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Table of Contents
Related Manuals for LORCH V Series
Summary of Contents for LORCH V Series
- Page 1 Service Manual V Series 909.0340.1-05...
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Page 2: Table Of Contents
Contents Machine ................3 Safety precautions ............4 Common Logic functions ..........5 Inverter Principle.............. 6 Pc-board DK-MAPRO............7 Pc-board DK-DCI40 / DK-ACI40 ........10 Pc-board DK-DCI45 / DK-ACI45 ........11 Pc-board DK-DCDRV ............ 13 Pc-board DK-ACDRV ............ 18 Pc-board DK-PWRUP ........... 20 Pc-board DP-S3NEFI ............ -
Page 3: Machine
Machine Machine elements torch connector ground cable front panel connector external cooling unit mains switch mains cable connections gas hose page 3... -
Page 4: Safety Precautions
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: Common Logic Functions
Common Logic functions component function cause fan (power unit) power modul temperature over 40°C fan (power unit) power modul temperature below 40°C fan (cooling system) after detection “arc established“ fan (cooling system) after welding process, two minutes post-cooling time pump after detection “arc established“... -
Page 6: Inverter Principle
(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... -
Page 7: Pc-Board Dk-Mapro
Pc-board DK-MAPRO The pc-board DK-MAPRO is responsible for the welding sequence and is managing the process control of the V-Series (MAPRO = MAster-PROcess) Functions Logicfunctions of the welding process generating and monitoring supply voltages driving powerup-relais driving power unit/units driving ignition device monitoring control and operating elements (DK-ACI40/DK-DCI40, remote control, torch buttons) driving solenoid valve driving fans... - Page 8 Measuring points designation measure point result gas valve X1/1 X1/2 +24V DC supply from control transformer X6/1 230V AC X6/2 supply voltage fan group 1 X7/1 230V AC X7/2 supply voltage fan group 2 X25/1 230V AC X25/2 supply voltage fan (cooling unit) X26/1 230V AC X26/2...
- Page 9 Picture pc-board DK-MAPRO LED1 LED2 LED5 LED3 LED6 LED4 CPLD 3,3V Master measuring point X9 control transformer page 9...
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Page 10: Pc-Board Dk-Dci40 / Dk-Aci40
Pc-board DK-DCI40 / DK-ACI40 The pc-board DK-DCI40 (DC machines) and 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... -
Page 11: Pc-Board Dk-Dci45 / Dk-Aci45
Pc-board DK-DCI45 / DK-ACI45 The pc-board 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 page 11... - Page 12 Function test of the front panel The front panel has an internal function test. With this test, all LEDs and encoders can be checked. Switch be- tween the single test forth and back with the arrow keys at any time. Start test: press arrow key “left“...
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Page 13: Pc-Board Dk-Dcdrv
Pc-board DK-DCDRV The pc-board DK-DCDRV is managing the primary drive level of the power unit. Functions encoding power unit connection of the thermal sensor (at heat sink) supply current sensor monitoring bus voltage and supply voltage safety shut-down of power unit passthrough signal power-up relay passthrough output of current sensor Encoding power unit... - Page 14 Picture pc-board DK-DCDRV / DK-S3DRV D00.0050.6-02 LED6 UZmin LED6 LED4 LED4 UZmax LED1 LED2 LED2 drv low LED1 ovr cur LED5 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 Overview connectors pc-board DCDRV connector designation connector to pc-board DP-MAPRO connector current sensor and pc-board PRWUP 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).
- Page 16 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 ver- sions are not mixed up (do not combine “old“ with “new“). •...
- Page 17 DCDR2x with new old driver IC: JC429CPA driver IC: TC4429 V27, V30, V50: pc-board part no. serial no. date identification MOSFET toroidal core diode driver ic DK-DCDRV 650.5262.x DCDR01 650.5258.x 7xx-1635-001 30.08.2006 DCDR11 650.5364.x 7xx-1749-001 30.11.2007 DCDR21 650.5371.x 7xx-1812-001 12.03.2008 V24, V40: pc-board part no.
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Page 18: Pc-Board Dk-Acdrv
Pc-board DK-ACDRV The pc-board DK-ACDRV is managing the drive level for the secondary inverter (AC power module with IGBT full-bridge) Functions encoding AC power unit drive level IGBTs connection of temperature sensor Encoding power unit setting machine type 2 IGBT V24, V40 4 IGBT V27, V30, V50... - Page 19 Overview connectors pc-board DK-ACDRV connector designation connector to IGBT output voltage of secondary rectifier connector to IGBT connector temperature sensor interface to pc-board DK-MAPRO Schematic AC inverter LED3 LED2 LED4 LED1 ACDRV C2E1 C2E1 page 19...
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Page 20: Pc-Board Dk-Pwrup
Pc-board DK-PWRUP The pc-board DK-PWRUP is the power-up circuit of the machine. 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 mains output L2 400V AC... -
Page 21: Pc-Board Dp-S3Nefi
Pc-board DP-S3NEFI The pc-board DP-S3NEFI is mains filter and power-up circuit in one for the V24 mobile. Functions mains filter 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... -
Page 22: Pc-Board Nefi3X32
Pc-board NEFI3x32 The pc-board NEFI3x32 is the mains filter for the V30 mobile. Functions mains filter Picture pc-board NEFI3x32 connector designation mains input L1 mains input L2 mains input L3 mains output L1 mains output L2 mains output L3 page 22... - Page 23 Pc-board DK-GLCL The pc-board DK-GLCL is for wiring the secondary rectifier diodes. Functions - wiring secondary diodes - pulse smoothing Picture pc-board DK-GLCL 650.5265.x DK-GLCL RP312/2 D00.0050.9-00 page 23...
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Page 24: Pc-Board Dk-Glcl3
Pc-board DK-GLCL3 Since 02.12.2011 the pc-board DK-GLCL was replaced by the pc-board 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... -
Page 25: Pc-Board Dk-Ksdc / Dk-Ksdcd / Dk-Ksdcn
Pc-board DK-KSDC / DK-KSDCD / DK-KSDCN The pc-board DK-KSDC is an additional support for the HF ignition. Functions electronic short-circuit switch for HF ignition support LEDs normal state designation 1 (green) supply voltage +15V DC ok malfunction state cause 1 (green) supply voltage +15V DC of pc-board DK-MAPRO is missing Measuring points designation... - Page 26 Schematic DK-KSDCN DK-KSDCN X1 / 3 +15V X1 / 10 X1 / 11 X1 / 14 X5 (+) X1 / 5 X1 / 4 X7 (-) The DK-KSDCN produces an additional voltage spike of about 350V for the support 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.
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Page 27: Pc-Board Dk-Hfdc / Dk-Hfdc Hv
Pc-board DK-HFDC / DK-HFDC HV The pc-board DK-HFDC is the ignition device of the welding machine. In 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... - Page 28 Schematic DK-HFDC DK-MAPRO DK-HFDC X11 / 1 X1 / 1 +24V X11 / 2 X1 / 2 Power Unit X11 / 4 X1 / 4 +15V X11 / 8 load ig. X1 / 8 CPLD X11 / 3 X1 / 3 X11 / 10 X1 / 10 X11 / 9...
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Page 29: Pc-Board Dk-Ufi
Pc-board DK-UFI The pc-board DK-UFI is for wiring the welding sockets. Functions - wiring welding sockets - providing output voltage Measuring points designation measuring point result secondary output voltage ca. 58V DC in MMA (stick electrode) mode ca. 58V DC X1/1 ca. -
Page 30: Pc-Board Lsw
Pc-board LSW The pc-board LSW is the current sensor of the machine (potential free). 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 serial no. -
Page 31: Control Transformer
Control transformer The control transformer 655.8022.0 is used in all “driveable“ machines of the V series. The control transformer 655.8025.0 is used in the V mobile machines. 400V 18V/4A 655.8022.0 230V/3A primary 1 secondary 1 0.400V 0.18V 400V 0.42V secondary... -
Page 32: 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 coefficient). The higher the temperature, the lower the resistance value of the sensor. Schematic DK-MAPRO +3.3V DCDRV1... -
Page 33: Supply Voltages
Supply voltages On the MAPRO pcb, all internal supply voltages are generated from the output of the control transformer. Schematic DK-MAPRO +15V DC +5V DC potential free potential free 18V AC +24V DC +15V DC -15V DC +3,3V DC +5V DC +5V DC (Process) ext. -
Page 34: 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 DK-MAPRO +3.3V DCDRV1 X2 / 3 X1 / 16... -
Page 35: Monitoring Welding Voltage
Monitoring welding voltage The output voltage is measured via X19 of the pc-board DK-MAPRO. As well as the Master and the Process (DSP) are measuring the output voltage independently. Schematic DK-MAPRO Master DK-EMV X1 / 1 X19 / 1 workp. (+) X1 / 2 X19 / 2 electr. -
Page 36: Cooling Unit
Cooling unit At watercooled machines, the flowrate of the cooling liquid is measured in the return flow. The flowmeter output is a digital signal where it’s frequency is proportional to the flowrate. The higher the flowrate, the higher the frequen- cy. - Page 37 Flow meter To open the flow meter, 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 37...
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Page 38: Torch Control
Torch control The buttons of the torch are monitored by the Master of the DK-MAPRO board. Schematic 5 pin Tuchel Master START STOP START / STOP DOWN DOWN Kennung „gasgekühlt“ identification “gas cooled“ In case of short circuits between the connecting pins, the machine will stop and displays E10 (error torch connec- tion). -
Page 39: 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 40: 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 cur- rent 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 41: Power-Up Cycle
Power-up cycle After switching on the machine with the mains switch, the capacitors on the DCDRV pcb are charged up first. These capacitors are buffering the bus voltage (rectified 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 rectifier. -
Page 42: 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 V40 or V50), only the error message with the... -
Page 43: Identification Power Units
Identification power units The pc-board DK-MAPRO is reading the configuration of the power units during the initialisation. On the primary sides (pc-board DCDRV) the configuration is set by a DIP switch. On the secondary sides at AC/DC machines (pc-board ACDRV) the configuration is set by a small jumper. The secondary side of the DC machines are the pc- board KSDCN, which have a fixed (not setable) configuration. -
Page 44: Checking Mosfets
Checking 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 44... -
Page 45: Inside Diagram Diodes
Inside diagram diodes PE protection (optional) The PE protection is an optional feature. 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. -
Page 46: List Of Error Codes
List of error codes Code designation cause remedy E 00 no program operating system and welding program doesn’t store welding programs matching to the operating match to each other system version, into the machine E 01 thermal overload temperature of power units are too high let machine cool down in standby (*1) see page 32 E 02... - 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...
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