LORCH Saprom S Service Manual

Service Manual
Saprom S

909.0620.1-01

2

Contents

Subject Page

Machine 3

Machine Elements 3

Safety precautions 4

Common Logic Functions 5

Schematic S-Series 6

Troubleshooting guide 7

Pc-board DP-MAPRO 8

Pc-board DMR 11

Pc-board DS20BF 13

Pc-board DK-DCDRV / DK-S3DRV 16

Pc-board DK-PWRUP 18

Pc-board PWRUP04 19

Pc-board DP-S3NEFI 20

Pc-board DK-GLCL 21

Pc-board DP-UFI 22

Pc-board DP-UFI-BO 23

Pc-board DP-EMV 23

Pc-board LSW 24

Pc-board DS-VA 24

Pc-board PP-90R 25

Pc-board DS-ERW 26

Control Transformer 27

3

Machine

Machine Elements

*)option

1 torch 9 air intake
2 pressure reducer 10 transport wheels
3 gas cylinder* 11 main switch
4 tray area 12 display current/voltage
5 facility for transport 13 ground clamp
6 handle 14 connector for ground cable
7 front panel 15 display cover
8 connections

4

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.

Only qualified workers who are knowledgeabel and have been trained to work safely with test instruments 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 parts or improper use of the test instru

-

ments and equipment.

Use only original spare parts

Replace immediately any components that are not in perfect condition.

Norms

Please follow the current safety regulations corresponding to your country.

5

Common Logic Functions

Gas test

- press the buttons (arrow up) and “gas type“ (+) at the same time

- the gas valve is activated for 30 sec.

- a countdown is shown in the display

- press button “gas type“ (+) 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 “material type“ (-) again to end the test manually

Reset adjustments

- press the buttons (arrow up) and “TT Enter“ at the same time

- all secondary parameters are reset to their default values

- if Tiptronic is active, the settings of the current job are reset to their programmed values

- all adjustments of the Extras menu remain unchanged

Master reset

- press the buttons (arrow up) and “Mode“ together for about five sec.

- the display shows “Master Reset“

- the machine is reset completely to factory settings

!!! CAUTION : all Tiptronic jobs are deleted !!!

component function associated event

fan (power unit) on power modul temperature over 40°C

fan (power unit) off power modul temperature below 40°C

fan (cooling system) on after detection „welding current on“

fan (cooling system) off after welding process, two minutes post-cooling time

pump on after detection „welding current on“

pump off after welding process, two minutes post-cooling time

6

Schematic S-Series

7

Troubleshooting guide

(*1) display the module temperatures in menu Extras > Diagnosis > Module temperatures
(*2) display the supply voltages in menu Extras > Diagnosis > Operating voltages
(*3) display the flow rate in menu Extras > Diagnosis > Flow rate cooling system

code description reason removal

E 00 no program no welding parameters available for selected material-

wire-gas combination (no reasonable combination)

select other material-wire-gas combination

E 01 thermal overload thermal sensor of power unit measures a too high tem-

perature

let machine cool down in standby (*1)

E 02 mains overvoltage mains voltage too high (24V supply > 36V) check mains voltage and control transformer (*2)

E 03 secondary overcurrent welding current is too high check pc-board LSW

E 04 air cooling error Temp. sensor of the power unit detects that the unit

heats up too fast

check fan and air hardening lime

E 05 cooling system error flowrate of the cooling liquid is too low (< 0,3 l/min)

pump is not working

check connectors of flow-meter, level of cooling liquid and
flowrate (*3)
check fuse SI7 (2,5A) on pc-board DP-MAPRO

E 06 secondary overvoltage Master detects output voltage is too high exchange power unit

E 07 EEProm checksum error no welding program stored or error during reading from

memory

transfer welding programs to machine again

E 08 wire feed / tacho power consumption of wire feed motor too high

no tacho signal
no CAN-Bus connection between MAPRO and DMR

blow out torch package with compressed air
check wire feed unit
check wiring of wire feed motor and pc-board DMR

E 09 error v/a measuring measuring difference between Master and Process check wiring of pc-board LSW and pc-board DK-UFI

E 10 torch socket / cable short circuit of torch control cables or between torch

switch wires and welding potential

check torch control cables and torch interface

E 11 remote-control conn. short circuit between remote control cables check remote control and wiring of remote control socket

E 12 Communication Process Process is not responding to Master switch the machine off and on again

optionally exchange pc-board DP-MAPRO

E 13 Temp. sensor error Temp. sensor is defective check resistor value and wiring of the sensor

E 14 Op. voltages error supply voltage is too low (< 17V) check mains voltage and control transformer (*2)

E 16 primary overcurrent

protection1

power consumption of power unti 1 is too high exchange power unit

E 18 overload protection safety shutdown to protect electrical components

temp. sensor is disconnected

let machine cool down in standby
check temp. sensor

E 20 Overvoltage sec. Process reports a too high output voltage exchange power unit

E 21 Output voltage/current external current/voltage or measure-difference between

Master and Process

exchange power unit

E 22 Mains undervoltage 1 power unit 1 reports mains voltage too low check mains voltage and mains rectifier

E 23 Mains overvoltage power unit reports mains voltage too high check mains voltage

E 24 Overcurrent protection2 power consumption of power unti 2 is too high exchange power unit

E 25 Power module detection Jumper on pc-board DK-DCDRV have been set wrong check junper J1, J2 on pc-board DK-DCDRV

E27 no program (DSP) welding programs faulty or not available select other material-wire-gas combination

transfer welding programs to machine again

E 30 Mains undervoltage 2 power unit 2 reports mains voltage too low check mains voltage and mains rectifier

E 31 Communication error Master is not responding to Process switch the machine off and on again

optionally exchange pc-board DP-MAPRO

8

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

- driving coolingpump

- monitoring flowmeter

- monitoring mains- and output voltage

- generating signal „welding current on“

- managing communications between PC and machine

- managing and storage of all welding parameters

- CAN-bus

LED displays :

If the LEDs are indicating a malfunction which can not be relieved by switching the machine off and on again,
it is recommended that the pc-board DP-MAPRO is exchanged.

normal

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) flashing DSP is working

6 (green) flashing micro controller is working

malfunction

LED state designation

1 (green) never on CPLD-processor is not working

2 (red) on DSP is not working

3 (green) off supply voltage 3,3V DC is missing

check 18V~ AC of control transformer X2/1 X2/2

4 (red) on micro controller is not working

5 (green) never on DSP is not working

6 (green) never on micro controller is not working

9

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
operation they has to be set to “OFF“.
If the pc-board is used in a Saprom S3 mobile, the DIP switch 4 has to be set to “ON“. For the use in a standard
Saprom S3, S5 or S8, DIP switch 4 has to be set to “OFF“.

Overview fuses DP-MAPRO

fuse value [A] Safeguarding

Si 6 1 fans (power unit)

Si 7 2,5 cooling pump

Measuring Points

designation measure point result

solenoid valve X10/1

X10/2

+

GND

+24V DC

supply voltage
control transformer

X6/1
X6/3

~
~

230V AC

supply voltage
fan group 1

X7/1
X7/2

~
~

230V AC

supply voltage
fan group 2

X25/1
X25/2

~
~

230V AC

supply voltage
cooling pump

X13/1
X13/2

~
~

230V AC

supply voltage
control transformer

X2/1
X2/2

~
~

18V AC

X2/3
X2/4

~
~

42V AC

supply voltage
flow meter

X9/1
X9/3

+

GND

+15V DC

supply voltage
CAN bus

X8/1
X8/2

GND

+

+15V DC

X14/1
X14/2

GND

+

+15V DC

X20/1
X20/2

GND

+

+15V DC

DIP switch ON OFF

1 mode seriel programming mode normal operation

2 mode seriel programming mode normal operation

3 mode seriel programming mode normal operation

4 configuration S3 mobile configuration S3, S5, S8

10

Picture Pc-board DP-MAPRO

X5

X6

X7

X25

X9

X18

X13

X19

LED 4

LED 6

LED 3

X1

X4

X14

X17

X20X8

X3

X10

X11

X16

X23

X21

X22

LED 1

LED 5

LED 2

X2

11

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

LED state designation

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 5V not ok

Measuring points

designation measure point result

solenoid valve X6/1

X6/2

+

GND

+24V DC

supply voltage
Tacho

X5/1
X5/3

+

GND

5V DC

drive level for pc-board PP90R
(Push-Pull)

X7/1
X7/3

+

GND

+24V DC

wire insert button
(when button pressed)

X1/1
X1/2

0Ω

wire insert button
(when button pressed)

X4/1
X4/2

0Ω

supply wire feed motor X10

X11

-

+

0-42V DC

supply voltage
CAN bus

X20/1
X20/2

GND

+

+15V DC

12

Picture Pc-board DMR

13

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

14

At a machine with separated front panels, the pc-boards DS21BF and DS22BF are used.

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. 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 encoders are
checked. The LCD-Display shows a cursor which can be moved by the rotary impulse encoders. At first the
cursor has to be moved to the left with the left rotary impulse encoder then to the right. After that the cursor has
to be moved to the left and right with the right rotary impulse encoder.
Then the test are completed and the LCD-Display shows „End of Tests“ and the machine goes back into normal
mode, which was displayed before the display test was executed.

16

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

- safety shut-down of power unit

- passthrough signal powerup relais

- passthrough signal „welding current on“ (from pc-board LSW)

Encoding Power Unit

0 = contact open
1 = contact closed
If DIP switches are used instead of jumper: 0 = “OFF“, 1 = “ON“

LED displays

jumper J1 jumper J2 setting machine type

0 0 240 A S5

0 1 270 A S3

1 0 300 A S8

1 1 reserved

normal

LED state designation

1 (red) off primary overcurrent shut down

2 (green) on drive level of low-side is ok

4 (green) on DC link voltage max is ok

5 (green) on drive level of high-side is ok

6 (green) on DC link voltage min is ok

malfunction

LED state reason

1 (red) on primary current is too high, power unit has been switched off

2 (green) never on no drive level low-side

4 (green) off DC link voltage is too high (e.g. mains overvoltage)

5 (green) never on no drive level high-side

6 (green) off DC link voltage is too low (e.g. mains voltage too low)

17

Measuring Points

Picture Pc-board DK-DCDRV / DK-S3DRV

designation Messpunkt Messergebnis

supply voltage pc-board
LSW

X2/1
X2/6

+

GND

15V DC

supply voltage pc-board
LSW

X2/3
X2/6

-

GND

-15V DC

thermal sensor X3/1

X3/2

GND

+

10kΩ at 25°C

(about +2V DC)

18

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

Picture Pc-board DK-PWRUP

Fuses

Safeguarding the control transformer via Si1, Si2 : each 4A idle

Beschreibung Messpunkt Messergebnis

mains input L1
mains input L2
mains input L3

X5
X6
X7

~
~
~

400V AC

mains output L1
mains output L2
mains output L3

X1
X2
X3

~
~
~

400V AC

supply voltage control transformer X10/1

X10/2

~
~

400V AC

drive level relay X4/1,3

X4/2,4

+

-

24V DC

19

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

Picture Pc-board PWRUP04

Fuses

Safeguarding the control transformer via Si1, Si2 : each 4A idle

designation measure point result

mains input L1
mains input L2
mains input L3

X5
X6
X7

~
~
~

400V AC

mains output L1
mains output L2
mains output L3

X1
X2
X3

~
~
~

400V AC

supply voltage control transformer X10/1

X10/2

~
~

400V AC

drive level relay X4/1,3

X4/2,4

+

-

24V DC

20

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

Picture pc-board DP-S3NEFI

Fuses

Safeguarding the control transformer via Si3, Si4 : each 4A idle

designation measure point result

mains input L1 LP1 ~ 400V AC

mains input L2 LP2 ~ 400V AC

mains input L3 LP3 ~ 400V AC

drive level power-up relais X4/1, X4/3

X4/2, X4/4

+

-

+24V DC

GND

supply control transformer X10/1

X10/2

~
~

400V AC

mains output L1 LP4 ~ 400V AC

mains output L2 LP5 ~ 400V AC

mains output L3 LP6 ~ 400V AC

X4

X10

SI3

SI4

LP1

LP2

LP3

LP4

LP6

LP5

LP7

650.1281.x DP-S3NEFI RP359/1

D00.0107.0-00

21

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

22

Pc-board DP-UFI

The pc-board DK-UFI is for wiring the welding sockets.

Functions

- wiring welding sockets

- providing output voltage

Measuring points

Picture Pc-board DP-UFI

Since the following serial no. the pc-board DP-UFI was replaced by the boards DP-UFI-BO and DP-EMV:

designation measure point result

secondary output voltage

(nm MMA mode)

X3
X2

+

GND

ca. 81V DC

socket „+“

socket „-“

+

GND

ca. 81V DC

X1/1
X1/2

+

GND

ca. 81V DC

machine serial no. date

Saprom S3 405-1525-001 22.06.2005

Saprom S5 403-1525-001 22.06.2005

Saprom S8 404-1525-001 22.06.2005

Saprom S3 mobile [phone].2005

23

Pc-board DP-UFI-BO

Functions

- wiring welding sockets

- providing output voltage

Picture Pc-board DP-UFI-BO

Pc-board DP-EMV

Functions

- EMC filter

Picture Pc-board DP-EMV

X3

X2

X1

650.5311.x DP-UFI-BO RP393/2

D00.0107.2-00

X3

X2

650.5316.x DP-EMV RP399/2
D00.0107.1-00

24

Pc-board LSW

The pc-board LSW is a potential free current sensor.

Functions

- measuring the welding current

Measuring points

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

Picture Pc-board DS-VA:

designation measure point result

supply voltage X1/1

X1/3

-

+

+30V DC

normal

LED state designation

41 (green) on hold-function active

25

Pc-board PP-90R

management for Lorch Push-Pull torches.

Functions:

- supply Push-Pull motor

- managing start signal

Measuring points:

Picture Pc-board PP-90R:

designation measuring point result

supply voltage X1/2

X1/5

~
~

42VAC

motor voltage X1/4

X1/1

-

+

+60VDC

drive level relay X1/7

X1/6

GND++24VDC

26

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

Measuring Points

Picture Pc-board DS-ERW

normal

LED state designation

1 (green) off wire feed unit 1 active

on wire feed unit 2 active

designation measuring point result

solenoid valve 1 X5/1

X5/2

GND+

24V DC

solenoid valve 1 X6/1

X6/2

GND+

24V DC

water valve 1 X7/1

X7/2

~
~

42V AC

water valve 2 X8/1

X8/2

~
~

42V AC

27

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.

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

0.400V

1

0.42V

42V/3,5A

400V

2

Pos.

4

3

7

8

Pos.

20V/3A

0.20V

5

6

primary

secondary

5

11

655.8021.0

3

1

2

10

4

8

9

12

13

14

15

5

9

12

10

11

13

15

14

4

8

Pos.

230V/2,5A

19V/3A

0.19V

1

2

34

5

6

7

8

primary

secondary

Secondary

primary

secondary

1

2

3

4