OFF ON 350A S3 P3x00 ON OFF 300A S8 P5500 ON ON reserved Tab 16 DIP switch DCDR LEDs LED state meaning 1 red off normal operation on input current too high power unit is blocked 2 green off no supply for driver circuit low side on supply for driver circuit low side is ok 4 green off bus voltage too high on bus voltage ok 5 green off no supply for driver circuit...

Page 33: ...nger screws are used A A UZ UZ The rest of the ISOTOP screws are the short ones All screws need to be tightened with a torque of 2 2Nm If a MOSFET should fail all MOSFETs have to be replaced including the DCDR This is necessary because all MOSFETs must have the same switching times all MOSFETs out of one production batch In the case of a defective MOSFET it is very likely that the drive circuit on...

Page 34: ...ry current The A wire of the transformer primary coil is going through a current sensor As soon as the primary input current gets too high the driver circuits are locked and via pin 8 of the flat ribbon cable the DCDR signals to the MAPRO that an overcurrent has occured see details on page 59 Monitoring bus voltage The bus voltage is monitored by the DCDR board As soon as the bus voltage gets too ...

Page 35: ...uses 2 x 4A 500V slow 2 x 6 3A 500V slow Tab 20 Useage pc boards DK PWRUP Functions limitation of inrush current when charging up the capacitors on pc board DCDR supply for control transformer Measuring points designation measuring point result mains input L1 X5 400V AC mains input L2 X6 mains input L3 X7 mains output L1 X1 400V AC mains output L2 X2 mains output L3 X3 supply voltage control trans...

Page 36: ...500V slow Tab 22 Pc boards DK PWRUP Functions limitation of inrush current when charging up the capacitors on pc board DCDR supply for control transformer Measuring points designation measuring 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 AC relay vo...

Page 37: ...or control transformer Measuring points designation measuring point result mains input L1 LP1 400V AC mains input L2 LP2 mains input L3 LP3 mains output L1 LP4 400V AC mains output L2 LP5 mains output L3 LP6 supply voltage control transformer X10 1 X10 2 400V AC relay voltage X4 1 3 X4 2 4 24V DC Tab 24 Measuring points S3NEFI Picture pc board S3NEFI X4 X10 SI3 SI4 LP1 LP2 LP3 LP4 LP6 LP5 LP7 650 ...

Page 38: ...revent 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 a charge up time for about two seconds the resistors on the PWRUP pcb are shorted with the relays so the the full mains input is present and the bus voltage is at maximum 560V DC to 580V DC The bus voltage is monitored by the DSP Process and the r...

Page 39: ...LCL3 The pc board DK GLCL3 is for connecting wiring the secondary rectifier diodes Functions connecting diodes impulse smoothng diode protection Picture pc board DK GLCL3 Fig 27 Pc board DK GLCL3 Schematic D3 D2 D1 X1 Fig 28 schematic welding rectifier ...

Page 40: ...put voltage Picture pc board DP UFI BO X3 X2 X1 650 5311 x DP UFI BO RP393 2 D00 0107 2 00 Fig 29 Pc board DP UFI BO 7 17 Pc board DP EMV The pc board DP EMV is a emc filter circuit for the compliance with emc regulations Functions emc filter Picture pc board DP EMV X3 X2 650 5316 x DP EMV RP399 2 D00 0107 1 00 Fig 30 Pc board DP EMV Schematic Fig 31 Schematic filter pc boards ...

Page 41: ...d unit 2 is active Tab 25 LEDs DS ERW Picture pc board DS ERW X3 X10 X4 X7 X8 X6 X5 LED1 X2 X1 650 1248 x DS ERW RP331 D00 0091 0 00 Fig 32 Pc board DS ERW Overview connectors pc board DS ERW connector designation X1 connector to pc board MAPRO05 X2 connector to pc board MAPRO05 interpass hose X3 connector to pc board DMR 1 first wire feed unit X4 connector to pc board DMR 2 second wire feed unit ...

Page 42: ...RO DS ERW DMR1 DMR2 X5 X3 X3 X4 8 10 X2 X1 X8 X8 X7 1 X7 2 X8 1 X8 2 8 8 In addition to the two DMR boards the water valves are also connected the DS ERW Depending on the active torch feed one or two the water cooling circuit is also switched over ...

Page 43: ...onnector bi directional single wire communication or via the start contact wires of the remote control socket RC20 Functions display and change of welding parameter and Tiptronic jobs torch button start stop Picture pc board TC21 data white gnd brown central connector top view torch button data white gnd brown torch button PowerMaster torch RC20 X1 14 pin AMP 1 2 Fig 33 Pc board TC21 Schematic TC2...

Page 44: ...rrent sensor is used to measure the weldng current Measuring points designation measuring point result supply voltage X1 1 X1 2 X1 4 15V DC 15V DC sensor output X1 3 output current signal 1 2000 Tab 27 Measuring point current sensor VAC Picture current sensor VAC M 4 3 2 1 Fig 35 Current sensor VAC ...

Page 45: ...s mounted relatively close to the welding choke and sporadically there were false measurings In these cases the power source responded with error messages E16 or E24 overcurrent Since 17 09 2018 the VAC is mounted with a retaining plate 602 1437 0 in a new position to ensure a greater distance to the inductor While the current sensor was in the positive line with the previous wiring it is now in t...

Page 46: ...h pressure Tab 28 Conrol transformers 3 1 2 10 4 8 9 12 13 14 15 5 11 655 8021 0 655 8031 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 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_42V 42V 3 5A 400V 2 Pos 4 3 7 8 Pos 20V 3A 0_20V 5 6 primary secondary secondary primary secondary primary secondary primary2 secondary2 1 2 3 4 3...

Page 47: ...fore the mode can be selected via the mode button at the front panel see also 9 14 Service Codes on page 63 retrofit kit part number power source driveable 570 8035 0 power source mobile 570 8036 0 Tab 29 Overview retrofit kits TIG option Schematic DP MAPRO DS ERW X5 2 X5 1 X3 1 X3 2 X3 3 X3 6 X3 7 X1 1 X1 2 X1 3 X1 6 X1 7 5 pin Tuchel X15 1 X15 2 1 2 24V DC 5 pin Tuchel X15 1 X15 2 1 2 X10 1 X10 ...

Page 48: ...maximum value the machine will stop and displays E01 thermal overload The actual value of the temperature can be displayed at the front panel in menu Extras Diagnosis Module Temperatures Machine type max Temperature S3 S3 mobile P3000 mobile P3500 77 C S5 P4500 80 C S8 P5500 75 C Tab 30 Maximum temperatures If the connection of the sensors to the MAPRO is interrupted loose contact at any of the co...

Page 49: ...s are monitored by the Microcontroller 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 voltage limit reaction 24V DC 17V DC Shutdown with E14 24V DC 36V DC Shutdown with E02 Tab 31 Voltage limits The actual values of the 24V and 15V can be checked v...

Page 50: ...sor output is 150mA The output current is measured via an internal shunt resistor by the Master and Process independant measurings If the Master measures a current 120 of the maximum value the machine will stop and displays E03 secondary overcurrent For example the maximum welding current of a Saprom S5 is 400A if the Master measures a welding current 480A it stops with E03 If the Master measures ...

Page 51: ...PRO05 board As soon as the gas pressure switch opens gas bottle is empty the machine would stop with E04 02 Stop peripherals error The message is only shown if the switch opens during the time the gas valve is active during welding gas post flow time or gas test Schematic MAPRO Master PE P gas Option X26 6 X26 3 X26 5 X26 2 L N Both monitoring functions PE and gas are self activating functions tha...

Page 52: ...Flowrate Cool System At gas cooled machines instead of the flowmeter there is a small cable bridge between pin 1 and 4 at con nector X9 This cable bridge is deactivating the monitoring of the flowmeter Schematic external cooling unit X9 2 X9 3 X9 1 X9 4 2 3 1 X1 4 X1 5 X1 3 X1 6 WUK 15V 15V MASTER DP MAPRO X8 4 X8 5 X8 3 X8 6 X1 1 X1 2 X5 2 X5 4 X8 1 X8 2 X13 1 X13 2 X6 1 X6 3 42V AC 230V power so...

Page 53: ...r is recommended Depend ing on the degree of pollution the coolant tank should be completely washed out as dirt can accumulate at the bottom of the tank over time to open the flow meter turn the housing halves against each other bayonet assem bly take off the top halve take out sealing ring and the turbine CAUTION mind the right flow direc tion do not reverse in and output when mounting the flow m...

Page 54: ...ee versions version pump control transformer fuse PWRUP standard standard 665 5571 0 standard 655 8021 0 2 x 4A slow Standard double cooling Twin only possible at B or BB machines standard 665 5571 0 standard 655 8021 0 2 x 4A slow Standard Twin High Pressure only together with double cooler Twin only possible at B or BB machines High Pressure 665 5573 0 stronger 655 8037 0 2 x 6 3A slow Twin High...

Page 55: ...age higher that 100V the machine will stop and displays E20 Overvoltage secondary If no voltage can be measured at all then machine will stop and displays also E20 Possible reasons could be disconnected measuring wires red and blue loose connection of the connectors interchanged wires red with blue If the Master is measuring another voltage than the DSP the machine will stop and displays E09 V A m...

Page 56: ...controller If the current consumption of the motor is too high e g if wire feed unit is blocked mechanically or if the tacho is not connected the machine will stop and displays E08 wire feed tacho The DMR and the MAPRO are communicating via the CAN bus with the Master If the communication is interfered or jammed the machine will stop and displays also E08 Is one of the CAN bus wires is disconnecte...

Page 57: ...X1 2 X9 X16 24V CAN high CAN low 70V mot gnd mot gnd CAN high CAN low 24V gnd 1 2 1 4 3 6 5 8 7 10 9 2 1 4 3 2 1 4 3 6 5 8 7 2 1 4 3 2 1 4 3 6 5 2 1 12V 24V 5V 10 11 12 13 14 16 7 8 15 3 4 9 6 5 1 2 1 2 1 2 3 4 24V M X6 2 1 X12 2 1 3 DMRPP C 5V temp Koffer aktiv Vorschub Motor Kollisionsschutz Gastest Drahteinlauf Kollisionsschutz Gastest Draht einlauf Lüfer Draht rückzug Drahtende Sensor Ausblaß ...

Page 58: ...ch trigger switch weld energy 4 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 valid if the identification external on pin 6 and 7 is active identification external 6 as soon as pin 6 is connected to pin 7 gnd the analog input pin 4 is valid and t...

Page 59: ...f power unit 2 is malfunctioning In this case power unit 1 has to generate all the weld energy by itself Which is possible to a certain amount of power 200A to 250A but beyond that the unit will stop with E16 malfunction at DCDR pcb of power unit 1 e g optocoupler output malfunction bad flat ribbon cables between MAPRO pcb and power units short circuit at output diodes There is a simple way to fin...

Page 60: ...essage E22 Mains undervoltage 1 E23 Mains overvoltage E30 Mains undervoltage 2 Should the mains voltage be too low at both power units at S5 or S8 P4500 or P5500 only the error message with the highest number is displayed E30 Schematic bus voltage LED4 LED6 optocoupler min bus volt pin 10 optocoupler max bus volt pin 9 error message 0 250V on off high low E22 E30 255V 700V on on low low 705V off o...

Page 61: ...r units are connected The identification of the power units is made by a DIP switch at the DCDR pcbs Should the MAPRO detect that the configuration is not valid it will stop and displays E25 Power module detection Schematic DIP1 DIP2 setting type OFF OFF 240A S5 P4500 OFF ON 350A S3 P3x00 ON OFF 300A S8 P5500 ON ON reserved Tab 34 Power unit configuration ...

Page 62: ...G D S GS G D S GS G D S GS G D 9V Batterie 9V battery 9V Batterie benutzen um die Drain Source Strecke einzuschalten Drain Source Strecke ist niederohmig Kurzschluss zwischen Gate und Source um Drain Source Strecke auszuschalten Drain Source Strecke ist hochohmig 9 13 Inside diagram diodes ...

Page 63: ...Powermaster On 665 deactivate gas pressure switch monitoring Gas monitor Off 666 deactivate PowerMaster buttons Powermaster Off 668 activate 10 correction at Tiptronic with lock level 2 or 3 PlusMinus10 On 669 deactivate 10 correction at Tiptronic with lock level 2 or 3 PlusMinus10 Off 670 activate US units US units On 671 deactivate US units US units Off Entering the Codes enter menu Extras Lockf...

Page 64: ...d flow sensor check gas supply check min gas flow setting in customize menu E 05 Cooling system error flowrate of the cooling liquid is too low 0 3 l min pump is not working check level of cooling liquid and flowrate 3 check connectors of flow meter check fuse SI7 4A on MAPRO check all hoses incl torch and inter pass hose see page 52 for details E 06 Secondary overvoltage Master detects output vol...

Page 65: ...n the torch button wires short circuit between torch button wires to welding potential or motor wires check torch and torch control wires M12 Calibration error only at DMRPP calibration of the PushPull torch was unsuccessful check torch and torch control wires check pressure lever of wire feed unit and of PushPull torch insert the wire M13 Machine ID unknown only at DMRPP the internal power source...

Page 66: ...rical components let machine cool down in standby check temp sensor see page 48 for details E 20 Overvoltage sec Process reports a too high output voltage 100V or no voltage check wiring of power unit especially wiring from output sockets to pc baord MAPRO see page 55 for details E 21 Output voltage current external current or voltage check wiring of current sensor VAC and pc board DP UFI BO check...

Page 67: ...pass hose package check all phases from mains supply see page 56 for details nop no program no welding parameters available for selected material wire gas combina tion no reasonable combination select other material wire gas combi nation CFG ERR CFG ERR is shown in volt amps display wrong front panel connected only at P Basic connect the correct front panel pc board MAT BF blinking volt amps displ...

Page 68: ...Lorch Schweißtechnik GmbH Im Anwänder 24 26 D 71549 Auenwald Germany Tel 49 7191 503 0 Fax 49 7191 503 199 info lorch eu www lorch eu ...

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