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LORCH MicorMIG Series Service Manual
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LORCH MicorMIG Series Service Manual

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Service Manual
MicorMIG
909.2130.1-10

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Summary of Contents for LORCH MicorMIG Series

  • Page 1 Service Manual MicorMIG 909.2130.1-10...
  • Page 2 Contents Machine ................3 Safety precautions ............4 The MicorBoost Inverter Principle ........5 Counting pins for Minifit and Microfit connectors ..... 5 Common Functions ............6 Pc-Board NEFI02 ............12 Pc-Board NEFI04 ............13 Pc-Board NEFI05 ............14 Pc-Board NEFI07 ............15 Pc-Board DRV03 / DRV13 ..........
  • Page 3 Machine page 3...
  • Page 4 Norms IEC 60974-4 In-service inspection and testing Testing Lorch machines according to IEC 60974-4 it is not necessary to disconnect any components of the power unit for the test it is recommended to disconnect the torch at water cooled machines...
  • Page 5 The MicorBoost Inverter Principle A welding inverter is a electronically controlled welding power source. At conventional transformer based ma- chines, the mains voltage with 50/60 Hz is directly switched to the welding transformer. At a welding inverter the mains voltage is rectified first and with electronic power switches (MOSFETs or IGBTs) chopped into a much higher frequency, to drive the transformer.
  • Page 6 Common Functions Gas test press key A14 the gas test LED is lit the solenoid valve is switched on for 30 seconds press key A14 again to switch off the valve manually Fan test When switching on the machine at the on/off switch, the fans are activated for a short time during initialisation. Water pump test Basic/BasicPlus: press key A2 and keep it pressed for about 5 seconds (menu machine configuration)
  • Page 7 Front panel MicorMIG BasicPlus Front panel MicorMIG ControlPro page 7...
  • Page 8 Front panel MicorMIG Feeder Panel Schematic MAPRO DMR-RT3 µP µP µP UART +16V +24V 13 13 At compact machines the front panel is directly connected to the MAPRO. At a wire feeder MF08 the front panel is connected to the DMR-RT3. All front panels are designed for a supply voltage range of 15V to 24V DC. The data communication is done via CAN-bus only (pins 2 and 3 of the flat ribbon cable).
  • Page 9 Synergic selection panel Since week 24 of 2018 new welding programs have been added to the new software version 2.12 including new materials and 0.9mm wire. Thus the synergic selection panel were changed also. wire feeder power source Schematic synergic selection panel keys LEDs Since May 2017 there are locking clips available to keep the flat ribbon cables fixed at the front panels and pre-...
  • Page 10 Picture pc-board BF07 (Basic Plus wire feeder) X301 X701 X401 Since week 10 in 2015 the front panels of the wire feeder are equipped with longer flat ribbon cables. With this it is possible to use the wire feeder horizontally in a lying way and turn the front panel by 90°. Picture pc-board SF17 The pc-board SF17 is used for illuminating the interior of the MF08 wire feeder and is connected to the front panel pc-board (connector X701).
  • Page 11 Picture pc-board BF11 (ControlPro power source) X301 X401 Overview changes front panels Some front panels had been exchanged by versions with bigger memory. Since week 51 from 2017 the version “Pulse” was added. front panel designation part no. designation part no. version part no.
  • Page 12 Pc-Board NEFI02 The pc-board NEFI02 is the mains filter board of the MicorMIG 300 and 350. Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620). Functions mains filter mains detection safeguarding control transformer (2 x 4.0A, 500V, slow) Picture pc-board NEFI02 LP15 (PE)
  • Page 13 Pc-Board NEFI04 The pc-board NEFI04 is the mains filter board of the MicorMIG 400. Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620). Functions mains filter mains detection safeguarding control transformer (2 x 4.0A, 500V, slow) Picture pc-board NEFI04 LP15 (PE) LP14...
  • Page 14 Pc-Board NEFI05 The pc-board NEFI05 is the mains filter board of the MicorMIG 500. Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620). Functions mains filter mains detection safeguarding control transformer (2 x 4.0A, 500V, slow) power-up function Picture pc-board NEFI05 LP1 LP3...
  • Page 15 Pc-Board NEFI07 The pc-board NEFI07 is the mains filter board of the MIcorMIG 400 MV and 500 MV. Functions mains filter mains detection safeguarding control transformer (2 x 4.0A, 500V, slow) power-up function Picture pc-board NEFI07 Schematic NEFI07 RE1+2 X2-3 X2-1 X1-1 RE3+4...
  • Page 16 Pc-Board DRV03 / DRV13 The pc-board DRV03 is the primary driver board of the MicorMIG 300 and 350. Since week18 2017 the DRV03 was replaced by the DRV13. For details see page 27. Functions primary driving of the transformer capture primary input current measuring temperatures generating internal supply voltages driving fans...
  • Page 17 Picture pc-board DRV13 aux. transf. aux. transf. sec. prim. X7 X11 PE-prot. MAPRO NEFI MAPRO temp.sens. DIP1 LED1 Inside diagram power module 16 15 12 11 ϑ page 17...
  • Page 18 Schematic DRV03 SF02 +24V X5-2 +24Vext. X5-1 +16V X5-3 +3,3V +60V X5-4 +16Vprim. X13-3 X13-1 +3,3V Fuses DRV13 fuse value Si1 (24V) 6.3 A Si2 (24V ext.) 1.5 A Si3 (60V) 6.3 A Si4 (16V) 0.63 A Pc-Board SF02 The pc-board SF02 contains the primary resonance capacitors and is only used together with the pc-board DRV03.
  • Page 19 Pc-Board DRV05 / DRV15 The pc-board DRV05 is the primary driver board of the MicorMIG 400. Since week18 2017 the DRV05 was replaced by the DRV15. For details see page 27. Functions primary driving of the transformer capture primary input current measuring temperatures generating internal supply voltages driving fans...
  • Page 20 Picture pc-board DRV15 Uz/2 Uz/2 LED1 DIP1 Change from MOSFET to IGBT (DRV05) Since the 10th of July 2015, since serial number 4062-2528-0021-6 only IGBTs are used for the MicorMIG 400. type T12 - T15 MOSFET (711.2614.0) IGBT (711.0530.0) T16 - T19 IGBT (711.2616.0) IGBT (711.0530.0) page 20...
  • Page 21 Schematic DRV05 X17-4 (+) X17-3 (A) X17-2 (B) X17-1 (-) X2-5 X2-6 X19-4 +24Vext. X19-3 +24V X5-2 +24Vext. X5-1 X3-12 +16V X3-9 X5-3 +3,3V +60V X5-4 +16Vprim. µP X13-3 X13-1 +3,3V *the connector X19 was later renamed to X2 Fuses DRV15 designation value Si1 (24V) 6.3 A...
  • Page 22 Pc-Board DRV07 / DRV17 The pc-board DRV07 is the primary driver board of the MicorMIG 500. Since week18 2017 the DRV07 was replaced by the DRV17. For details see page 27. Functions primary driving of the transformer capture primary input current measuring temperatures generating internal supply voltages driving fans...
  • Page 23 Picture pc-board DRV17 DIP1 LED1 Uz/2 Uz/2 page 23...
  • Page 24 Schematic DRV17 X21 (+) X24 (-) X17-1 X17-3 X2-5 X2-6 X19-4 +24Vext. +24V X5-2 +24Vext. X5-1 X19-3 +16V X3-12 X5-3 +3,3V X3-9 +60V X5-4 +16Vprim. µP X13-3 X13-1 +3,3V Fuses DRV17 designation value Si1 (24V) 6.3 A Si3 (60V) 6.3 A Si4 (16V) 0.63 A page 24...
  • Page 25 Overview DRV versions In the past the software of the primary processor on the pc-board DRV was changed and improvments had been implemented. The different versions were marked manually on the grey bus-voltage foil capacitors. marking description none initial version “S”...
  • Page 26 marking description “R32” - useage since week 40 2016 - modification of filter for bus-voltage measuring “V1.08” - useage since week 18 2017 “V1.10” - multivoltage (3-phase 230V / 400V) - preparation for generator use “V1.11R” - useage since week 30 2018 - fully fit for generator use - since week 40 2018: new terminals for transformer wires and supply page 26...
  • Page 27 Change from pc-board DRV0x toe DRV1x Since week 18 2017 the new DRV boards are used in the MicorMIG series. To ensure the multivoltage function and generator useage, not only the hard and software of the DRV were changed, also the software of the MAPRO board (version 2.02 for Master and Process firmware) needed to be changed.
  • Page 28 Pc-Board DC01 The pc-board DC01 is the secondary board for wiring the secondary diodes at the MicorMIG 300 and 350. Functions wiring secondary diodes connecting resonance capacitors providing output voltage for measuring Measuring points designation measuring result point output voltage X2-5 +80V DC* X2-1...
  • Page 29 Pc-Board DC03 The pc-board DC03 is the secondary board for wiring the secondary diodes at the MicorMIG 400. Functions wiring secondary diodes connecting resonance capacitors providing output voltage for measuring Measuring points designation measuring result point output voltage X2-5 +80V DC* X2-1 *only at machines with no VRD, at machines with activated VRD, the VRD voltage is measured.
  • Page 30 Pc-Board DC04 The pc-board DC04 is the secondary board for wiring the secondary diodes at the MicorMIG 500. Functions wiring secondary diodes connecting resonance capacitors providing output voltage for measuring Measuring points designation measuring result point output voltage X2-5 +80V DC* X2-1 *only at machines with no VRD, at machines with activated VRD, the VRD voltage is measured.
  • Page 31 Pc-Board MAPRO04 The pc-board MAPRO04 is the main control logic of the MicorMIG machines. Functions welding process control weld sequence control fan control open circuit voltage generator temperature monitoring monitoring primary input current monitoring welding- current/voltage communication operating elements (front panel, remote control) Picture pc-board MAPRO04 Change MAPRO04 since July 2015 Overview connectors pc-board MAPRO04...
  • Page 32 Pc-Board DMR-RT3 The pc-board DMR-RT3 is the wire feed control of the MicorMIG machines. Functions driving and monitoring the wire feed motor monitoring torch trigger switch communication PowerMaster torch LEDs status designation 1 (red) until software version 1.11: normal operation from software version 1.12 on : micorprocessor not working blinking until software version 1.11: malfunction LorchNet (CAN bus)
  • Page 33 Pc-Board DMRPP05 The pc-board DMRPP05 is the control unit for Push-Pull torches and the NanoFeeder. In case of a Push-Pull application the DMRPP05 replaces the standard motor control pc-board DMR-RT3. it consists of two pc-boards that are connected via flat ribbon cables: pc-board DMRPP-P: power board containing the motor driver circuits pc-board DMRPP-C05: control logic Functions...
  • Page 34 Picture pc-board DMRPP05 LED2 LED1 LED3 LED3 LED1 LED2 page 34...
  • Page 35 page 35...
  • Page 36 Pc-Board SF18 The pc-board SF18 was the control logic of the water cooling unit. Since September the 16th 2015 it was replaced by the pc-board SF24. LEDs state designation 1 (red) lit weak microprocessor not programmed blinking irregular LorchNet (CAN-bus) error blinking synchronous with LED2 flowrate too low (<0.3 l/min) 2 (green) status not ok...
  • Page 37 Schematic pc-board SF18 SF18 X10-6 X10-2 2.5A X10-3 400V X10-5 X10-1 400V +24V X7-1 X7-2 X7-3 X7-4 X1-1 X1-2 X1-3 X1-4 !!! CAUTION !!! Because the pc-board SF18 is no longer produced and not available as spare part, the pc-board SF23 is used instead in case of a repalcement.
  • Page 38 Pc-board SF23 The pc-board SF23 is the standard control of the Robo-MicorMIG. It is also used as replacement pc-board for the SF18 as well as in the retrofit kit, to retrofit the water monitoring in machines build before 2016. Picture pc-board SF23 X4 X5 X3 X2 LED4...
  • Page 39 Schematic pc-board SF23 SF23 X10-6 X10-2 2.5A X10-3 400V X10-5 X10-1 400V +24V +10V X7-1 X7-2 X7-3 X7-4 X1-1 X1-2 X1-3 X1-4 Connector Function X1-1 +5V DC supply X1-2 sensor input flow rate < 0.3 liter/minute : pins X1-2 and X1-3 are open (error message E05) flow rate >...
  • Page 40 Pc-board SF24 The pc-board SF24 is replacing the pc-board SF18. Since serial number 40xx-2538-0001-x. the SF24 is the standard control board for the water cooling unit of the MicorMIG. At the same time the pc-board DRV was changed (implementation of connector X19) to drive the relay on the SF24. Since January 14th 2016 (with the introduction of cooling water detection) the SF24 was replaced with the pc- board SF27.
  • Page 41 Pc-board SF27 The pc-board SF27 is the actual control board for the water cooling unit with water flow detection. The sensor can only detect if water is flowing or not. It cannot measure the flow rate. Picture pc-board SF27 Schematic pc-board SF27 SF27 X10-6 X10-2...
  • Page 42 Pc-board SF37 Since 07/15/2020 (from serial number 4xxx-3029-xxxx-x), the SF37 is used as a standard pc-board used for water cooling. The threshold value for detection of water flowing / water not flowing has been raised by 10 Kelvin. Fur- thermore, the fuse SI2 has been changed: 1.25A (instead of 1A) because at the same of the switch to SF37, the autotransformer was changed to a stronger version.
  • Page 43 Transformer 400V/230V At the same time as the switch to the SF37 board, a more powerful transformer was used. A retrofit kit is available for older systems: 981.8131.0 This includes an adapter plate (adaptation to the hole pattern of the old transformer) and the 1.25A fuse for the SF27 pc-board.
  • Page 44 Connection cooling unit At machines with internal water cooling, the pc-board SF18 was the main control board of the cooling unit. It has a microprocessor and was connected via the internal CAN-bus (LorchNet) to the pc-board DRV (x6 or X7, X11). Since September 16th 2015 the pc-board Sf18 was replaced by the pc-board SF24, without microprocessor.
  • Page 45 Control of the water cooling unit Connection diagram water cooling unit SF18/SF23 SF18 X10-6 X10-2 2.5A X10-3 400V X10-5 X10-1 400V +24V X7-1 MAPRO X7-2 X8-3 X2-7 X6-3 X7-3 X8-4 X2-8 X6-4 X7-4 X7-3 X7-4 X1-1 X1-2 X11-3 X1-3 X11-4 X1-4 Connection diagram water cooling unit SF24 SF24...
  • Page 46 Temperature monitoring Schematic MicorMIG 300/350 µP ϑ X2-3 X7-4 FPGA X2-4 X7-5 +3.3V X3-16 X1-16 ϑ X3-10 X1-10 MAPRO ϑ 10kΩ : 25°C Schematic MicorMIG 400/500 +3.3V µP X2-3 X7-4 FPGA X2-4 X7-5 +3.3V X3-16 X1-16 X3-10 X1-10 MAPRO ϑ ϑ...
  • Page 47 The temperature sensors are temperature dependant NTC resistors. As soon as one of the sensors is measur- ing a too high temperature, the machine stops with E01 “Overtemperature”. The sub-code indicates which sensor detected the overtemperature. The fans keep running to cool down the machine. If the temperature drops below 55°C, the error code disappears and the machine can be used again.
  • Page 48 Monitoring bus voltage Right from switching on the machine, the bus voltage is monitored directly by the DSP of the DRV. The actual value of the bus voltage is send from the DSP of the DRV to the MAPRO. As soon as the voltage gets too high, the machine stops with E02 “Overvoltage”. In this case the power-up relays on the DRV are switched off, so that the power-up resistors are active again, lowering the input voltage.
  • Page 49 Cooling unit Since January 14th 2016 the water cooled machines of the MicorMIG series are equiped with a water monitoring. A sensor is mounted in the water tank, that is washed around by the cooling water of the return-flow. The sensor is a “self-heating”...
  • Page 50 Monitoring Output Voltage The output-/welding voltage is measured directly by the DSP of the MAPRO. If a voltage >100V DC is measured for longer than 100ms, the machine stops with E06-00 “Overvoltage secondary”. In case that the FPGA is measuring the too high voltage, the machine stops with E06-01 “Overvoltage secondary FPGA”.
  • Page 51 Open Circuit Voltage Generator & VRD The open circuit voltage of the MicorMIG machines is not produced via the power unit, it is a DC signal voltage generated by the MAPRO. At machines with active VRD, the VRD voltage is programmed with a lower voltage (like 24V) instead of 80V.
  • Page 52 Monitoring and driving the wire feed motor The wire feed motor is driven and monitored by the pc-board DMR-RT3. If the current consumption of the motor is too high, the machine stops with the error code E08 “Motor overcurrent”. Motor identification The pc-board DMR-RT3 is also used in other machines with other motors, not only at the MicorMIG.
  • Page 53 Schematic DMRPP05 Schweiß- potential DMRPP-C Amphenol 17+PE Drahteinlauf +24V Kaltdraht- Sensor Gas- Ausblaß- Draht- Draht- Lüfer Drahtende- Gastest ventil ventil rückzug einlauf Sensor Gastest Brenner- interface data Kollisionsschutz Kollisionsschutz analog Eingang +12V +12V +10V analog in +24V +24V ext. analog digital2 PushPull digital1...
  • Page 54 Supply Voltages The MAPRO is supplied with 16V from the DRV. If the voltage gets below 12V, the machine stops with E14-00 “Undervoltage”. Schematic MicorMIG 300/350 NEFI +3.3V prim. +16V prim. X1-1 X13-3 X15-1 PE-mon. X13-1 X15-2 X1-3 500V X5-3 +60V X1-5 X8-5...
  • Page 55 Machine Configuration The hardware configuration is saved internally inside the machine. When switching on, the MAPRO is reading the configuration and compares it with the actual present hardware identifications of the DRV, the actual software ver- sion and the identification of the front panel. If the configuration does not match the actual hardware configuration or if the configuration could not be read cor- rectly, the machines stops with E30 “Configuration”.
  • Page 56 Monitoring Primary Input Current The current consumption of the machine is monitored by the DSP and the FPGA. As soon as the input current is getting too high, the machines stops with the error code E32-01 “Overcurrent FPGA” or E32-04 “Overcurrent IPMax”.
  • Page 57 If no current zero crossing is measured after a certain time when activating the welding transformer (polarity rever- sal of the full bridge inverter), the system stops with E32-02 “Timeout”. Especially with the MicorMIG 500, the current direction of the primary current sensor must be set to the correct mounting position: The black connecting lead of the sensor must point in the direction of the cable shoe of the transformer lead.
  • Page 58 Fan Control The cooling fans of the machine are driven and monitored directly by the MAPRO. The MicorMIG 300/350 have two fans, the MicorMIG 400/500 have three fans. As soon as the current consumption of the fans is getting too high, the machine stops with the error code E34-00 “error fan current”.
  • Page 59 LorchNet-Remote LorchNet-Remote is the optional remote control interface of the MicorMIG. It is connected to the power source via the 4-pin socket “LorchNet” at the rear-side, where also the “LorchNet Connect” can be plugged in. If the start contact (pins 1 and 2) is closed during the time the machine is switched on, the error message E25-01 is displayed at the front panel.
  • Page 60 To connect a computer to a MicorMIG machine, a LorchNet-Connect adapter box (570.4030.0) is necessary. It provides the LorchNet interface potentially separated for “external” use. With the software tool “Lorch System Manager” software updates can be made or the list of the last error mes- sages can be read out.
  • Page 61 Measuring CAN bus The CAN bus is easily checked at each pc-board by measuring the resistance value between CAN-low and CAN-high against GND (ground). Before measuring, disconnect the pc-board completely from the machine. If the measuring result is too low (1k ohm or lower), the CAN controller chip is damaged and the pc-board must be exchanged.
  • Page 62 The machine shows “nFc Act” at the front panel. In this condition a smartphone with NFC functions must be held to the front panel. The machine transfers the data to the smartphone and accesses a Lorch web site automati- cally that displays the data: The email address of the user/technician can be put into the field “E-Mail”...
  • Page 63 Read out via QR-code With a ControlPro front panel the machine data can be transferred via QR-code. A smartphone with installed QR- code scanner app is required for this. To read out the data follow these steps: switch off the machine press the menu button and keep it pressed switch on the machine release the menu button...
  • Page 64 Use a suitable NFC card NFC card not suitable for this product family/ nFc-H32 Invalid product family Use a suitable NFC card series Lorch authorisation card must be used first, or nFc-H33 Authorisation required Perform authorisation again time run out nFc-H34 Insufficient user level e.g.
  • Page 65 (error memory). A maximum of 16 error codes can be saved. Using a computer with CAN interface and LorchNet Connect adapter, the error memory can be read out via the program “Lorch System Manager”. Code designation cause...
  • Page 66 The data of the machine configuration Switch the machine off and on again, con- could not be read or is corrupted. tact Lorch Service if necessary. E30-06 Configuration software The actual software is not compatible to Re-program the machine with the correct the machine hardware.
  • Page 67 Code designation cause remarks E33-01 Unsymmetrical bus voltage The difference between the bus voltages - check power modules of the power modules 1 and 2 is >60V. - check the flat ribbon cable between MAPRO and DRV E33-02 Unsymmetrical bus voltage Startup The difference between the bus voltages - check connector X17 on DRV of the power modules 1 and 2 is >60V at...
  • Page 68 Lorch Schweißtechnik GmbH Im Anwänder 24-26 71549 Auenwald Germany Tel. +49 (0)7191 503-0 Fax +49 (0)7191 503-199 info@lorch.eu www.lorch.eu...

This manual is also suitable for:

Micormig 300Micormig 350Micormig 400Micormig 500Micormig 400 mvMicormig 500 mv