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

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 1fans (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
1mode seriel programming mode normal operation
2mode seriel programming mode normal operation
3mode seriel programming mode normal operation
4configuration S3 mobile configuration S3, S5, S8

10
Picture Pc-board DP-MAPRO
X5
X6
X7
X25
X9
X18 X13
X19
LED4
LED6
LED3
X1
X4
X14
X17
X20X8
X3
X10
X11
X16
X23
X21
X22
LED1
LED5
LED2
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
+
10kΩat 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