LORCH V Series, Service Manual

Page 1: ...Service Manual V Series 909 0340 1 05 ...

Page 2: ...GLCL3 24 Pc board DK KSDC DK KSDCD DK KSDCN 25 Pc board DK HFDC DK HFDC HV 27 Pc board DK UFI 29 Pc board DK EMV 29 Pc board LSW 30 Current sensor VAC 30 Control transformer 31 Temperature monitoring 32 Supply voltages 33 Monitoring welding current 34 Monitoring welding voltage 35 Cooling unit 36 Torch control 38 Remote control interface 39 Monitoring primary current 40 Power up cycle 41 Monitorin...

Page 3: ...page 3 Machine Machine elements 1 torch 5 connector ground cable 2 front panel 6 connector external cooling unit 3 mains switch 7 mains cable 4 connections 8 gas hose 2 3 6 4 8 7 1 5 4 3 2 1 ...

Page 4: ...uments 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 instruments and equipment Use only original spare parts Replace immediately any components that are not in perfect condition Norms IEC 60974 4 In service inspection and testi...

Page 5: ...time the pump is switched on for one minute the buttons Acknowledge and gas test again to end the test manually Reset settings press the button Acknowledge and the button TT Enter at the same time all parameters are reset to their factory settings doing the reset in Tiptronic mode only the settings of the actual Job are reset all settings in Menu Extras remain unchanged Master Reset press the butt...

Page 6: ...is rectified first and with electronic power switches MOSFETs or IGBTs chopped into a frequency of 80 kHz This allows a very small construction of the welding transformer because it s driven at this high fre quency The basic structure of a welding inverter is always the same at Lorch power sources mains rectifier primary inverter transformer secondary rectifier mains filter 3 phase mains input rec...

Page 7: ... 3 green on supply voltage 3 3V ok 4 red off Microcontroller ok 5 green flashing DSP is working 6 green flashing Microcontroller is working malfunction LED state meaning 1 green never on CPLD not working 2 red on DSP not working 3 green off supply voltage 3 3V missing check 18V of control transformer X9 1 X9 2 4 red on Microcontroller not working 5 green never on DSP not working 6 green never on M...

Page 8: ...wer unit 1 primary X3 connector to power unit 2 primary X4 connector to power unit 1 secondary X5 connector to power unit 2 secondary X6 230V supply fans cooling unit from control transformer X7 connector fan group 1 power unit X8 connector pump with X24 X9 connector control transformer supply voltage for pc board X11 interface for HF ignition unit X12 connector flow meter X13 connector remote con...

Page 9: ...pc board DK MAPRO X14 X13 X12 X11 X26 X8 X24 X25 X7 X6 X15 X16 X17 X18 X20 X19 X22 X21 X2 X3 X4 X5 X1 X23 X9 LED3 3 3V DIP S1 LED2 LED5 DSP LED1 CPLD LED6 LED4 Master earth screw measuring point X9 control transformer ...

Page 10: ...nd DK ACI40 AC machines is the front panel with all buttons and opti cal displays Functions operating and handling of the machine display of operational parameters and error messages Picture pc board DK DCI40 DK ACI40 buttons and LEDs only mounted at pc board DK ACI40 X1 ...

Page 11: ...rd DK DCI45 and DK ACI45 are the front panels with all buttons and optical displays of the V mobile machines Functions operating and handling of the machine display of operational parameters and error messages Picture pc board DK DCI45 DK ACI45 X1 ...

Page 12: ...ion of the display is shown e g D 3 030204 11 press right arrow key all LEDs are flashing and the LCD is toggeling between bright and dark press right arrow key the red LED at the key electrode diameter is on press right arrow key all keys are tested the key to be checked is indicated with a lit LED press right arrow key move the cursor in LCD with the encoder to the right and back to the left the...

Page 13: ...ys normal LED state designation 1 red off primary overcurrent shut down 2 green on drive level of low side is ok 4 green on bus voltage max is ok 5 green on drive level of high side is ok 6 green on bus 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 bus voltage is too high e g...

Page 14: ...ED5 T T T T T T T T D D00 0050 6 02 L L L L L L LED6 UZmin LED4 UZmax LED1 ovr cur LED2 drv low LED5 drv hi T MOSFET power transistor D diode CAUTION at all positions where cables are attached the longer screws are used A A UZ UZ The rest of the ISOTOP screws are the short ones ...

Page 15: ... connector temperature sensor Primary Driver The pc baord 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 flat ribbon cable and the PWM signals PWM Pulse Width Modulation for driving the MOSFETs are at pin 5 low side and pin 6 high side Schematic Ubus Ubus ...

Page 16: ...by DCDR 01 and DCDR 02 Since December 2007 additional diodes had been added to the pc boards change from DCDR0x to DCDR1x Since April 2008 a new driver circuit was used change from DCDR1x to DCDR2x type part no designation picture old MOSFET 711 2606 0 E26NA90 new MOSFET 711 2608 0 IXFN26N90 The new pc boards DCDR 01 and DCDR 02 can be easily distinguished from the old pc board DK DCDRV At the new...

Page 17: ...CDRV24 650 5259 x old no no old DCDR02 650 5257 x 7xx 1635 001 30 08 2006 new yes no old DCDR12 650 5365 x 7xx 1749 001 30 11 2007 new yes yes old DCDR22 650 5372 x 7xx 1812 001 12 03 2008 new yes yes new CAUTION the new MOSFETs are not compatible with the old type The new MOSFETs must only be used with the new pc boards DCDRxx The new parts must not be mixed with the old parts under no circumstan...

Page 18: ...rature sensor Encoding power unit J1 setting machine type 0 2 IGBT V24 V40 1 4 IGBT V27 V30 V50 0 contact open 1 contact closed LEDs The LEDs on the pc board DK ACDRV are showing the drive level state of the IGBT LED on IGBT not driven LED off IGBT driven Measuring points designation measure point result temperature sensor X5 1 X5 2 GND 10kΩ at 25 C about 2V DC Picture pc board DK ACDRV IGBT X2 X6...

Page 19: ...on X1 connector to IGBT X2 output voltage of secondary rectifier X3 connector to IGBT X5 connector temperature sensor X6 interface to pc board DK MAPRO Schematic AC inverter C1 E2 C2E1 G1 G2 E1 E2 C1 E2 C2E1 G1 G2 E1 E2 ACDRV X3 X1 2 1 5 4 1 2 4 5 LED1 LED4 LED2 LED3 ...

Page 20: ...former Measuring Points designation measure point result mains input L1 X5 400V AC mains input L2 X6 mains input L3 X7 mains output L1 X1 400V AC mains output L2 X2 mains output L3 X3 supply voltage control transformer X10 1 X10 2 400V AC drive level relay X4 1 and 3 X4 2 and 4 24V DC Picture Pc board DK PWRUP Fuses Safeguarding the control transformer via Si1 Si2 each 4A 400V slow ...

Page 21: ... designation measure point result mains input L1 LP1 400V AC mains input L2 LP2 mains input L3 LP3 mains output L1 LP4 400V AC mains output L2 LP5 mains output L3 LP6 supply voltage control transformer X10 1 X10 2 400V AC drive level relay X4 1 3 X4 2 4 24V DC Picture pc board DP S3NEFI X4 X10 SI3 SI4 LP1 LP2 LP3 LP4 LP6 LP5 LP7 650 1281 x DP S3NEFI RP359 1 D00 0107 0 00 Fuses Safeguarding the con...

Page 22: ...rd NEFI3x32 is the mains filter for the V30 mobile Functions mains filter Picture pc board NEFI3x32 connector designation KL1 KL2 KL2 mains input L1 mains input L2 mains input L3 KL4 KL5 KL6 mains output L1 mains output L2 mains output L3 ...

Page 23: ...K GLCL is for wiring the secondary rectifier diodes Functions wiring secondary diodes pulse smoothing Picture pc board DK GLCL C1 C2 C3 D4 D5 D6 KK1 KK2 KK3 R1 R2 R3 R4 R5 R6 R7 U 1 U 2 ZD4 ZD5 ZD6 X1 650 5265 x DK GLCL RP312 2 D00 0050 9 00 ...

Page 24: ...DK GLCL3 Since 09 03 2012 the secondary diodes 713 0298 0 were replaced by a new diode tyoe 713 0301 0 The new diode types are NOT compatible with the old pc board DK GLCL Compatibility diode type DK GLCL DK GLCL3 713 0298 0 ok ok 713 0301 0 X ok Picture pc board DK GLCL3 Schematic D3 D2 D1 X1 ...

Page 25: ...points designation measuring point result secondary output voltage in stick electrode mode X5 X7 GND about 58V DC Picture pc board DK KSDCN UG UG red blue X1 15V C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 D1 D2 D5 D6 D7 D8 D9 DRO1 DRO2 IC1 1 2 3 IC2 IC3 KK1 KK2 LED1 OK1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R36 SI1 T1 T2 ZD2 ZD3 X5 X7 Ov...

Page 26: ...ort of the HF ignition At the output of the power unit a short circuit is made by a MOSFET then the output current is increased step wise Until a certain current is reached the MOSFET opens up and produces the voltage spike Changes pc board DK KSDCN Since February 2021 from serial number 0709 3105 0001 8 a new version of the KSDCN is used in the series old KSDCN new KSDCN ...

Page 27: ...n the machines V40 and V50 the pc board DK HFDC HV is used All other machines are equipped with the pc board DK HFDC Functions generating high voltage pulses Picture pc board DK HFDC Overview connections pc board DK HFDC connector designation X1 interface to pc board DK MAPRO X3 connector for HF inductor ...

Page 28: ...he ignition capacitor up to 1000V The charging process is monitored by the CPLD As soon as the 1000V are reached the ignition impulse is triggered with a thyristor trigger impulse via pins 5 and 6 If the CPLD can not read the PWM signals of the ignition board the complete process is stopped and the error meassage E19 error ignition device is shown in the display of the machine Possible reasons cou...

Page 29: ...easuring point result secondary output voltage in MMA stick electrode mode X2 x3 GND ca 58V DC X6 X7 GND ca 58V DC X1 1 X1 2 GND ca 58V DC Picture pc board DK UFI X1 X2 X3 X7 X6 X5 X4 Pc board DK EMV The pc board DK UFI was replaced by the pc board DK EMV Since serial no xxx 1602 001 from the 9th Jan 2006 the pc board DK EMV is used Picture pc board DK EMV X1 X2 X3 ...

Page 30: ...supply voltage X1 1 X1 3 30V DC Picture pc board LSW X1 650 5160 x LSW RP163 1 D0000231 00 Current sensor VAC Since serial no xxx 1724 001 from the 13th of June 2007 a new current sensor VAC is used instead of the LSW Measuring points designation measure point result supply voltage X1 1 X1 2 X1 4 GND 15V DC 15V DC GND sensor output X1 3 2000 1 Picture current sensor VAC M 4 3 2 1 ...

Page 31: ...e machines of the V series The control transformer 655 8025 0 is used in the V mobile machines 655 8022 0 400V 18V 4A 0 18V 0 400V 230V 3A 3 2 4 5 1 1 1 1 2 5 6 7 8 0 400V 1 0 42V 400V 2 8 20V 3A 0 20V 5 6 7 42V 012A secondary secondary primary primary 1 secondary 1 secondary 1 primary 1 ...

Page 32: ...X5 2 X6 11 X6 14 ACDRV2 ϑ X5 11 X5 14 3 3V 3 3V 3 3V 3 3V DSP DK MAPRO The DSP is monitoring the temperature of the heatsink and as soon as the temperature reaches the programmed maximum value the machine will stop and displays E01 thermal overload The actual value of the temperature can be displayed at the front panel in menu Extras Diagnosis Module Tem peratures If one of the temperature sensors...

Page 33: ...oller Master 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 Voltage limits supply voltage limit result 24V 17V shutdown with E14 24V 36V shutdown with E02 The actual values of the 24V a...

Page 34: ...9 error v a measuring If the Process is measuring a welding current 20A although the machine is not welding standby the machine will stop and displays E21 Output voltage current At V40 or V50 machines with double power units both power units are working parallel For example the ma chine is set for 200A welding current then 100A are generated from power unit 1 and the other 100A are gener ated from...

Page 35: ...cess should detect a voltage higher than 100V the machine will stop and displays E20 Overvoltage secondary If no voltage can be measured at all then machine will stop and displays also E20 Possible reasons could be disconnected measuring wires red and blue loose connection of the connectors interchanged wires red with blue If the Master is measuring another voltage than the DSP the machine will st...

Page 36: ...t WUK X12 2 X12 3 X12 1 X12 4 2 3 1 X1 4 X1 5 X1 3 X1 6 WUK 15V 15V MASTER DK MAPRO X7 4 X7 5 X7 3 X7 6 X1 1 X1 2 X5 2 X5 4 X7 1 X7 2 X10 1 X10 2 X6 1 X6 3 42V AC power source tank pump hose connector blue hose connector red flow meter cooler At gas cooled machines a small cable bridge is shorting pins 1 and 4 at connector X12 instead of a flow meter This is the identification to deactivate the mo...

Page 37: ...er turn the housing halves against each other bayonet assembly take off the top halve take out sealing ring and the turbine CAUTION mind the right flow direction do not reverse in and output when mounting the flow meter back into the machine ...

Page 38: ...ns the machine will stop and displays E10 error torch connec tion All gas cooled torches must have an internal cable bridge between pins 4 and 5 This is the identification for the machine to detect if the water cooling unit should be activated or not If there is no connection between pins 4 and 5 the machines will activate the pump as soon as it detects that an arc is ignited If the start contact ...

Page 39: ...n as pin 1 and 2 are connected the machine starts same function as pressing the torch trigger switch weld energy 4 analog input for setting the weld energy e g with an potentiometer 0V minimum setting of the actual welding program 15V maximum setting of the actual welding program CAUTION this analog input is only valid if the identification external on pin 6 and 7 is active identification external...

Page 40: ...much current the machine will stop and displays E16 primary overcurrent protection1 If power unit 2 draws too much current the machine will stop and displays E24 primary overcurrent protection2 For example E16 primary overcurrent protection1 possible reasons could be power unit 1 is broken hardware defect like broken MOSFET power unit 2 is not active if driver signals for the second power unit are...

Page 41: ...PWRUP pcb where each phase is conducted via resistors to the mains rectifier After the bus voltage reached a certain voltage 250V DC the resistors on the PWRUP pcb are short circuit with relays so the the full mains input is present and the bus voltage is at maximum 560V DC to 580V DC The bus voltage is monitored by the DSP Process and the relays on the PWRUP board are switched by the microcontrol...

Page 42: ...s only at V40 or V50 only the error message with the highest number is displayed E30 Schematic LED6 DCDRV1 X1 10 X1 4 X2 10 X2 4 CPLD DSP 15V DCDRV2 DK MAPRO LED4 X1 9 X2 9 15V LED6 X1 10 X1 4 X3 10 X3 4 15V LED4 X1 9 X3 9 15V U bus1 U bus1 U bus2 U bus2 max bus volt ok min bus volt ok max bus volt ok min bus volt ok Voltage limits bus voltage LED4 LED6 optocoupler output min bus volt ok pin 10 op...

Page 43: ...DCN which have a fixed not setable configuration If the DK MAPRO detects a non valid configuration it will display the error code E25 Powermodul detection Schematic 3 3V 3 3V 3 3V 3 3V DSP 1 2 1 2 X1 4 X2 4 DCDRV2 DK MAPRO X2 11 DCDRV1 ACDRV1 X1 11 X1 4 X1 11 X6 14 X6 10 X6 14 X6 10 ACDRV2 X4 14 X4 10 X3 4 X3 11 X5 14 X5 10 primary side on DCDRV boards DIP 1 DIP 2 setting type OFF OFF 240 A V24 V4...

Page 44: ...G D S GS G D S GS G D S GS G D 9V Batterie 9V battery use a 9V battery to switch on the drain source path 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 45: ...eature As sson as a current 15A is flowing via the protective earth wire of the mains cable the machine stops immediately and the error code E16 primary overcurrent protection 1 is dis played Schematic L1 L2 L3 PE 16 16 MAPRO DCDRV ADP08 SF07 PWRUP X4 X10 X6 X9 X2 X1 X2 X11 X1 X2 X3 X1 X2 ...

Page 46: ... of power unti 1 is too high PE protection became active check DK DCDRV and MOSFETs of power unit1 check ground cable and wiring of power unit see page 40 and page 45 E 17 Error current symmetry output difference between power units check power units 4 see page 34 E 19 Ignition unit error no response of ignition unit to pc board DK MAPRO check exchange pc board DK HFDC see page 28 E 20 Overvoltage...

Page 47: ...page 47 ...

Page 48: ...Lorch Schweißtechnik GmbH Postfach 1160 D 71547 Auenwald Germany Tel 49 0 7191 503 0 Fax 49 0 7191 503 199 info lorch biz www lorch biz ...