Service Manual

Saprom S
S-SpeedPulse
P-SpeedArc

909.0620.1-08
Contens
Machine............................................................................ 3
Safety precautions............................................................ 4
Common Logic Functions................................................. 5
Menu Extras..................................................................... 6
Customize settings........................................................... 7
Inverter Principle.............................................................. 8
Pc-board DP-MAPRO.................................................... 13
Pc-board DMR................................................................ 16
Pc-board DMR-RT.......................................................... 18
Pc-board DMR-RT1........................................................ 20
Pc-board DMR-RT2........................................................ 21
Pc-board DS20BF.......................................................... 22
Pc-board DK-DCDRV / DK-S3DRV................................ 24
Pc-board DK-PWRUP.................................................... 29
Pc-board PWRUP04...................................................... 30
Pc-board DP-S3NEFI..................................................... 31
Pc-board DK-GLCL3...................................................... 33
Pc-board DP-UFI............................................................ 34
Pc-board DP-UFI-BO..................................................... 35
Pc-board DP-EMV.......................................................... 35
Pc-board LSW................................................................ 36
Current Sensor VAC....................................................... 36
Pc-board DS-VA............................................................. 37
Pc-board PP-90R........................................................... 38
Pc-board DMRPP / DMRPP04....................................... 39
Pc-board DS-ERW......................................................... 42
Pc-board TC20 / TC21................................................... 43
TIG Option...................................................................... 44
Control Transformer....................................................... 45
Temperature Monitoring................................................. 46
Supply Voltages.............................................................. 47
Monitoring Welding Current............................................ 48
PE protection / gas pressure switch............................... 49
Cooling Unit.................................................................... 50
Welding voltage monitoring............................................ 52
Control and monitoring wire feed motor......................... 53
Remote control interface................................................ 55
Monitoring primary current............................................. 56
Power-up cycle............................................................... 57
Monitoring bus voltage................................................... 58
Identification power units................................................ 59
Testing MOSFETs........................................................... 60
Inside diagram diodes.................................................... 60
Service Codes................................................................ 61
Troubleshooting guide.................................................... 62

page 2
Machine

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

*) accessory

page 3
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 qualified/trained staff. Please follow safetyregulations and use safety precautions in order to
prevent accident when working with these machines.

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 instruments and
equipment.

Use only original spare parts

Replace any components that are not in perfect condition immediately.

Carry out the safety inspection after every repair or hardware change of the machine.

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
-- the machine has to be cleaned properly before the test
-- switch to MMA mode (stick electrode) if possible
-- the test of the protective earth monitoring circuit is not demanded by the norm, because all safety related ele-
ments of the machine are fully covered by the necessary normative measurements

page 4
Common Logic Functions
component function cause
fan (power unit) on power modul temperature over 40°C
off power modul temperature below 40°C
fan (cooling system) on after detection „arc established“
off after welding process, two minutes post-cooling time
pump on after detection „arc established“
off after welding process, two minutes post-cooling time

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
TT
Enter
-- 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
Mode
-- 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 after a Master Reset !!!

page 5
Menu Extras

The menu Extras can be directly accessed by pressing the buttons “arrow up” + “arrow down” at the
same time.
menu item selection designation
1:Machine data 1:OS Master Display of the actual operating system version of the Master.
e.g. M 2 160611 (21) = version 2.21
160611 = date of creation 16th June 2011
2:OS Process Display of the actual operating system version of the Process.
3:OS Wirefeeder Display of the actual operating system version of the DMR resp. DMRPP.
The system is supporting up to two wire feed units, both operating system ver-
sions are displayed alternating (DMR1 and DMR2). Is only one DMR connected,
only “0 000000 (00)” is displayed for the second (missing) unit.
4:Welding programs Display of the actual version of the welding programs.
5:Operating hour counter Actual count of the operating hour counter in h. min. sec. The counter is not
affected by a Master-Reset, re-programming or software update and can not be
reset in any way.
The counter indicates “pure welding time”: as soon as welding current is flow-
ing, the counter runs.
6:Configuration Display of the hardware configuration and serial number. The DIP switch set-
tings of the DCDRV boards and the serial number of the machine are shown
alternately.
7:Options Display of all unlocked options (Seamtracking, Welddata).
2:Diagnosis 1:Last error messages: Display of the last three error messages with their operation hour counter to the
time when the error occured.
After a Master-Reset the saved error messages are not visible any more.
2:Module temperatures °C Display of the actual temperatures of the power units.
3:Op. voltages 15 / 24V Display of the actual, internal supply voltages of the MAPRO.
The 24V are not stabilized (changes with the actual mains voltage), the 15V are
electrically stabilized.
4:Flow rate cool. system Display of the actual flow rate of the cooling liquid in l/min.
5:W.feeder motor current Display of the motor current from all (active) feed motors. A maximum of three
motors is possible: primary wire feed motor, intermediate feeder motor and
PushPull motor.
6:Arc power Display of the actual electrical arc power in kW.
3:Sprache/Language Language: 0-17 Selection of the language.
4:Display contrast Display contrast: 10-60 Value of the LCD contrast, factory setting = 36
5:Mode cooling system 0 = Auto The cooling pump is switched on as soon as welding current is flowing, after
welding there is a post flow time of about 2 minutes.
1 = On The pumpe is switched on permanently.
2 = Off The pump is off at all times (deactivated).
3 = 30 min The cooling pump is switched on as soon as welding current is flowing, after
welding there is a post flow time of 30 minutes (necessary for long torches like
PushPull or at automation applications).
6:Lock function level 0 With the lock function the front panel functions can be locked out in three levels:
0 = all free
level 1 1 = secondary welding parameter locked
level 2 2 = secondary welding parameter + Tiptronic locked
level 3 front panel completely locked
7:Throat thickness 4,0mm = 11cm/min The throat thickness can be pre-set (e.g. 4mm), the machine shows the neces-
sary welding speed based on the actual setting of the welding current.
8:Arc lenght control 0 = Voltage The arc lenght correction (function of the right encoder of the front panel) is
controlled via the welding voltage (the wire feed speed remains unchanged).
A positive correction (higher voltage) is causing a longer arc.
1 = wire feed speed The arc lenght correction is controlled via the wire feed speed.
A positive correction (faster wire speed) is causing a shorter arc.
9:Welding cable lenght 10-100 m To compensate a power loss at long welding cables, the complete lenght of the
welding current circuit can be set in this menu.
For example: 5m torch + 10m interconn. cbale + 10m earth lead = 25m
This menu item was implemented since software version 2.20.

page 6
menu item selection designation
10:Robot interface This menu item is only visible/selectable, if a robot/automation interface (pc-
board INT06-1) or LorchNet Connector is connected to the machine.
Via this menu the interface or LorchNet Connector can be configured.
In the operating manual “INT06-1” (909.0530.0) and operating manual LorchNet
Connector (909.1570.0) all details are described.
A:Torch / aux. drive 0 - 18 This menu item is only visible/selectable, when a digital PushPull interface (pc-
board DMRPP) is installed or connected.
Via this menu the type of the PushPull torch can be selected and calibrated if
necessary.

Customize settings

Press the button “up” and the button “wire diameter” and keep them pressed for about five seconds,
the menu “Customize settings” is displayed. In this menu special function can be activated or deactivated.
Menu item function designation
CS01 4-stroke 2 Special 4 stroke
If the torch trigger is pressed briefly during welding in 4-stroke mode, the machine switches to the second-
ary current (the secondary current can be set as a percentage of the main current in the list of welding
parameters). If the torch trigger is pressed briefly again, the machine switches back to the main welding
current.
CS02 TorchPotPow If a torch with integrated potentiometer shall be used, it can be connected to the remote control interface of
the MAPRO (also the remote control interface of the DMRPP can be used, if available). With the function
activated, the potentiometer controls the welding energy.
CS03 TorchPotArc If a torch with integrated potentiometer shall be used, it can be connected to the remote control interface of
the MAPRO (also the remote control interface of the DMRPP can be used, if available). With the function
activated, the potentiometer controls the arc lenght.
The function „TorchPotArc“ has a higher priority than the function „TorchPotPow“.
CS04 4-stroke TT Special 4-stroke Tiptronic
If the torch trigger is pressed briefly during welding in Tiptronic mode, the machine scwitched to the next
active job number. If the torch trigger is pressed briefly again, the machine switches back to the previous
job number.
The function „4-stroke TT“ has a higher priority than the function „4-stroke 2“.
CS05 Remote 10V In the standard configuration the analog input of the remote control interface is working with a voltage level
of 0-15V. Activating this function, the input works with a voltage level of 0-10V.
CS06 MMA w. feed Special MMA lockout: the MMA mode (stick electrode) can only be selected if no wire feed unit is attached
(pc-board DMR) to the power source.
This function is activated (=On) as factory setting, that the MMA mode can be selected even when a wire
feeder is connected.
CS07 SpdArc Hard Off: noise reduced SpeedArc mode
CS08 Reserved 8 reserved / not used
CS09 Min. Gas Minimum gas flowrate in liters/minute, factory setting: 2.0 l/min (only operational with mounted gas flowrate
meter and connected INT07 interface).
If the gas flowrate drops below the selected value,the machine stops with error code E04-02. The monitor-
ing is only active when the gas valve is switched on.

!!! CAUTION !!!

A Master-Reset does NOT reset the Customize settings !

page 7
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 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

3 phase mains

mains-
filter

power-
up

primary
rectifier

primary
driver switch

transformer

secondary
rectifier

page 8
 X1
L1 L2 L3 PE
F5
0.42
Q1 1 3 5 400 X8
42 1 2 3 4 5 6
2 4 6
0.20

L1 L2 L3 X10/2 0.400 20
X10/1
T1
A1 F3
F4

X2/1

X2/2

X2/3

X6/1

X2/4

X6/3

X13/1

X13/2

X9/1

X9/2

X9/3

X9/4
X26/3
X26/6
X4/1
L1A L2A L3A X4/2 X5
X26/1 X8/1 1 GND

A2 ~1 ~2 ~3 X26/4 X8/2 2 +VCC

X8/3 3 CAN_L
F2 F1
X8/4 4 CAN_H

*
- +

X6
X18/1 1 Start / Stop

- + X18/2 2
X2/6

X2/5

X3/1

X3/2

A10 X18/3 3
+10VDC GND

0-10VDC
X18/4 4
16
A3 X1 X1 X18/5 5
A+
X18/6 6 Ken. extern
external
X2/3

X2/2

X2/1

A- X18/7 7
2 takt
X18/8 8 2 stroke

X18/9 9
I>0
X18/10 10
.
X10/1

X10/2

X17/1

X17/2

.
T2
X5

.
8
14
24VDC

X5/4
X8

+ - XT/4
X5/1
M
XT/3
X5/2
A4 - + - M1
XT/1
X5/3 G
M2
X11
+ M -

X10
A13-15 X6/1
+24VDC

A5 A11 Y1
X1/1
X1/2

X1/3

X6/2
S2
X4/1
L1
X4/2
S1
X1/1
X12/2
X1/2

10 A8
X2 X3 X1/1 X2 X1
A7
X3 A6 X3 X2 X1/2

X2 10 A9
X3 X1
X2 X3 X4
- + + * Option /optional equipment
Stromlaufplan / schematic-diagram
erstellt am/von
provided to/of B.Schieber S3 mobil SpeedPulse
S00.0055.0-01
geändert am/von
changed to/of

page 9
 X1 L1 L2 L3 PE F5
F7
A12 L1 L2 L3
1 2 3
400 0.42
A8 A9
Q1 1 3 5
42

X1

X1
230
2 4 6 0.20 2 3 1 C1

X10/2 10 10 XP/1 M
X5

X6

X3

0.400 20 230
X10/1
T1 1~
A1 F3 F4 XP/3 0.230 M4
X6/3

X2/1
X2/2

X2/3
X2/4

X26/3
X26/6

X9/2

X9/3

X9/1

X9/4

X11

X16
X4/1
X1

X2

X3

X4/2 X6/1 XL/2 0.230 M

Brücke X9/1 zu X9/4 nur bei gasgekühlter Anlage

X13/1

Bridge X9/1 to X9/4 only at gas-cooled machine

1~
A2 ~1 ~2 ~3 X26/1 XL/1 230 M5-7
F6 X13/2
X26/4
F2
X5
X8/1 1 GND
- +

X8/2 2 +VCC

X8/3 3 CAN_L
- +
X2/6

X2/5

X3/1

X3/2

X8/4 4 CAN_H

*
X6
A3
16 A10 X18/1 1 Start / Stop
X1 X1
A+ X18/2 2
+10VDC GND
X18/3 3
X2/3

X2/2

X2/1

A- 0-10VDC
X18/4 4

X18/5 5

X18/6 6 Ken. extern

external
X18/7 7
2 takt
T2 X18/8 8 2 stroke

X18/9 9
F1 I>0
X18/10 10
X17/1

X17/2
X7/1

X7/2

.
X5

.
.
8
14

A4 1/3 2/5 4/6

0.230

X8

X5/4
XT/4
M X5/1
1~
XT/3
M1-2 X5/2

XT/1
A13-15 X5/3 G
L1 M3
X11
+ M -

A5 A11 X10
X1/1
X1/2

X1/3

+24VDC
X6/1

Y1
X12/2 X6/2
S2
X4/1
X2 X3 X1/1
A7 X4/2
X3 A6 X3 X2 X1/2 S1
X1/1
X2
X1/2
X2 X3 X4
- + + * Option /optional equipment
Stromlaufplan / schematic-diagram
erstellt am/von
provided to/of
11.12.2008 B.Schieber S3 SpeedPulse A
S00.0055.1-01
geändert am/von
17.05.2011 B.Schieber
changed to/of

page 10
 X1 L1 L2 L3 PE
F5
F7
A12 L1 L2 L3

1 2 3
400 0.42

A8 A9
Q1 L1 L2 L3
42

X1
X1
230
T1 T2 T3 2 3 1 C1
0.20

X10/2 10 10

L1
L2
L3
0.400 20 XP/1 230 M
X10/1
T1 1~
A1 F3 XP/3 0.230 M4
F4 X6/3

X11
X16
X4/1

X2/1
X2/2
X2/3
X2/4
X9/2
X9/3
X9/1
X9/4

X26/3
X26/6
T1 T2 T3 X4/2 X6/1 XL/2 0.230
X13/1
M
1~
A2 ~1 ~2 ~3 XL/1 230
X26/1 F6 X13/2
M5-7

F2a F2 X26/4
X5
X8/1 1 GND
- +

X8/2 2 +VCC

X8/3 3 CAN_L
- + - + X8/4 4 CAN_H

Brücke X9/1 zu X9/4 nur bei gasgekühlter Anlage

Bridge X9/1 to X9/4 only at gas-cooled machine

X3/1
X3/2
X2/6
X2/5
X3/1
X3/2
16
*
A+ A+ X1 X1 X6
A3a A3 A10 X18/1 1 Start / Stop

A- A- X18/2 2

X1
X2/3
X2/2
X2/1
+10VDC GND
X18/3 3
16
0-10VDC
X4 X18/4 4

X18/5 5

X18/6 6 Kennung extern

external
T2 X18/7 7
2 takt
X18/8 8 2 stroke

F1 X18/9 9
I>0
X18/10 10

X7/1
X7/2
X17/1
X17/2
X5
.
.
.
1 2 3 4 5 6 8
A4a A4 14

0.230
X5/4
X8

XT/4
X5/1
XT/3
M X5/2
1~
M1-2 XT/1
A13a-15a A13-15 X5/3 G
M3
+ M -
X11
L1
A11 X10
A5 +24VDC
X6/1
X1/1

X1/2
X1/3

Y1
X12/2 X6/2
S2
X4/1

X2 X3 X1/1 X4/2
A7 S1
X3 A6 X3 X2 X1/2 X1/1

X2 X1/2

X2 X3 X4
- + +
erstellt am/von 12.12.2008 B.Schieber S5 SpeedPuls A
* Option /optional equipment geändert am/von
S00.0055.3-00

page 11
 X1 L1 L2 L3 PE

F7 F5
A12 L1 L2 L3

page 12
1 2 3
400 0.42

Q1 L1 L2 L3 A8 A9
42

X1
X1
T1 T2 T3
230
0.20
2 3 1 C1

L1
L2
L3
X10/2 10 10 XP/1
0.400 20 230 M
X10/1
A1 F3 T1 1~
F4 XP/3 0.230 M4
X4/1 X6/3

X11
X16
T1 T2 T3 X4/2

X2/1
X2/2
X2/3
X2/4
X9/2
X9/3
X9/1
X9/4

X26/3
X26/6
X6/1 XL/2 0.230
X13/1
M
1~
X26/1 XL/1 230 M5-7
F6 X13/2
A2a ~1 ~2 ~3 A2 ~1 ~2 ~3 X26/4
F2a F2
X5
X8/1 1 GND

X8/2 2 +VCC
- + - +

X8/3 3 CAN_L
- + - + X8/4 4 CAN_H

Brücke X9/1 zu X9/4 nur bei gasgekühlter Anlage

Bridge X9/1 to X9/4 only at gas-cooled machine

X3/1
X3/2
X2/6
X2/5
X3/1
X3/2
*
16
X1 X1

A+
A+
A+
A+
A3a A3 X6
A10 X18/1 1 Start / Stop

A-
A-
A-
A-
X18/2 2

X1
X2/3
X2/2
X2/1
+10VDC GND
X18/3 3
16
0-10VDC
X4 X18/4 4

X18/5 5

X18/6 6 Kennung extern

external
T2 X18/7 7
2 takt
X18/8 8 2 stroke

F1 X18/9 9
I>0
X18/10 10

X7/1
X7/2
X17/1
X17/2
X5
.
.
8 .
- + + - - + + -
A4a A4 14
X5/4

X8
XT/4
X5/1
XT/3

0.230
X5/2
M
1~ XT/1
M1-2 X5/3 G
A13a-15a A13-15
M3
+ M -
X11

L1 A11 X10
+24VDC
X6/1
A5

X1/1
Y1

X1/2
X1/3
X6/2
S2
X12/2 X4/1

X4/2
S1
X2 X3 X1/1 X1/1
A7
X3 A6 X3 X2 X1/2 X1/2

X2

X2 X3 X4 erstellt am/von 12.12.2008 B.Schieber

- + +
S8 SpeedPulse A
* Option /optional equipment geändert am/von 13.05.2009 F. Becker S00.0055.5-02
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“ (arc established)
-- managing communications between PC and machine
-- managing and storage of all welding parameters
-- CAN-bus communication

LED displays :
normal
LED state designation
1 (green) flashing (half freq. of LED5) CPLD 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 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

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.

Overview fuses DP-MAPRO

fuse value [A] Safeguarding
Si 6 1 fans (power unit)
Si 7 2,5 cooling pump

Settings DIP Switch

If the DSP (Process) of 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 are 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“.

DIP switch ON OFF

1-3 mode seriel programming mode normal operation
4 configuration S3 mobile configuration S3, S5, S8

page 13
Measuring points
designation measure point result
solenoid valve X10/1 + +24V DC
X10/2 gnd
supply voltage X6/1 ~ 230V AC
control transformer X6/3 ~
supply voltage X7/1 ~ 230V AC
fan group 1 X7/2 ~
supply voltage X25/1 ~ 230V AC
fan group 2 X25/2 ~
supply voltage X13/1 ~ 230V AC
cooling pump X13/2 ~
output voltage X2/1 ~ 18V AC
control transformer X2/2 ~
X2/3 ~ 42V AC
X2/4 ~
supply voltage X9/1 + +15V DC
flow meter X9/3 gnd
supply voltage X8/1 gnd
CAN bus X8/2 + +15V DC
X14/1 gnd
X14/2 + +15V DC
X20/1 gnd
X20/2 + +15V DC

Overview connectors pc-board DP-MAPRO

connector designation
X1 connector to power uint 1
X2 connector control transformer (supply of pc-board)
X3 connector to pc-baord DS-ERW (only used at machines with two wire feed units)
X4 connector to power uint 2
X5 connector to Interpass hose package
X6 230V supply fans/cooling unit (from control transformer)
X7 connector fan group 1
X8 CAN connector
X9 connector flow meter
X10 connector gas valve (only used when TIG option is installed)
X11 connector front panel
X13 connector cooling unit
X14 CAN connector
X15 connector TIG torch button
X16 connector volt/amp display
X17 connector output voltage (to pc-board DP-UFI-BO)
X18 connector remote control
X19 connector gas test button
X20 CAN connector
X21 connector JTAG interface (internal programming port)
X22 connector JTAG interface (internal programming port)
X23 connector serial Interface (RS232: internal programming port)
X26 connector PE and gas monitoring

page 14
Picture Pc-board DP-MAPRO

LED5 LED2 LED4 LED6 LED3

DSP DSP Master Master 3,3V

LED5 LED2

LED1
X26

LED3
X22

LED4 LED6
X1 X4
X23

X21

X17

X19

X5

X2 control transformer
X14

measuring point
X2
X20

X6 X8
earth screw

X3

X10
X25

X15
X7

X13 X9 X18 X11 X16

1A 2.5A

page 15
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 + +24V DC
X6/2 gnd
supply voltage tacho X5/1 + 5V DC
X5/3 gnd
drive level for pc-board PP90R X7/1 + +24V DC
(Push-Pull) X7/3 gnd
wire insert button X1/1 0W
(when button pressed) X1/2
supply wire feed motor X10 -
X11 + 0-42V DC
supply voltage X20/1 gnd
CAN bus X20/2 + +15V DC

page 16
Picture Pc-board DMR
LED2 LED1
5V error

Overview connectors Pc-board DMR

connector designation
X1 torch trigger switch
X2 front panel
X3 volt/amp display
X4 wire insert button
X5 tacho
X6 gas valve
X7 pc-board PP90R (Push-Pull option)
X8 Interpass hose package
X10 wire feed motor “-“ (minus)
X11 wire feed motor “+“ (plus)
X12 welding potential
X18 remote control interface
!!! CAUTION !!! only the start contact (pins 1 and 2) is available. There is no analog input or a digital output (welding cur-
rent on : I>0)
X20 CAN bus

page 17
Pc-board DMR-RT
The pc-board DMR-RT is the control board in the robot wire-feeder. In comparison to the “normal“ DMR, this
board can ReTract the wire. With a relay (polarity-change relay) the polarity to the motor is inverted. The green
LED3 is lit as soon as the retract function is active.
Due to space reasons the remote control interface was removed, apart from that the pc-board is fully compatible
to the “normal“ DMR (hard- and software).

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
3 (green) on wire retract active
off normal wire feed

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 + +24V DC
X6/2 gnd
supply voltage tacho X5/1 + 5V DC
X5/3 gnd
drive level for pc-board PP90R X7/1 + +24V DC
(Push-Pull) X7/3 gnd
supply wire feed motor X10 -
X11 + 0-42V DC
supply voltage X20/1 gnd
CAN bus X20/2 + +15V DC

page 18
Picture Pc-board DMR-RT

X2

LED2
LED2 +5V

LED3 LED3
retract LED1
LED1 error

X3

X12
X8

X4 X5 X1 X20 X7
X6
X11 X10

Overview connectors Pc-board DMR-RT

connector designation
X1 torch trigger switch
X2 front panel
X3 volt/amp display
X4 wire insert button
X5 tacho
X6 gas valve
X7 pc-board PP90R (Push-Pull option)
X8 Interpass hose package
X10 wire feed motor “-“ (minus)
X11 wire feed motor “+“ (plus)
X12 welding potential
X20 CAN bus

page 19
Pc-board DMR-RT1
Over the time the original pc-board DMR-RT was enhanced with addtional features.

History of changes
Date Pc-board Remarks
since 24.08.2009 DMR-RT enhancement of the DMR with the function "retract“ to pull back the wire
since 16.11.2011 DMR-RT1 enhancement with additional connector for the air blast valve
since 13,07,2012 DMR-RT2 enhancement with additional input for collision protection

Picture pc-board DMR-RT1

X2

LED2
LED2 +5V

LED3 LED3
retract LED1
LED1 error

X9
X3

X12
X8

X4 X5 X1 X20 X7
X6
X11 X10

Since 16.11.2011 the DMR-RT was replaced by the DMR-RT1. New is the additional 6 pin Microfit connector X9.
At this connector the air blast valve, wire inching button and retract button can be connected directly.

Pin assignment connector X9

pin no. designation
1 air blast valve
DMR-RT1
X9-2
2 +24V DC +24V
3 gnd X9-1
air blast valve
4 wire retract
X9-4
5 gnd
6 wire inching µP wire retract
X9-3

X9-6

X9-5
wire inching
gnd

page 20
Pc-board DMR-RT2
Since 13.07.2012 the DMR-RT1 was replaced by the DMR-RT2. New are the additional Minifit connectors X13
and X14. At these connectors additional digital inputs and a free relay contact are available.

Picture pc-board DMR-RT2

X13
X13

X14 X14

LED2
LED2 +5V

LED3 LED3
retract LED1
LED1 error

X9 X9

X3
X12
X8

X4 X5 X1 X20 X7
X6
X11 X10

DMR-RT2

+24V X14-2

X14-4

µP
Din4 X14-1 collision protection

X14-3
gnd

Din5 X13-1

Din1 X13-2

Din6 X13-3

Din2 X13-4

Din3 X13-5

Din7 X13-6

X13-7...12
gnd

page 21
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

LED9
X1

LED5 LED6 LED7 LED8

LED1 LED14 LED15 LED16

LED13 LED17

LED2 LED3 LED4 LED12 LED18

S1 S2

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“ (TA2) and “slope“ (TA3).

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 alternately. 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.

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

page 22
Picture pc-board DS-21BF
650.1244.0 DS21BF RP327
D00.0068.9-00

X1

LED5 LED6 LED7 LED8

LED1 LED11 LED12 LED13

LED10 LED14

LED2 LED3 LED4 LED9 LED15

S1 S2

Picture pc-board DS-22BF

650.1243.0 DS22BF RP326
D00.0069.0-00

LED11 LED10

LED9
X1

Pc-board MAT-BF
The pc-board MAT-BF is the front panel of the P-Basic machines.

Displaytest of the front panel

The display test at the P-Basic machines is activated by pressing the two outer buttons (mode and main param-
eter).

page 23
Pc-board DK-DCDRV / DK-S3DRV
The pc-board DK-DCDRV is managing the primary drive level of the power unit S5 and S8 (P4500/P5500).
The pc-board DK-S3DRV is managing the primary drive level of the power unit Saprom S3 (3x00/mobil).

Functions
- encoding power unit
- connection temperature sensor of heat sink
- supply current sensor
- monitoring bus voltage and supply voltage
- safety shut-down of power unit
- passthrough signal power-up relay
- passthrough signal „welding current on“ (from current sensor)

Encoding Power Unit

The type of the power unit is set via the DIP switch.
DIP 1 DIP 2 setting machine type
OFF OFF 240 A S5 / P4500
OFF ON 350 A S3 / P3x00
ON OFF 300 A S8 / P5500
ON ON reserved

LED displays
normal
LED state designation
1 (red) off primary overcurrent shut down
2 (green) on supply of low-side driver is ok
4 (green) on bus voltage is ok
5 (green) on supply of high-side driver is ok
6 (green) on bus voltage 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 supply for low-side driver
4 (green) off bus voltage is too high (e.g. mains overvoltage)
5 (green) never on no supply of high-side driver
6 (green) off bus voltage is too low (e.g. mains voltage too low)

Measuring Points
designation measure point result
supply voltage current sensor X2/1 + +15V DC
X2/6 gnd
supply voltage current sensor X2/3 - -15V DC
X2/6 gnd
temperature sensor X3/1 gnd 10kW at 25°C
X3/2 + (about +2V DC)

page 24
Picture Pc-board DK-DCDRV / DK-S3DRV
D00.0050.6-02

X2 X3

X1 S1 T T

L
T T
L L

D
LED6
UZmin
LED6
LED4
LED4 L L
UZmax
LED2 LED2
LED1 T T
drv low L
LED1
ovr cur

LED5 LED5
drv hi

T T

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.

Overview connectors pc-board DCDRV

connector designation
X1 connector to pc-board DP-MAPRO
X2 connector current sensor and pc-board PRWUP
X3 connector temperature sensor

page 25
PWM-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).

Monitoring primary current

The “A+” wire of the transformer (primary coil) is going through a current sensor. As soon as the primary input
current gets too high, the driver circuits are locked and via pin 8 of the flat ribbon cable the DCDR signals to the
DP-MAPRO that an “overcurrent” has occured (see details on page 56).

Monitoring bus voltage

The bus voltage is monitored by the DCDR board. As soon as the bus voltage gets too high or too low, the DCDR
signals to the DP-MAPRO via pins 9 (overvoltage) and 10 (undervoltage) that the bus voltage is out of limits (see
details on page 58).

Schematic

DCDRV
+UZ
T10
T12
T16
X1-6 PWM drv high T17

X1-8

X1-1 A+
Vcc high LED1
X1-3 LED5
X1-2 Vcc low A-
LED2 T6
T7
X1-5 PWM T9
drv low T11

-UZ
X1-9 UZmax
LED6
X1-10
UZmin
LED4

page 26
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“).
!!! CAUTION !!! :S-SpeedPulse and P-SpeedArc machines are not affected !!!.

• Since september 2006 the MOSFET (711.2606.0) was replaced by a new type (711.2608.0). In this context the
pc-boards DK-DCDRV/DK-S3DRV were replaced by DCDR-01 and DCDR-03.
• 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-03 can be easily distinguished from the „old“ pc-board DK-DCDRV. At
the „new“ pc-boards the gate resistors have a small toroidal core:

The main difference between the DCDR0x and DCDR1x is an additional diode:

DCDR1x DCDR0x
with additional diode

page 27
 old driver ic: JC429CPA DCDR2x with new
driver ic: TC4429

Saprom S3 mobile:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-S3DRV 650.1274.x old no no old
DCDR03 650.5256.x 406-1638-001 21.09.2006 new yes no old
DCDR13 650.5366.x 406-1749-001 30.11.2007 new yes yes old
DCDR23 650.5373.x 406-1814-001 02.04.2008 new yes yes new

Saprom S3:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-S3DRV 650.1274.x old no no old
DCDR03 650.5256.x 405-1638-001 20.09.2006 new yes no old
DCDR13 650.5366.x 405-1748-004 30.11.2007 new yes yes old
DCDR23 650.5373.x 405-1814-001 02.04.2008 new yes yes new

Saprom S5:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-DCDRV 650.5262.x old no no old
DCDR01 650.5258.x 403-1637-012 20.09.2006 new yes no old
DCDR11 650.5364.x 403-1748-002 30.11.2007 new yes yes old
DCDR21 650.5371.x 403-1811-001 12.03.2008 new yes yes new

Saprom S8:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-DCDRV 650.5262.x old no no old
DCDR01 650.5258.x 404-1637-003 20.09.2006 new yes no old
DCDR11 650.5364.x 404-1748-001 30.11.2007 new yes yes old
DCDR21 650.5371.x 404-1811-001 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 circumstances !
Especially at the machines with double power units (Saprom S5 and S8) it must be ensured, that both power units
are equipped completely with only one version.

page 28
Pc-board DK-PWRUP
The pc-board DK-PWRUP is the power-up circuit of the Saprom S3 / P3500.

Functions
- reducing start-up peak current for capacitors
- supply and safeguarding of control transformer

Measuring Points
designation measure point result
mains input L1 X5 ~
mains input L2 X6 ~ 400V AC
mains input L3 X7 ~
mains output L1 X1 ~
mains output L2 X2 ~ 400V AC
mains output L3 X3 ~
supply voltage control transformer X10/1 ~ 400V AC
X10/2 ~
drive level relay X4/1 and 3 + +24V DC
X4/2 and 4 -

Picture Pc-board DK-PWRUP

Fuses
Safeguarding the control transformer via Si1, Si2 : each 4A, 400V/500V (slow)

page 29
Pc-board PWRUP04
The pc-board DK-PWRUP is the power up-circuit of the Saprom S5/S8 and P4500/P5500.

Functions
- reducing start-up peak current for capacitors
- supply and safeguarding of control transformer

Measuring Points
designation measure point result
mains input L1 X1 ~
mains input L2 X2 ~ 400V AC
mains input L3 X3 ~
mains output L1 X11 ~
mains output L2 X12 ~ 400V AC
mains output L3 X13 ~
supply voltage control transformer X10/1 ~ 400V AC
X10/2 ~
drive level relay X4/1 and 3 + +24V DC
X4/2 and 4 -

Picture Pc-board PWRUP04

650.1252.x PWRUP04DKL RP397/1
D00.0090.8-01

SI1 X10 SI2

X11

X13

X12

X1 X3 X2

X4

Fuses
Safeguarding the control transformer via Si1, Si2 : each 4A, 400V/500V (slow)

page 30
Pc-board DP-S3NEFI
The pc-board DP-S3NEFI is the mains filter and power up board of the Saprom S3 mobile / P3000 mobile.

Functions
- mains filter
- reducing start-up peak current for capacitors
- supply and safeguarding for control transformer

Measuring Points
designation measure point result
mains input L1 LP1 ~
mains input L2 LP2 ~ 400V AC
mains input L3 LP3 ~
drive level power-up relays X4/1 and 3 + +24V DC
X4/2 and 4 -
supply control transformer X10/1 ~ 400V AC
X10/2 ~
mains output L1 LP4 ~
mains output L2 LP5 ~ 400V AC
mains output L3 LP6 ~

Picture pc-board DP-S3NEFI

650.1281.x DP-S3NEFI RP359/1
D00.0107.0-00

LP5

LP1 LP7

LP6

LP2

LP4

LP3 SI3 X4

SI4 X10

Fuses
Safeguarding the control transformer via Si1, Si2 : each 4A, 400V/500V (slow)

page 31
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
U$2

C3
R7

D4
KK1

ZD6
R1
R3

R2

C2

KK2
D6

ZD4
R4

R5

R6

ZD5
C1

KK3
D5
X1
U$1

page 32
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
713.0298.0 ok ok
713.0301.0 X ok

Picture pc-board DK-GLCL3

Schematic

D1
D2

D3

X1

page 33
Pc-board DP-UFI
The pc-board DK-UFI is for wiring the welding sockets.

Functions
- wiring welding sockets
- providing output voltage

Measuring points
designation measure point result
secondary output voltage X3 + ca. 81V DC
in MMA (stick electrode) mode X2 gnd
socket “+“ + ca. 81V DC
socket “-“ gnd
X1/1 + ca. 81V DC
X1/2 gnd
PE (earth) X4, X5

Picture Pc-board DP-UFI

650.1262.x DP-UFI RP341
D00.00911-00

X1

"-" “+"

X2 X5 X4 X3

Schematic
DP-UFI
R1,2,3
X1-1
X3

C7

X1-2
X2

C1,3 C2,4

X4 X5

page 34
Since the following serial no. the pc-board DP-UFI was replaced by the boards DP-UFI-BO and DP-EMV:
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 406-1524-001 24.06.2005

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

X3
X2

X1

Pc-board DP-EMV
Functions
- EMC filter

Picture Pc-board DP-EMV

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

X3 X2

page 35
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

X1

Current Sensor VAC

Since the following serial no. the current sensor VAC is used instead of the pc-board LSW:
machine Serial no. date
Saprom S3 405-1724-002 13.06.2007
Saprom S5 403-1724-004 13.06.2007
Saprom S8 404-1725-001 19.06.2007
Saprom S3 mobile 406-1726-001 27.06.2007

Measuring points:
designation measure point result
supply X1/1 + +15V DC
X1/2 - -15V DC
X1/4 gnd
sensor output X1/3 (ratio 2000:1)

Picture Current Sensor:

M
4
3
2
1

page 36
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 state designation

41 (green) on hold-function active

Picture Pc-board DS-VA:

650.1228.0 DS-VA RP260/2
D0000138-01

R3
R4 C6

C5
R5

H4 H5 H6 X1 H7 H8 H9
C7
C8

R1
R42

LED41
IC1
C10

C2

Display-Test
There is an internal display test for the pc-board DS-VA. To carry out the test a PowerMaster torch or RC20 is
necessary. Pressing the “mode” button and the rocker switch “left” at the same time and keep them pressed, all
segments and LEDs of the pc-board DS-VA are lit cyclically.

Displaytest

page 37
Pc-board PP-90R
management for Lorch Push-Pull torches.

Functions:
- supply Push-Pull motor

Measuring points:
designation measuring point result
supply voltage X1/2 ~ 42VAC
X1/5 ~
motor voltage X1/4 -
X1/1 + +60VDC
drive level relay X1/7 gnd
X1/6 + +24V DC

Picture Pc-board PP-90R:

650.6271.0 PP-90R RP87/2

D0000139-00

R2
GLR1

7
C1
RE1
X1

R1

Schematic
DMR PP90R
X7-1 X1-7

X7-3 X1-6

X7-2 X1-2 X1-1

X7-4 X1-5 X1-4

M

X1-3

page 38
Pc-board DMRPP / DMRPP04
The pc-board DMRPP04 is the (digital) control board to use a Lorch Push-Pull torch (optional).
It is also necessary for the use of an intermediate feeder or for the NanoFeeder.
If a digital PushPull shall be retrofitted into an existing machine, the pc-board DMR is replaced by the DMRPP04.
Since the introduction of the NanoFeeder, the pc-board DMRPP was replaced by the pc-board DMRPP04.
Only the DMRPP04 is capable of driving the NanoFeeder.
The pc-board DMRPP04 consists of two single boards which are connected via flat ribboncables with each other:
-- pc-board DMRPP-P: power driver circuit for motor
-- pc-board DMRPP-C04: control logic

Functions
-- drive level and monitoring wire feed motor / PushPull motor / intermediate feed motor
-- driving gas valve
-- control and monitoring operating elements (front panel, remote control, torch button)

LED displays
normal
LED state designation
1 (red) off DSP is ok
lit bright pc-board is in flash/programming mode: DIP switch 1 = ON
2 (green) on internal 5V supply voltage ok
3 (green) flashing DSP is working

malfuction
LED state designation
1 (ret) lit weak DSP is not programmed (no operationg system)
2 (green) off 5V supply voltage is not present
3 (green) on permanently no intermediate feeder found/present (when DIP switch 2 set to ON)

Measuring ponits
designation measure point result
solenoid valve X6/1 + +24V DC
X6/2 0V
supply voltage tacho X5/1 + +5V DC
X5/3 gnd
supply wire feed motor X10 - 0-42V DC (PWM)
X11 +
supply voltage CAN interface X20/1 gnd +24V DC
X20/2 +

DIP switch
DIP switch setting function
ON programming modus active
1
OFF normal operation mode
ON configuration intermediate feeder
2
OFF configuration PushPull / NanoFeeder

Configuration intermediate feeder

When using an intermediate feeder, a stronger control transformer is used in the power source to provide enough
power for the intermediate unit.
Detailed information is given in the mounting instruction “Digital PushPull with auxiliary drive“ (E00.0320.1).

page 39
Picture pc-board DMRPP04
LED2 DIP S1 LED1 LED3

X14 X15

X2 X17

LED3

X13

X3 LED1

X16
LED2 S1

X9

X18

X8

X12 X4 X5 X1 X20 X6
X11 X10

X1 X2

page 40
Overview connectors pc-board DMRPP04
connector designation
X1 torch trigger switch
X2 front panel
X3 volt/amp display
X4 wire inch button
X5 tacho wire feed motor
X6 solenoid valve
X8 control cable (Interpass hose package)
X9 wire inch and retract button
X10 wire feed motor “-” (minus)
X11 wire feed motor “+” (plus)
X12 welding potential (PowerMaster signal compensation)
X13 control cable PushPull
X14 flat ribbon connector motor wires
X15 flat ribbon connector PWM control
X16 wire-end sensor
X17 PushPull motor
X18 remote control interface
X20 CAN bus
See also „Connection diagram DMRPP04“ on page 54

Overview PushPull, Intermediate feeder, NanoFeeder

DMRPP
M M

DMRPP
M M

DMRPP DMRPP M
M M
DMRPP
M

DMRPP M
M

NanoFeeder
DMRPP
M
M
DMRPP
M

NanoFeeder
M

page 41
Pc-board DS-ERW
The pc-board DS-ERW is the extension pc-board for machines with additional wire feeder (AB or BB version).

Functions
- switching between wire feeder 1 / wire feeder 2
- driving solenoid valve
- driving water valves

LED state designation

1 (green) off wire feed unit 1 active
on wire feed unit 2 active

Measuring Points
designation measuring point result
solenoid valve 1 X5/1 gnd
X5/2 + +24V DC
solenoid valve 2 X6/1 gnd
X6/2 + +24V DC
water valve 1 X7/1 ~ 42V AC
X7/2 ~
water valve 2 X8/1 ~ 42V AC
X8/2 ~

Picture Pc-board DS-ERW

650.1248.x DS-ERW RP331
D00.0091.0-00

X3 X5
X2 X7

X10

X1
X4 X8
X6

LED1

Overview connectors pc-board DS-ERW

connector designation
X1 connector to pc-board DP-MAPRO
X2 connector to pc-board DP-MAPRO (interpass hose)
X3 connector to pc-board DMR1 (first wire feed unit)
X4 connector to pc-board DMR2 (second wire feed unit)
X5 connector gas valve 1
X6 connector gas valve 2
X7 connector water valve 1
X8 connector water valve 2
X10 connector for “old“ pc-board DS-C with additional front panel

page 42
Pc-board TC20 / TC21
The pc-board TC20 is the control board used inside the PowerMaster torches and in the hand remote control
RC20. Since 01.08.2011 the TC20 was replaced with the TC21. The main difference between the two versions is
the compatibility to the NanoFeeder in terms of data communication. PowerMaster torches which shall be used at
the NanoFeeder, must have the pc-board TC21 inside. All PowerMaster torches which have the TC21 inside are
labeled „NanoFeeder Ready“.
The pc-board TC20 is NOT compatible to the NanoFeeder.

Functions
-- display and change of welding parameter and Tiptronic jobs
-- torch button (start/stop)

Picture pc-board TC20 / TC21

PowerMaster torch RC20

data gnd data gnd

(white) (brown) torch button (white) (brown) torch button
+ - + -
2 1

X1
central connector 14 pin AMP
(top view)

Schematic

DMR cent. TC21

con.
X1-2 LP1
INT. PIC
X1-1 LP2

LP3

LP4

page 43
TIG Option
The TIG mode can be retrofit into all Saprom machines. The retrofit kit contains all necessary parts like a addi-
tional solenoid valve and a TIG control socket. The TIG function must be activated first, before the mode can be
activated via the mode button at the front panel (see also chapter „Service Codes“ on page 61).

There are two retrofit kits available:

type part no.
Saprom “driveable” 570.8035.0
Saprom mobile 570.8036.0

Schematic

DP-MAPRO DS-ERW
X3-1 X1-1

X3-2 X1-2 X5-2

+24V DC

X3-3 X1-3 X5-1

X3-6 X1-6

X3-7 X1-7

S3 mobil
5 pin Tuchel

X15-1 1

X15-2 2

DP-MAPRO

X10-1
+24V DC

X10-2

S3, S5, S8
5 pin Tuchel

X15-1 1

X15-2 2

page 44
Control Transformer
The control transformer 655.8021.0 is used in Saprom S3, S5 and S8 / Px500.
The control transformer 655.8023.0 is used in Saprom S3 mobile / P3000 mobile.

3 Pos.
4
42V/4A
400V 4

5 0_42V 3
2
8 19V/3A
0_19V
655.8021.0 2 9
1

10 18V/1A
230V/2,5A
11 0_18V
12 18V/0,4A
13 0_18V
primary
secondary2
15
14 18V/0,4A
1 2 14
3 secondary primary2
12
13
15 0_18V
4 5 10 11
8 9
0_400V 1

Pos.
Pos.
2 7
655.8023.0 400V 3 0_42V
secondary
8
4 42V/3,5A
primary
5 0_20V
secondary
20V/3A
primary secondary
6
0_400V 1 6

1 2 3 4 7 8 5

D00.0110.4-01

page 45
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

DP-MAPRO
+3.3V

DCDRV1

X3/2 X1/12 X1/12

DSP
(Process)
ϑ
X3/1 X1/4 X1/4

+3.3V

DCDRV2

X3/2 X1/12 X4/12

ϑ
X3/1 X1/4 X4/4

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.

Maximum Temperatures
Machine type max. Temperature
S3, S3 mobile 77°C
S5 80°C
S8 75°C

If the connection of the sensors to the MAPRO is interrupted (loose contact at any of the connectors), the machine
will stop after some time and displays E13, because a rise of the temperature can not be detected.
There is a special overload program active in the DSP, which calculates and monitors the inside temperature of
the semiconductors (MOSFET power transistors). Before the inside temperature reaches a critical limit, the ma-
chine will stop and displays E18 (Overload protection).

page 46
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).

Supply voltage Limit Result

+24V DC <17V Shutdown with E14
+24V DC >36V Shutdown with E02

The actual values of the 24V and 15V can be checked via the front panel in menu Extras, Diagnosis, Op. Volt-
ages.

page 47
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

DSP

DCDRV
X2 / 3 X1 / 16
+15V

X2 / 2 X1 / 15
4
MASTER
3
2 X2 / 1 X1 / 14
1
current -15V
sensor

The output of the current sensor is a current with a ratio of 1:2000, meaning at a welding current of 300A the
sensor output is 150mA. The output current is measured via an internal shunt resistor by the Master and Process
(independant measurings).

If the Master measures a current >120% of the maximum value, the machine will stop and displays E03 (second-
ary overcurrent). For example the maximum welding current of a Saprom S5 is 400A, if the Master measures a
welding current > 480A, it stops with E03.

If the Master measures a voltage >3.5V at the shunt resistor (that would mean a welding current >988A), the ma-
chine will stop and displays E09 (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).

page 48
PE protection / gas pressure switch
Since the software release 2.20 an optional PE protection and a gas pressure switch was implemented. Both
switches are opening contacts. Since 9th May 2011 the PE protection was implemented into the serie as a stand-
ard feature. The gas pressure switch is optional.
Since the following serial numbers the machines are equipped with the PE protection feature:
machine type since serial no.
S3 Puls 0855-2118-0001
Saprom S3 mobil 0406-2118-0001
S5 Puls 0856-2118-0001
S8 Puls 4019-2118-0001
S 3 mobil SpeedPulse 0836-2118-0001
S 3 SpeedPulse 0833-2118-0001
S 5 SpeedPulse 0834-2118-0001
S 8 SpeedPulse 0835-2118-0001
P 3000 mobil 0840-2118-0001
P 3500 0837-2118-0001
P 4500 0838-2118-0001
P 5500 0839-2118-0001

Schematic

MAPRO L
PE N
X26-6

X26-3
Master

X26-5 P
gas
X26-2 (Option)

Both monitoring functions (PE wire and gas) are self-activating functions, that means as soon as the Master de-
tects a closed contact at the input (logic low), the respective monitoring is activated permanently !
With a installed monitoring hardware, the contact is closed in normal condition. As soon as a current > 15A is flow-
ing through the protective earth wire, the contact opens and the machine will stop and displays the error message
E04-01.

As soon as the gas pressure switch opens, the machine will stop and displays the error message E04-02. The
message will only be displayed, when the switch opens during the solenoid valve is activated (during welding, gas
post flow time or gas test).

The monitoring functions can be deactivated with the special Service codes 663 and 665 (see „Service Codes“ on
page 61).

page 49
Cooling Unit
At watercooled machines, the flowrate of the coolant 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 frequency.
If the flowrate is below 0.3 liter per minute, the machines will stop and dislays E05 (cooling system error).

Schematic internal cooling unit

The actual flowrate can be monitored via the front panel in menu Extras, Diagnosis, Flowrate Cool. System.
At gas cooled machines instead of the flowmeter, there is a small cable bridge between pin 1 and 4 at connector
X9. This cable bridge is deactivating the monitoring of the flowmeter.

Schematic external cooling unit

WUK power source

DP-MAPRO

+15V
tank

1 X1 / 4 X8 / 4 X9 / 2

2 X1 / 5 X8 / 5 X9 / 3
flow meter
X1 / 3 X8 / 3 MASTER
pump 3 X9 / 1
+15V
hose connector X1 / 6 X8 / 6 X9 / 4
blue
X5 / 2 X1 / 1 X8 / 1
hose connector 230V
red X5 / 4 X1 / 2 X8 / 2

X13 / 1

X13 / 2

cooler
X6 / 1

X6 / 3

42V AC

At “mobile“ machines the bridge between pin 1 and 4 is used to detect if an external cooling unit is attached or
not. Therefore the DIP switch 4 on pc-board DP-MAPRO must be set: ON = mobile OFF = “driveable“.

page 50
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 51
Welding voltage monitoring
The output voltage is conducted via a low pass filter (pc-board DP-UFI-BO) to the MAPRO pcb. The voltage is
measured by the Master as well as the Process.

Schematic

If the Master is measuring a voltage >100V, the machine will stop and displays E06 (secondary overvoltage). If the
Process should detect a voltage higher that 100V, the machine will stop and displays E20 (Overvoltage second-
ary).
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 stop and displays E09 (V/A measuring
error).

If the Process is measuring an output voltage >60V when the machine is not welding (standby), the machine dis-
plays the error message E21 (Output voltage/current).

page 52
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.

Connection diagram DMR

The current consumption and the tacho signal of the motor are monitored by the microcontroller. If the current
consumption of the motor is too high (e.g. if wire feed unit is blocked mechanically) or if the tacho signal is miss-
ing, the machine will stop and displays E08 (wire feed / tacho).
The DMR and the MAPRO are communicating via the CAN bus with the Master. If the communication is interfered
or jammed, the machine will stop and displays also E08.

Is one of the CAN bus wires is disconnected (loose connection) between MAPRO and DMR, the display (con-
nected to the DMR) is only showing a “?”.

page 53
Connection diagram DMRPP04
wire inch
weld
potential
M

DMRPP-C 1 2 3 X12 1 2 X6 1 2 3 4 5 6 X9 1 2 3 4 X16 1 2 X4 Amphenol 17+PE

X13
11 2
wire inch
10 6
wire +24V
sensor gas air blast retract wire inch fan wire
X1 gas test
13 4
valve end
gas test
gnd 1
torch sensor 12 12
data 2 interface
collision 16 5
protection collision protection
X18 14 14
1 8 3
2
analog in
7 13
3
+12V 3 10 +12V
+10V
4
analog in 15 8
5
+24V 4 7 +24V
6
ext.
7
+5V 2 16 +5V
8
2T
analog
9 analog tacho 9 9
G
10
6 15 digital2
digital tacho2 G PushPull
X20
1 5 11 digital1
gnd digital tacho1 G M
2 1
+24V
3 1
CAN high CAN
4
CAN low bus X17
1 17
+12V +10V 2 PE
X8 +24V
1 +5V +3.3V
gnd 2
X5
3 1 XT4
CAN high +5V
4 2 XT3
CAN low tach_in
5 3 XT1
+70V mot. +70V gnd G
6 4
gnd mot. tach_on
wire feed PushPull
feeder active
7 motor motor gnd feed motor
8
temp. current current X10
+24V M
+5V
X11
2 15 3 4-11 12 13 16 14 1 24 25 26 1 2 3 16 17 20 21 6 7 8 11 12 13
X15 X14

X2 2 15 3 4-11 12 13 16 14 1 24 25 26 1 2 3 16 17 20 21 6 7 8 11 12 13 X1
8
I I
+24V
mon. mon.
+5V

5 7 1 3
ϑ FET
Control 6 8 2 4

DMRPP-P

page 54
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 dis-
plays E11 (remote control conn.). Also if the start contact is closed during switching on the machine, the machine
shows E11 in the display.

Schematic

Signal overview
Signal pin designation
weld start 1 and 2 as soon as pin 1 and 2 are connected, the machine starts (same function as pressing the torch trig-
ger 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“ 6 as soon as pin 6 is connected to pin 7, the analog input on pin 4 is valid
ground 7 gnd for the identification signals on pins 6 and 8
identification “2 stroke“ 8 as soon as pin 8 is connected to pin 7, the machine operates in 2-stroke mode at “weld start“
arc established 9 and 10 potential free relay contact (closing contact)
as soon as welding current is flowing, this relay contact is connecting pin 9 to 10
maximum contact load: 1A

page 55
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. At the Saprom S5 and S8, the weld energy
is generated with two power units at the same time. The Saprom S3 and S3 mobile only have one power unit.

Schematic

If power unit 1 draws too 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 missing or the DCDRV pcb of power
unit 2 is malfunctioning)
In this case power unit 1 has to generate all the weld energy by itself. Which is possible to a certain amount of
power (200A to 250A) but beyond that, the unit will stop with E16
-- malfunction at DCDRV pcb of power unit 1 (e.g. optocoupler output malfunction)
-- bad flat ribbon cables between MAPRO pcb and power units

There is a simple way to find out if the power unit itself is bad or not (only possible at Saprom S5 or S8):
exchange the flat ribbon cables at the MAPRO pcb against each other (connectors X1 and X4) so that power
unit 1 becomes power unit 2 and vice versa. If the machine now shuts down with E24 (Overcurrent protection 2)
instead of E16, the power unit itself is faulty.
If the E16 should still remain, it is very likely that the MAPRO pcb is faulty.

page 56
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. After a charge up time for about
two seconds, the resistors on the PWRUP pcb are shorted with the 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
microcontroller (Master).

Schematic

page 57
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 Saprom S5 or S8), only the error message with
the highest number is displayed (E30).

Schematic

Voltage limits
bus voltage LED4 LED6 optocoupler output optocoupler output error message
min. bus volt. ok (pin 10) max. bus volt. ok (pin 9)
0 - 250V on off high low E22, E30
255V - 700V on on low low -
705V - off on low high E23

page 58
Identification power units
During the initialisation of the machine (switching on), the MAPRO pcb is detecting what power units are connect-
ed. The identification of the power units is made by a DIP switch at the DCDRV pcbs. Should the MAPRO detect
that configuration is not valid, it will stop and displays E25 (Power module detection).

Schematic

DIP switch settings

DIP 1 DIP 2 setting type
OFF OFF 240 A S5 / P4500
OFF ON 350 A S3 / P3x00 (mobile)
ON OFF 300 A S8 / P5500
ON ON reserved

page 59
Testing MOSFETs
D

D G
MOSFET - Test
GS S G
GS S

0Ω
use a 9V battery to “switch on“ the
drain - source path

D G
9V Batterie
9V battery
GS S

drain - source path is low resistant

∞Ω

short circuit between gate and source

to “switch off“ the drain - source path
D G

GS S

drain - source path is high resistant

Inside diagram diodes

page 60
Service Codes
Via menu Extras, Lock function special Service codes can be entered to enanble or disable different functions.

code function displayed message

644 reset the three-digit code of the lock function to “000” Code = 0
660 activate TIG mode selection TIG mode On
661 deactivate TIG mode selection TIG mode Off
663 deactivate PE protection PEC control Off
664 activate PowerMaster buttons Powermaster On
665 deactivate gas pressure switch monitoring Gas monitor. Off
666 deactivate PowerMaster buttons Powermaster Off

Entering the Codes

-- enter menu Extras, Lockfunction
-- press button material (minus) or button gas (plus)
-- acknowledge the question „Change Parameter?“ with button “arrow up”
-- press button minus or plus
-- enter the code number with the encoder of the front panel
-- acknowledge with button “arrow down”

page 61
Troubleshooting guide
code description reason removal
E 01 thermal overload thermal sensor of power unit measures a too high let machine cool down in standby (*1)
temperature see page 46 for details
E 02 mains overvoltage mains voltage too high check mains voltage and control transformer (*2)
internal 24V supply > 36V see page 47 for details
E 03 secondary overcurrent welding current is too high (>120%) check current sensor and its wiring
see page 48 for details
E 04 Stop/ Peripherals error PE protection has detected a current >15A flow- check X26 on DP-MAPRO board
sub code -01 ing via the protective earth wire of the mains switch the machine off and on again to reset the
cable error message
see page 49 for details
Stop/ Peripherals error the gas pressure switch (optional feature) has check / replace the gas bottle
sub code -02 opened: not enough gas pressure left check X26 on DP-MAPRO board
switch the machine off and on again to reset the
error message
see page 49 for details
E 05 cooling system error -- flowrate of the cooling liquid is too low check connectors of flow-meter, level of cooling
(< 0,3 l/min) liquid and flowrate (*3)
-- pump is not working check fuse SI7 (2,5A) on pc-board DP-MAPRO
see page 50 for details
E 06 secondary overvoltage Master detects output voltage is too high (>100V) check wiring of power unit
see page 52 for details
E 07 EEProm checksum error no welding program stored or error during read- switch the machine off and on again, if necessary
ing from memory transfer the welding programs to machine again
E 08 wire feed / tacho -- power consumption of wire feed motor too high -- blow out torch package with compressed air
-- no tacho signal -- check wire feed unit
-- no CAN-Bus connection between pc-board -- check motor current (*4)
MAPRO and pc-board DMR -- check wiring of wire feed motor and pc-board
DMR
see page 53 for details
M01 Motor overvoltage supply voltage for motor driver is too high -- check control transformer
(only at DMRPP) (70V DC > 130V DC) -- check motor supply
M02 Motor op. voltages supply voltage for motor driver is too low -- check control transformer
(only at DMRPP) (70V DC < 30V DC) -- check motor supply
M03 Motor 1 overcurrent wire feed motor draws too much current -- check wire feed unit and motor
(only at DMRPP) -- check motor current (*4)
M04 Motor 2 overcurrent PushPull-motor draws too much current -- check PushPull-torch and -motor
(only at DMRPP) -- check motor current (*4)
M05 Tachometer motor 1 -- tacho signal of wire feed motor is missing or -- check wiring of the tacho
(only at DMRPP) bad -- check wiring of the motor, exchange motor if
-- wire feed motor is not running necessary
M06 Tachometer motor 2 -- tacho signal of PushPull motor is missing or bad -- check PushPull torch and wiring of the PushPull
(only at DMRPP) -- PushPull motor is not running motor
-- wrong PushPull torch type selected -- set correct type of PushPull torch
M07 EEProm access no access to EEProm memory (hardware) switch the machine off and on again, exchange
(only at DMRPP) pc-board DMRPP if necessary
M08 EEProm checksum data in EEProm memory wrong/corrupted (soft- switch the machine off and on again
(only at DMRPP) ware) reprogram the DMRPP
exchange pc-board DMRPP if necessary
M09 Remote-control start contact (remote control interface DMRPP) check remote control and the wiring of the remote
conn. was closed during switching on the machine control socket/interface
(only at DMRPP)
M10 Torch connection -- start button (torch trigger switch) was pressed check torch and torch control wires
(only at DMRPP) during switching on the machine
-- too high voltage on the torch button wires (short
circuit between torch button wires to welding
potential or motor wires.
M12 Calibration error calibration of the PushPull torch was unsuccess- -- check torch and torch control wires
(only at DMRPP) ful -- check pressure lever of wire feed unit and of
PushPull torch
-- insert the wire

page 62
code description reason removal
E08 M13 Machine ID un- the internal power source id couldn’t be recog- switch the machine off and on again
known nized (unknown power source) reprogram (flash) the DMRPP or exchange it if
(only at DMRPP) necessary
M14 Thermal overload the temperature of the lower pc-board DMRPP-P let the pc-board cool down when the machine is
(only at DMRPP) is too high switched off
M15 Wire end detection wire-end sensor has detected no wire (wire spool !!! this error message is active/implemented !!!
(only at DMRPP) empty)
at all sub messages Mxx of the DMRPP: see also hardware details on page 54
E 09 error v/a measuring too high welding current or voltage measuring check wiring of current sensor VAC and pc-board
difference between Master and Process DP-UFI-BO
see page 48 and page 52 for details
E 11 remote-control conn. start contact was closed during switching on the check remote control and wiring of remote control
machine socket
short circuit between remote control cables see page 55 for details
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 no temperature rising was detected after some -- check resistor value and wiring of the sensor
welding time: Temp. sensor is faulty or loose -- check temperature (*1)
contact see page 46 for details
E 14 Op. voltages error internal MAPRO supply voltage is too low check mains voltage and control transformer (*2)
(24V supply < 17V) see page 47 for details
E15 error configuration wrong or faulty pc-board, wrong software -- check connecor X26 on pc-board MAPRO
sub code #1 - #5 -- switch the machine off and on again
-- contact Lorch Service if necessary
sub code #10 setting of DIP switch 4 does not match to serial -- check DIP switch 4 on MAPRO
number of the machine (only at P3000)
sub code #14 operating system version of the Process does not reprogram the MAPRO with the correct operating
match to the version of the Master system versions
E 16 primary overcurrent power consumption of power unti 1 is too high check MOSFETs and pc-board DCDRV
protection1 see page 56 for details
E 18 overload protection safety shutdown to protect electrical components -- let machine cool down in standby
-- check temp. sensor
see page 46 for details
E 20 Overvoltage sec. Process reports a too high output voltage check wiring of power unit, especially wiring from
(>100V) or no voltage output sockets to pc-baord DP-MAPRO
see page 52 for details
E 21 Output voltage/current external current or voltage check wiring of current sensor VAC and pc-board
DP-UFI-BO
see page 48 and page 52 for details
E 22 Mains undervoltage 1 power unit 1 detected a too low bus voltage check mains voltage, mains rectifier, pc-board
PWRUP and DCDRV
see page 58 for details
E 23 Mains overvoltage power units detected a too high bus voltage check mains voltage, mains rectifier and pc-board
DCDRV
see page 58 for details
E 24 Overcurrent protection2 power consumption of power unti 2 is too high check MOSFETs and pc-board DCDRV
see page 56 for details
E 25 Power module detection wrong DIP switch setting on pc-board DCDRV -- check machine configuration (*5)
-- check DIP switch on pc-board DCDRV
see page 59 for details
E27 no program (DSP) invalid material-wire-gas combination selected select valid material-wire-gas combination or
welding programs faulty or not available transfer welding programs to machine again
E28 Error EEPROM access to EEPROM memory not possible (hard- switch the machine off and on again, exchange
ware) the MAPRO if necessary
E29 EEProm checksum error data in EEPROM memory faulty/corrupt switch the machine off and on again, exchange
the MAPRO if necessary
E 30 Mains undervoltage 2 power unit 2 detected a too low bus voltage check mains voltage, mains rectifier, pc-board
PWRUP and DCDRV
see page 58 for details
E 31 Communication error Master is not responding to Process switch the machine off and on again
optionally exchange pc-board DP-MAPRO

page 63
 code description reason removal
“?” the display shows only the display doesn‘t get any data from MAPRO no CAN bus connection between pc-board DMR
a “?“ and pc-board DP-MAPRO
check flat ribbon cable and/or interpass hose
package
see page 53 for details
“nop” no program no welding parameters available for selected select other material-wire-gas combination
material-wire-gas combination (no reasonable
combination)
CFG “CFG ERR” is shown in wrong front panel connected (only at P Basic) connect the correct front panel (pc-board MAT-BF)
ERR volt/amps display
blinking volt/amps display Overload, the power unit was electrically over- indication goes away together with the hold LED
loaded, the machine is limiting the max. power
output

(*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
(*4) display the motor current in menu Extras > Diagnosis > W.Feeder motor current
(*5) display the configuration in menu Extras > Machine data > Configuration

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