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LORCH V24 - User Manual

LORCH V24
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Service Manual
V Series
909.0340.1-05
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LORCH V24 Specifications

General IconGeneral
BrandLORCH
ModelV24
CategoryWelding System
LanguageEnglish

Summary

Machine Overview

Machine Elements Identification

Identifies key external components of the welding machine.

Safety Precautions and Testing

General Safety Requirements

Outlines mandatory safety practices for machine operation and maintenance.

Testing Standards

Details testing procedures according to IEC 60974-4 for Lorch machines.

Common Logic Functions

Pump Test Procedure

Describes the steps for performing a pump functionality test.

Resetting Machine Settings

Explains how to reset machine parameters to factory defaults.

Master Reset Function

Details the procedure and impact of a master reset operation.

Inverter Principle

Core Inverter Components

Explains the basic structure: rectifier, driver, transformer, secondary rectifier.

DK-MAPRO Control Board

Board Functions Overview

Lists the primary responsibilities of the DK-MAPRO board.

LED Status Indicators

Describes normal and malfunction states indicated by board LEDs.

DIP Switch Configuration

Explains settings for programming and machine type selection.

Fuse Identification

Lists the fuses present on the DK-MAPRO board and their ratings.

DK-MAPRO Board Details

Measurement Point Descriptions

Details specific test points and expected results on the board.

Connector Designations

Lists all connectors on the DK-MAPRO board and their purpose.

DK-MAPRO Board Diagram

Component Layout

Visual representation of the DK-MAPRO board's physical layout.

DK-DCI40; DK-ACI40 Front Panel

Board Functions

Describes the role of the front panel board in machine operation.

Front Panel Diagram

Visual layout of buttons and LEDs on the DK-AC140 front panel.

DK-DCI45; DK-ACI45 Front Panel

Board Functions

Details the front panel board's functions for V mobile machines.

Front Panel Component Layout

Diagram showing components on the DK-DCI45/DK-ACI45 board.

Front Panel Function Test

Test Procedure Initiation

Steps to start and navigate the front panel's internal test function.

DK-DCDRV Primary Driver Board

Board Functions Overview

Outlines the DK-DCDRV board's role in managing the primary drive level.

Power Unit Encoding

Explains how DIP switches set the power unit type.

LED Status Indicators

Details normal and malfunction states shown by board LEDs.

Measurement Points

Identifies key points for voltage and temperature measurement.

DK-DCDRV;DK-S3 DRV Board Diagram

Component Identification

Visual guide to MOSFETs, diodes, and connectors on the board.

DK-DCDRV Connector and Schematic

Connector Assignments

Lists connectors and their designations for the DCDRV board.

Primary Driver Circuit

Schematic diagram of the half-bridge primary driver design.

DK-DCDRV MOSFET and Board Revisions

MOSFET Component Changes

Details the transition from older to newer MOSFET types and compatible boards.

DK-ACDRV Secondary Inverter Board

Board Functions Overview

Explains the DK-ACDRV board's role in managing the secondary inverter.

Power Unit Encoding

Describes how J1 setting selects the machine type (IGBT count).

LED Status Indicators

Details the meaning of LEDs indicating IGBT drive status.

Measurement Points

Identifies points for temperature sensor measurement.

DK-ACDRV Connectors and Schematic

Connector Assignments

Lists connectors for the DK-ACDRV board and their interface purposes.

AC Inverter Circuit Diagram

Schematic illustrating the AC inverter using IGBTs.

DK-PWRUP Power-Up Circuit

Board Functions

Describes the circuit's role in reducing start-up current and safeguarding the transformer.

Measurement Points

Identifies key points for measuring voltages and relay status.

Board Diagram

Visual layout of the DK-PWRUP board's components.

DP-S3 NEFI Filter and Power-Up Circuit

Board Functions

Details the mains filter and power-up functions for V24 mobile machines.

Measurement Points

Identifies points for measuring input/output voltages and relay status.

Board Diagram

Visual layout of the DP-S3NEFI board's components.

NEFI3 x32 Mains Filter

Board Functions

Describes the NEFI3x32 board as the mains filter for V30 mobile machines.

Board Diagram and Connectors

Visual layout and connector designations for the NEFI3x32 board.

DK-GLCL Secondary Rectifier Board

Board Functions

Explains the DK-GLCL board's function in wiring secondary rectifier diodes.

Board Diagram

Visual layout of components on the DK-GLCL board.

DK-GLCL3 Secondary Rectifier Board

Board Compatibility

Details compatibility between old and new diode types and boards.

Board Diagram

Visual layout of components on the DK-GLCL3 board.

Circuit Schematic

Diagram illustrating the circuit design of the DK-GLCL3 board.

DK-KSDC;KSDCD;KSDCN HF Ignition Support

Board Functions

Describes the board's role as support for HF ignition.

LED Status Indicators

Details normal and malfunction states indicated by the board's LED.

Measurement Points

Identifies points for measuring secondary output voltage.

Board Diagram

Visual layout of components on the DK-KSDCN board.

DK-KSDCN Schematic and Changes

Circuit Schematic

Diagram illustrating the DK-KSDCN circuit for HF ignition support.

Board Version Updates

Details changes made to the DK-KSDCN board version.

DK-HFDC;DK-HFDC HV Ignition Device

Board Functions

Explains the board's function as the welding machine's ignition device.

Board Diagram

Visual layout of components on the DK-HFDC board.

DK-HFDC Ignition Sequence and Schematic

Ignition Process Description

Details the sequence of operations for the ignition device.

Circuit Schematic

Diagram illustrating the DK-HFDC circuit and its interaction.

DK-UFI Welding Socket Wiring

Board Functions

Describes the DK-UFI board's role in wiring welding sockets.

Measurement Points

Identifies points for measuring output voltage.

Board Diagram

Visual layout of components on the DK-UFI board.

DK-EMV Board Replacement

DK-EMV Board Diagram

Visual layout of components on the DK-EMV board.

LSW Current Sensor Board

Board Functions

Describes the LSW board as the machine's current sensor.

Measurement Points

Identifies points for measuring supply voltage and output.

Board Diagram

Visual layout of components on the LSW board.

VAC Current Sensor

Measurement Points

Identifies points for measuring supply voltage and sensor output.

Sensor Diagram

Visual representation of the VAC current sensor.

Control Transformer Overview

Transformer Models and Connections

Details the control transformers used in V series machines and their wiring.

Temperature Monitoring System

Monitoring Schematic

Diagram showing how temperature sensors connect to the DSP.

Maximum Temperature Limits

Table listing maximum allowable temperatures for different machine types.

Supply Voltage Generation and Monitoring

Supply Voltage Schematic

Diagram showing internal supply voltage generation from the control transformer.

Voltage Limit Specifications

Defines voltage limits and corresponding error codes for machine operation.

Welding Current Monitoring

Monitoring Schematic

Diagram showing how welding current is measured by sensors and processed.

Welding Voltage Monitoring

Monitoring Schematic

Diagram illustrating how welding voltage is measured and processed.

Cooling Unit Operation

Internal Cooling Unit Schematic

Diagram of the flow meter and cooler for internal cooling systems.

External Cooling Unit Schematic

Diagram of the flow meter and cooler for external WUK cooling systems.

Flow Meter Maintenance

Flow Meter Disassembly

Step-by-step guide on how to open and disassemble the flow meter.

Torch Control System

Torch Control Schematic

Diagram showing the connection and logic for torch buttons.

Remote Control Interface

Interface Schematic

Diagram illustrating the connections for a remote control.

Signal Overview Table

Details the signals, pins, and their functions for the remote interface.

Primary Current Monitoring

Monitoring Schematic

Diagram showing how primary current is monitored by the DCDRV board.

Power-Up Cycle Explanation

Power-Up Schematic

Diagram illustrating the power-up sequence and component interactions.

Bus Voltage Monitoring

Bus Voltage Schematic

Diagram showing how bus voltage is monitored by the DSP.

Voltage Limit Specifications

Defines bus voltage limits and corresponding error messages.

Power Unit Configuration Identification

Configuration Schematic

Diagram showing how power unit configuration is read by DK-MAPRO.

MOSFET Testing Procedure

MOSFET Test Method

Describes how to test MOSFETs using a multimeter and battery.

PE Protection (Optional Feature)

PE Protection Schematic

Diagram illustrating the optional PE protection circuit.

Troubleshooting Error Codes

Error Code E00-E14

Lists error codes E00-E14, their causes, and remedies.

Error Code E16-E31

Lists error codes E16-E31, their causes, and remedies.

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