Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Thermal Arc PowerMaster 320SP
Summary of Contents for Thermal Arc PowerMaster 320SP
- Page 1 Service Manual PowerMaster 320SP / 400SP / 500 SP 999.9997.9-97...
-
Page 2: Table Of Contents
Contents Safety precautions ............3 Common Logic Functions ..........4 Inverter Principle.............. 5 Troubleshooting guide ............. 6 Pc-board DP-MAPRO............7 Pc-board DMR ............... 10 Pc-board DS20BF ............12 Pc-board DK-DCDRV / DK-S3DRV ....... 14 Pc-board PWRUP04............19 Pc-board DP-S3NEFI ............ 20 Pc-board DP-UFI-BO............. -
Page 3: 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 appropriately and only by qualifi ed/trained staff. Please follow safety regulations and use safety precautions in order to prevent accidents when working with these machine. -
Page 4: Common Logic Functions
Common Logic Functions component function cause fan (power unit) power modul temperature over 30°C fan (power unit) power modul temperature below 30°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 5: Inverter Principle
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 rectifi ed fi rst and with electronic power switches (MOSFETs or IGBTs) chopped into a frequency of 80 kHz. -
Page 6: Troubleshooting Guide
Troubleshooting guide code description reason removal E 00 no program no welding parameters available for selected select other material-wire-gas combination material-wire-gas combination (no reasonable combination) E 01 thermal overload thermal sensor of power unit measures a too high let machine cool down in standby (*1) temperature E 02 mains overvoltage... -
Page 7: Pc-Board Dp-Mapro
Pc-board DP-MAPRO The pc-board DP-MAPRO is responsible for the welding sequence and is managing the process control of the PowerMaster. (MAPRO = MAster-PROcess) Functions Logicfunctions of the welding process generating and monitoring supply voltages driving powerup-relays driving power unit/units monitoring control and operating elements (DS20BF, remote control, torch buttons) driving fans driving coolingpump monitoring fl... - Page 8 Settings DIP Switch If the machine is to be programmed via the serial port, the DIP switches 1-3 has to be set to “ON“. In normal ope- ration they has to be set to “OFF“. If the pc-board is used in a 320SP, the DIP switch 4 has to be set to “ON“. For the use in a 400SP or 500SP, DIP switch 4 has to be set to “OFF“.
- Page 9 Picture Pc-board DP-MAPRO Overview connectors Pc-board DP-MAPRO connector designation connector to power uint 1 connector control transformer (supply of pc-board) connector to pc-baord DS-ERW (not used in Transmig machines) connector to power uint 2 connector to Interpass hose package 230V supply fans/cooling unit (from control transformer) connector fan group 1 CAN connector connector fl...
-
Page 10: 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 inch button supply pc-board PP90R (Push-Pull) LED displays normal state... - Page 11 Picture Pc-board DMR Overview connectors Pc-board DMR connector designation torch trigger switch front panel volt/amp display wire insert button tacho gas valve pc-board PP90R (Push-Pull option) Interpass hose package wire feed motor “-“ (minus) wire feed motor “+“ (plus) welding potential remote control interface page 11...
-
Page 12: 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 LED11 LED10... - Page 13 650.1243.0 DS22BF RP326 D00.0069.0-00 LED11 LED10 Display test The display has an internal function test. To execute the test press the buttons “arrow down“ (TA13) and Mode “mode“ (TA4) at the same time. At a machine with seperatd front panels, the test can also be executed at the DS21BF with the buttons “2-stroke/4-stroke“...
-
Page 14: 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 400SP and 500SP. The pc-board DK-S3DRV is managing the primary drive level of the power unit 320SP. !!! CAUTION !!!: there had been several changes at the boards, please read the detailed informations about the- se changes on page 17. - Page 15 Picture Pc-board DK-DCDRV / DK-S3DRV D00.0050.6-01 LED6 LED4 LED1 LED2 LED5 T = MOSFET (power transistor) D = diode page 15...
- Page 16 Overview connectors pc-baord DCDRV connector designation connector to pc-board DP-MAPRO connector current sensor and pc-board PRWUP 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 Changeover to new MOSFETs and new pc-board DK-DCDRV Over the time there had been some changes at the power units. Important is to make sure, that the different versi- ons are not mixed up (do not combine “old“ with “new“). •...
- Page 18 old driver ic: JC429CPA DCDR2x with new driver ic: TC4429 320SP: pc-board part no. serial no. date identifi cation MOSFET toroidal core diode driver ic DK-S3DRV 650.1274.x DCDR03 650.5256.x N630001 A W1000101 21.09.2006 DCDR13 650.5366.x T821001 A W1000101 30.11.2007 DCDR23 650.5373.x R802001 A W1000101 02.04.2008...
-
Page 19: Pc-Board Pwrup04
Pc-board PWRUP04 The pc-board DK-PWRUP is the power up-circuit of the 400SP and 500SP. 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 fi lter and power up board of the 320SP. Functions - mains fi lter - reducing start-up peak current for capacitors - supply and safeguarding for control transformer Measuring Points designation measure point result mains input L1 mains input L2... - Page 21 Pc-board DK-GLCL The pc-board DK-GLCL is for wiring the secondary rectifi er diodes. Functions - wiring secondary diodes - pulse smoothing Picture pc-board DK-GLCL 650.5265.x DK-GLCL RP312/2 D00.0050.9-00 page 21...
-
Page 22: 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 fi lter Picture Pc-board DP-EMV 650.5316.x DP-EMV RP399/2 D00.0107.1-00 page 22... -
Page 23: 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 650.5160.x LSW RP163/1 D0000231-00 Current Sensor VAC Since the following serial no. the current sensor VAC is used instead of the pc-board LSW: machine Serial no. -
Page 24: Pc-Board Ds-Va
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 state designation 41 (green) hold-function active Picture Pc-board DS-VA: 650.1228.0 DS-VA RP260/2 D0000138-01 LED41 Pc-board PP-90R management for Lorch Push-Pull torches. -
Page 25: Control Transformer
Control Transformer The control transformer 655.8021.0 is used in the 400SP and 500SP. The control transformer 655.8023.0 is used in the 320SP. 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 18V/0,4A secondary2 primary 0_18V primary2 secondary 0_400V 1 Pos. -
Page 26: Temperature Monitoring
Temperature Monitoring The temperature of the heat sink is constantly monitored via a temperaure sensor. This sensor is a temperature dependent resistor (NTC = negative temperature coeffi cient). The higher the temperature, the lower the resistance value of the sensor. Schematic ϑ... -
Page 27: Supply Voltages
Supply Voltages On the MAPRO pcb all internal supply voltages are generated out of the control transformer output. Schematic Different supply voltages 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). -
Page 28: Monitoring Welding Current
Monitoring Welding Current The welding current is measured via a separate current sensor (VAC or LSW pcb at older machine versions). The current is monitored by the Microcontroller (Master) and the DSP (Process) at the same time. Schematic MAPRO +3.3V DCDRV +15V X2 / 3... -
Page 29: Cooling Unit
Cooling Unit At watercooled machines, the fl owrate of the coolant is measured in the return fl ow. The fl owmeter output is a digital signal where it’s frequency is proportional to the fl owrate. The higher the fl owrate, the higher the frequency. If the fl... -
Page 30: Welding Voltage Monitoring
Welding voltage monitoring The output voltage is conducted via a low pass fi lter (pc-board DP-UFI-BO) to the MAPRO pcb. The voltage is measured by the Master as well as the Process. Schematic In case the Master is measuring a voltage higher than 100V, the machine will stop and displays E06 (secondary overvoltage). -
Page 31: Control And Monitoring Wire Feed Motor
Control and monitoring wire feed motor The pc-board DMR has it‘s own microcontroller which is responsible for driving, controlling and monitoring the wire feed motor. Schematic The current consumption 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. -
Page 32: Remote Control Interface
Remote control interface The remote control interface is for connecting a hand or foot remote control. It is also possible to use the interface for a small automation application. In case of “inpermissible“ short circuits between the connector pins of the interface, the machine will stop and displays E11 (remote control conn.). -
Page 33: Monitoring Primary Current
Monitoring primary current The input current of the power units is monitored at the DCDRV pcb. The current is measured with an internal current sensor, located on the pcb.As soon as the current is exceeding the maximum value, the CPLD (= Complex Programmable Logic Device) shuts down the power unit immediately. -
Page 34: Power-Up Cycle
Power-up cycle After switching on the machine with the mains switch, the capacitors on the DCDRV pcb are charged up fi rst. These capacitors are buffering the bus voltage (rectifi ed mains voltage). The input current during charge up can be very high and must be limited to prevent the mains fuses to break. The current limitation is made by the PWRUP pcb, where each phase is conducted via resistors to the mains rectifi... -
Page 35: Monitoring Bus Voltage
Monitoring bus voltage The bus voltage is monitored by the DSP (Process) directly. As soon as the bus voltage is too low or too high, the machine will stop and displays the corresponding error message: E22 : Mains undervoltage 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... -
Page 36: Identifi Cation Power Units
Identifi cation power units During the initialisation of the machine (switching on), the MAPRO pcb is detecting what power units are connec- ted. The identifi cation of the power units is made by a DIP switch at the DCDRV pcbs. Should the MAPRO detect that confi... -
Page 37: Testing Mosfets
Testing MOSFETs MOSFET - Test use a 9V battery to “switch on“ the drain - source path 9V Batterie 9V battery drain - source path is low resistant short circuit between gate and source to “switch off“ the drain - source path drain - source path is high resistant page 37... -
Page 38: Inside Diagram Diodes
Inside Diagram Diodes page 38... - Page 39 page 39...
Need help?
Do you have a question about the PowerMaster 320SP and is the answer not in the manual?
Questions and answers