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Summary of Contents for LORCH Saprom S
- Page 1 Service Manual Saprom S...
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Page 2: Table Of Contents
Contents Subject Page Machine Machine Elements Safety precautions Common Logic Functions Schematic S-Series Troubleshooting guide Pc-board DP-MAPRO Pc-board DMR Pc-board DS20BF Pc-board DK-DCDRV / DK-S3DRV Pc-board DK-PWRUP Pc-board PWRUP04 Pc-board DP-S3NEFI Pc-board DK-GLCL Pc-board DP-UFI Pc-board DP-UFI-BO Pc-board DP-EMV Pc-board LSW Pc-board DS-VA Pc-board PP-90R Pc-board DS-ERW... -
Page 3: Machine
Machine Machine Elements torch air intake pressure reducer transport wheels gas cylinder* main switch tray area display current/voltage facility for transport ground clamp handle connector for ground cable front panel display cover connections *)option... -
Page 4: Safety Precautions
Safety precautions Requirement Use and maintenance of welding and cutting machines can be dangerous. Please draw user´s attention to follow the safety precautions to avoid injuries. Welding and cutting machines must be used appro- priate and only by specialist staff. Please inform yourself constantly about the valid safety precautions and regulations of accident prevention by working with this machine. -
Page 5: Common Logic Functions
Common Logic Functions component function associated event fan (power unit) power modul temperature over 40°C fan (power unit) power modul temperature below 40°C fan (cooling system) after detection „welding current on“ fan (cooling system) after welding process, two minutes post-cooling time pump after detection „welding current on“... -
Page 6: Schematic S-Series
Schematic S-Series... -
Page 7: Troubleshooting Guide
Troubleshooting guide code description reason removal E 00 no program no welding parameters available for selected material- select other material-wire-gas combination wire-gas combination (no reasonable combination) E 01 thermal overload thermal sensor of power unit measures a too high tem- let machine cool down in standby (*1) perature E 02... -
Page 8: Pc-Board Dp-Mapro
Pc-boards Pc-board DP-MAPRO The pc-board DP-MAPRO is responsible for the welding sequence and is managing the process control of the S-Series. (MAPRO = MAster-PROcess) Functions - Logicfunctions of the welding process - generating and monitoring supply voltages - driving powerup-relais - driving power unit/units - monitoring control and operating elements (DS20BF, remote control, torch buttons) - driving fans... - Page 9 Overview fuses DP-MAPRO fuse value [A] Safeguarding Si 6 fans (power unit) Si 7 cooling pump Measuring Points designation measure point result solenoid valve X10/1 +24V DC X10/2 supply voltage X6/1 230V AC control transformer X6/3 supply voltage X7/1 230V AC fan group 1 X7/2 supply voltage...
- Page 10 Picture Pc-board DP-MAPRO...
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Page 11: Pc-Board Dmr
Pc-board DMR The pc-board DMR is the wire feed motor control of the machine. Functions - control and monitoring wire feed motor - driving solenoid valve - control and monitoring of operating elements (DS20BF, remote control, torch buttons) - monitoring wire insert button - supply pc-board PP90R (Push-Pull) LED displays normal... - Page 12 Picture Pc-board DMR...
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Page 13: Pc-Board Ds20Bf
Pc-board DS20BF The pc-board DS20BF is the front 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 At a machine with separated front panels, the pc-boards DS21BF and DS22BF are used.
- Page 15 Display test The display has a internal function test. To execute the test press the buttons „-“ (TA13) and „manual mode“ (TA4) at the same time. Now the LCD-Display shows „Display Test“ and the version number of the operating system. Press any button to start the first test, where all LEDs and the LCD-Display are turned on and off al- ternately.
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Page 16: Pc-Board Dk-Dcdrv / Dk-S3Drv
Pc-board DK-DCDRV / DK-S3DRV The pc-board DK-DCDRV is managing the primary drive level of the power unit Saprom S5 and S8. The pc-board DK-DCDRV is managing the primary drive level of the power unit Saprom S3. Functions - encoding power unit - connection temperature sensor of heat sink - supply pc-board LSW - monitoring DC link voltage and supply voltage... - Page 17 Measuring Points designation Messpunkt Messergebnis supply voltage pc-board X2/1 15V DC X2/6 supply voltage pc-board X2/3 -15V DC X2/6 thermal sensor X3/1 10kΩ at 25°C X3/2 (about +2V DC) Picture Pc-board DK-DCDRV / DK-S3DRV...
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Page 18: Pc-Board Dk-Pwrup
Pc-board DK-PWRUP The pc-board DK-PWRUP is the power up-circuit of the Saprom S3. Functions - reducing start-up peak current for capacitors - supply and safeguarding of control transformer Measuring Points Beschreibung Messpunkt Messergebnis mains input L1 mains input L2 400V AC mains input L3 mains output L1 mains output L2... -
Page 19: Pc-Board Pwrup04
Pc-board PWRUP04 The pc-board DK-PWRUP is the power up-circuit of the Saprom S5 und S8. Functions - reducing start-up peak current for capacitors - supply and safeguarding of control transformer Measuring Points designation measure point result mains input L1 mains input L2 400V AC mains input L3 mains output L1... -
Page 20: Pc-Board Dp-S3Nefi
Pc-board DP-S3NEFI The pc-board DP-S3NEFI is the mains filter and power up board of the Saprom S3 mobile. Functions - mains filter - reducing start-up peak current for capacitors - supply and safeguarding for control transformer Measuring Points designation measure point result mains input L1 400V AC... -
Page 21: Pc-Board Dk-Glcl
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: Pc-Board Dp-Ufi
Pc-board DP-UFI The pc-board DK-UFI is for wiring the welding sockets. Functions - wiring welding sockets - providing output voltage Measuring points designation measure point result secondary output voltage ca. 81V DC (nm MMA mode) socket „+“ ca. 81V DC socket „-“... -
Page 23: Pc-Board Dp-Ufi-Bo
Pc-board DP-UFI-BO Functions - wiring welding sockets - providing output voltage Picture Pc-board DP-UFI-BO 650.5311.x DP-UFI-BO RP393/2 D00.0107.2-00 Pc-board DP-EMV Functions - EMC filter Picture Pc-board DP-EMV 650.5316.x DP-EMV RP399/2 D00.0107.1-00... -
Page 24: Pc-Board Lsw
Pc-board LSW The pc-board LSW is a potential free current sensor. Functions - measuring the welding current Measuring points designation measure point result supply voltage X1/1 X1/3 +30V DC Picture 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 normal... -
Page 25: Pc-Board Pp-90R
Pc-board PP-90R management for Lorch Push-Pull torches. Functions: - supply Push-Pull motor - managing start signal Measuring points: designation measuring point result supply voltage X1/2 42VAC X1/5 motor voltage X1/4 +60VDC X1/1 drive level relay X1/7 +24VDC X1/6 Picture Pc-board PP-90R:... -
Page 26: Pc-Board Ds-Erw
Pc-board DS-ERW The pc-board DS-ERW is the extension pc-board for machines with additional wire feed case. Functions - switching between wire feed 1 / wire feeder 2 - driving solenoid valve - driving water valves LED displays normal state designation 1 (green) wire feed unit 1 active wire feed unit 2 active... -
Page 27: Control Transformer
Control Transformer The control transformer 655.8021.0 is used in Saprom S3, S5 and S8. Te control transformer 655.8023.0 is used in Saprom S3 mobile. Pos. 42V/4A 400V 0.42V 19V/3A 0.19V 655.8021.0 18V/1A 230V/2,5A 0.18V 18V/0,4A 0.18V primary 18V/0,4A secondary 0.18V 0.400V Pos.
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