Service Manual

MicorMIG

909.2130.1-10
Contents
Machine............................................................................ 3
Safety precautions............................................................ 4
The MicorBoost Inverter Principle.................................... 5
Counting pins for Minifit and Microfit connectors.............. 5
Common Functions.......................................................... 6
Pc-Board NEFI02........................................................... 12
Pc-Board NEFI04........................................................... 13
Pc-Board NEFI05........................................................... 14
Pc-Board NEFI07........................................................... 15
Pc-Board DRV03 / DRV13............................................. 16
Pc-Board SF02............................................................... 18
Pc-Board DRV05 / DRV15............................................. 19
Pc-Board DRV07 / DRV17............................................. 22
Pc-Board DC01.............................................................. 28
Pc-Board DC03.............................................................. 29
Pc-Board DC04.............................................................. 30
Pc-Board MAPRO04...................................................... 31
Pc-Board DMR-RT3....................................................... 32
Pc-Board DMRPP05...................................................... 33
Pc-Board SF18............................................................... 36
Pc-board SF23............................................................... 38
Pc-board SF24............................................................... 40
Pc-board SF27............................................................... 41
Pc-board SF37............................................................... 42
Temperature monitoring................................................. 46
Monitoring bus voltage................................................... 48
PE (Protective Earth) -Protection................................... 49
Cooling unit.................................................................... 49
Monitoring Output Voltage.............................................. 50
Open Circuit Voltage Generator & VRD......................... 51
Monitoring welding current............................................. 51
Monitoring and driving the wire feed motor.................... 52
Supply Voltages.............................................................. 54
Machine Configuration................................................... 55
Monitoring Primary Input Current................................... 56
Fan Control..................................................................... 58
Mains Monitoring............................................................ 58
LorchNet-Remote........................................................... 59
LorchNet Connect.......................................................... 60
Reading out machine data............................................. 62
Information Messages.................................................... 64
Error codes..................................................................... 65

Document no. 909.2130.1-10

Issue date: 03.11.2020

Machine elements
1 Hoisting point 10 Torch socket/digital push pull (optional)
2 Chain 11 Main switch
3 Diagnostics connection socket (internal bus) 12 Minus socket for ground cable (MIGMAG, MMA), electrode holder
(MMA), torch (TIG)
4 Inert gas hose 13 Plus socket for ground cable (MMA, TIG), electrode holder (MMA),
5 Mains cable 14 Coolant supply line and return line (optional)
6 Lock, side part, wire feed 15 Central bush
7 Hand grip 16 Coolant filling nozzle (optional)
8 Control panel 17 Interpass hose package
9 Protective cover, operating console 18 Rotary bearing

page 2
Machine
6 7 8 9 1

5
4 10
3 0
I

11
12
13
2
1

16 15 14

8
9

15
10
6

18 14

17

5 4

3 11
I

12
13

16
1
2

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 immediately any components that are not in perfect condition.

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

page 4
The MicorBoost 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 much
higher frequency, to drive the transformer. At conventional inverters this is a fixed frequency (e.g. 80kHz) at
MICOR machines the frequency is variabel (up to 200kHz), because the frequency is also used for controling the
welding process. Driving the transformer, the primary side is a serial resonant circuit (primary transformer coil in
series with a capacitor) and the secondary side is a parallel resonant circuit, so that the control has an additional
influence on the output voltage by shifting the frequency. With this principle an almost ideal output characteristic
can be realized.

Counting pins for Minifit and Microfit connectors

The way of reading the pin numbers on the Minifit- and Microfit-connectors is done always in the same way: when
looking from the top onto the connector, pin no.1 is alway on the far left, opposite to the clip.

1 1 2 1 2 3

2 3 4 4 5 6

Clip

page 5
Common Functions
Gas test
- press key A14
- the gas test LED is lit
- the solenoid valve is switched on for 30 seconds
- press key A14 again to switch off the valve manually

Fan test
When switching on the machine at the on/off switch, the fans are activated for a short time during initialisation.

Water pump test

Basic/BasicPlus:
- press key A2 and keep it pressed for about 5 seconds (menu machine configuration)
- select menu item “CoL” with the left encoder
- with the setting “on” the water pump runs continously
- with the setting “Aut” the water cooling runs in automatic mode (factory setting)
ControlPro:
- select menu item M4 Settings
- select Menu item M4-3 Mode cooling unit
- selection “On” the water pump is running continously
- selection “Auto” the water pump runs in automatic mode (factory setting)
- press knob A49 to confirm the new selection

Front panel test

- press keys A2 and A14 at the same time
- all LEDs are on

Master reset
Basic/BasicPlus:
- switch off the machine
- press key A2 and keep it pressed
- switch on the machine with the key pressed
- release key A2
- select parameter “rSt” with the left encoder
- press key “Save”
ControlPro:
- switch off the machine
- press and hold menu key A50
- switch on the machine with the key pressed
- release menu key A50
- selec parameter “Masterreset” with knob A49
- press knob A49 to confirm

Since software version 2.02, the start-menu can also be accessed without switching off the machine:
- press and hold the keys A2 and A32
- after about 3 seconds the start-menu is displayed
- select “rSt” (BasicPlus) or “Masterreset” (ControlPro)
- press key A14 “Save” (BasicPlus) or press knob A49 (ControlPro) to confirm

page 6
Front panel MicorMIG BasicPlus

A2 A14

A32

Front panel MicorMIG ControlPro

A2 A14

A49
A32

A50

page 7
Front panel MicorMIG Feeder Panel

A2 A14

Schematic
BF MAPRO DMR-RT3
X2 X3
2 2 2
CAN 3 3 CAN 3 CAN
µP 6 6 µP 6 µP
UART 7 7 7
5 5 5
+ +16V
9 9 9
+24V
1 1 1
10 10 10

13 13

At compact machines the front panel is directly connected to the MAPRO. At a wire feeder MF08 the front panel is
connected to the DMR-RT3. All front panels are designed for a supply voltage range of 15V to 24V DC.
The data communication is done via CAN-bus only (pins 2 and 3 of the flat ribbon cable). The serial interface
wires (UART on pins 6 and 7) are only used for programming the microprocessor (front panel software update).

page 8
Synergic selection panel
Since week 24 of 2018 new welding programs have been added to the new software version 2.12 including new
materials and 0.9mm wire. Thus the synergic selection panel were changed also.
wire feeder power source

Schematic synergic selection panel

4
keys
LEDs
5 1

Since May 2017 there are locking clips available to keep the flat ribbon cables fixed at the front panels and pre-
vent a disconnection from the flat ribbon socket at the PCBs.

773.0020.2 773.0021.2

page 9
Picture pc-board BF07 (Basic Plus wire feeder)

X301

X701
X201

X401

Since week 10 in 2015 the front panels of the wire feeder are equipped with longer flat ribbon cables. With this it
is possible to use the wire feeder horizontally in a lying way and turn the front panel by 90°.

Picture pc-board SF17

The pc-board SF17 is used for illuminating the interior of the MF08 wire feeder and is connected to the front panel
pc-board (connector X701).

page 10
Picture pc-board BF11 (ControlPro power source)

X301

X201

X401

Overview changes front panels

Some front panels had been exchanged by versions with bigger memory.
Since week 51 from 2017 the version “Pulse” was added.
front panel designation part no. designation part no. version part no. useage
(old) (new) pulse
FP01 BF05 653.0062.5 BF25 653.0083.5
Basic BF06 653.0048.5 BF26 653.0079.5 wire feeder
Basic Plus BF07 653.0049.5 BF27 653.0080.5 BF27 653.0107.5
Basic BF09 653.0051.5 BF29 653.0081.5
power source
Basic Plus BF10 653.0052.5 BF30 653.0082.5 BF30 653.0109.5

page 11
Pc-Board NEFI02
The pc-board NEFI02 is the mains filter board of the MicorMIG 300 and 350.
Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620).

Functions
- mains filter
- mains detection
- safeguarding control transformer (2 x 4.0A, 500V, slow)

Picture pc-board NEFI02

PE

LP3
LP2 LP6
LP7
LP1
LP5

X1

X2

LP15 (PE) LP14

Schematic

1 5 4 11
L1 +Uz
2 6
L2
3 7 8 12
L3 -Uz

X2-3 LP15 PE
X2-1 14
U mains
SI2
X1-3
SI1
X1-1

page 12
Pc-Board NEFI04
The pc-board NEFI04 is the mains filter board of the MicorMIG 400.
Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620).

Functions
- mains filter
- mains detection
- safeguarding control transformer (2 x 4.0A, 500V, slow)

Picture pc-board NEFI04

PE

LP3
LP2 LP6
LP7
LP1
LP5

X1

X2

LP15 (PE) LP14

Schematic

1 5 4 11
L1 +Uz
2 6
L2
3 7 8 12
L3 -Uz

X2-3 LP15 PE
X2-1 14
U mains
SI2
X1-3
SI1
X1-1

page 13
Pc-Board NEFI05
The pc-board NEFI05 is the mains filter board of the MicorMIG 500.
Since week 49 2015 the varistors at the mains input had been replaced by types with higher voltage (S20K620).

Functions
- mains filter
- mains detection
- safeguarding control transformer (2 x 4.0A, 500V, slow)
- power-up function

Picture pc-board NEFI05

LP1 LP3 LP2

X2 X1

PE

Schematic
9
25 24

26 RE1 RE2 10
RE1
27 28
RE2

1 5 4 11
L1 +Uz
2 6 R8 R7
L2
3 7 8 12
L3 -Uz

X2-3 LP15 PE
X2-1 14
U mains
SI2
X1-3
SI1
X1-1

page 14
Pc-Board NEFI07
The pc-board NEFI07 is the mains filter board of the MIcorMIG 400 MV and 500 MV.

Functions
- mains filter
- mains detection
- safeguarding control transformer (2 x 4.0A, 500V, slow)
- power-up function

Picture pc-board NEFI07

X4

X6 B

X5 A
X2

X3
X1

Schematic
NEFI07 DRV
LP3 + +
6 RE1+2 X3
Q2 PM1
5
LP5 A A
Q2 PE 4 X5
400 12 11
19 Q2
LP2 Si1 3
42 230 10 9 B B
11 0
LP6 X6
2
X2-3 Si2
Q2 PM2
1
X2-1 - -
U
LP4 X4
X1-1
RE3+4
LP10
X1-2 LP7
12V
LP8

page 15
Pc-Board DRV03 / DRV13
The pc-board DRV03 is the primary driver board of the MicorMIG 300 and 350.
Since week18 2017 the DRV03 was replaced by the DRV13. For details see page 27.

Functions
- primary driving of the transformer
- capture primary input current
- measuring temperatures
- generating internal supply voltages
- driving fans
- switching power-up relays
- PE monitoring
- coding power unit
- monitoring mains voltage
- monitoring bus voltage

LEDs
LED state designation
1 (red) blinking (1 Hz) normal operation
blinking (3 Hz) when switching off the machine (no mains voltage present)
lit weak DSP not programmed
off 3.3V supply voltage is missing

Measuring points
designation measuring result
point
bus voltage X17-4 +Uz ca. +580 V DC
(from rectifier) X17-1 -Uz
bus voltage D27 +Uz ca. +580 V DC
(at the power modules) D28 -Uz
supply voltage +24V X6-2, X7-2, X11-2 + +24V DC
X6-1, X7-1, X11-1 -
supply voltage +16V X2-1 + +16V DC
X2-2 -
supply voltage +60V X1-5 + +60V DC
X1-6 -

Measuring points bus voltage (power modules)

-Uz
+Uz

page 16
Picture pc-board DRV13
SI3 SI1aux. transf. SI4aux. transf.
DMR CAN sec. CAN fan prim.

X12
X8 X9 X13

X15
X1 X6 X7 X11 X5 PE-prot.

MAPRO X3
X14 NEFI

+ A B -

MAPRO X2 4 3 2 1
X17

TR4
SI2
temp.sens. X4
R75 R78
X19 D27 D28

+Uz -Uz

TR3

TR2
DIP1

TR1

LED1

Inside diagram power module

4
1 2 3 4 5 6

1 6

2 5
20 7
20 7
19 8
19 8

18 14 9
18 9
17 16 15 13 12 11 10 17 10
ϑ

16 15 12 11 14 13

page 17
Schematic
DRV03
RE1

R75
D27 TM2 SF02
C62 C67
1

X17 2
+ 4
+Uz

X4
Ip
A 3 TR1 TR2 3

B 2 4

TR3
- 1
-Uz
TR4 5
C61 C66

TM1
RE2

R78
D28

X5-2
Si1 +24V Si2
19V
+24Vext.
X5-1
+16V +5V

Si3
X5-3
+60V +3,3V
42V X5-4

X13-3
Si4 +16Vprim.
11V X13-1
+3,3V

-Uz

Fuses DRV13
fuse value
Si1 (24V) 6.3 A
Si2 (24V ext.) 1.5 A
Si3 (60V) 6.3 A
Si4 (16V) 0.63 A

Pc-Board SF02
The pc-board SF02 contains the primary resonance capacitors and is only used together with the pc-board
DRV03.

Functions
- wiring primary transformer wires
- connecting resonance capacitors

Picture pc-board SF02

X4
1
2
3
4
5

page 18
Pc-Board DRV05 / DRV15
The pc-board DRV05 is the primary driver board of the MicorMIG 400.
Since week18 2017 the DRV05 was replaced by the DRV15. For details see page 27.

Functions
- primary driving of the transformer
- capture primary input current
- measuring temperatures
- generating internal supply voltages
- driving fans
- switching power-up relays
- PE monitoring
- coding power unit
- monitoring mains voltage
- monitoring bus voltage

LEDs
LED state designation
1 (red) blinking (1 Hz) normal operation
blinking (3 Hz) when switching off the machine (no mains voltage present)
lit weak DSP not programmed
off 3.3V supply voltage is missing

Measuring points
designation measuring result
point
bus voltage X17-4 +Uz ca. +580 V DC
(from rectifier) X17-1 -Uz
bus voltage T13 +Uz ca. +580 V DC
(at the power modules) T14 -Uz
supply voltage +24V X6-2, X7-2, X11-2 + +24V DC
X6-1, X7-1, X11-1 -
supply voltage +16V (X19) X2-1 + +16V DC
(X19) X2-2 -
supply voltage +16V (primary) X14-2 + +16V DC
X17-1 / T14 -Uz
supply voltage +60V X1-5 + +60V DC
X1-6 -

page 19
Picture pc-board DRV15
Si2 Si3 Si1 Si4

X6 X11 X7

X16
X12

X15
X1 X8 X13

X9
X5

X3
X14

X4

D27
R75

T12 T16

X2

X19

1 2

T13 T17

+
+Uz Uz/2
X17 A
B
-

R78
T14 T18

-Uz Uz/2

D28
3
4

T15 T19

LED1
DIP1

Change from MOSFET to IGBT (DRV05)

Since the 10th of July 2015, since serial number 4062-2528-0021-6 only IGBTs are used for the MicorMIG 400.

type old new

T12 - T15 MOSFET (711.2614.0) IGBT (711.0530.0)
T16 - T19 IGBT (711.2616.0) IGBT (711.0530.0)

page 20
Schematic

DRV05
RE1
+Uz

R75
D27
TR4
T13 T16
TR3

X17-4 (+) T12 T17

X17-3 (A)
X17-2 (B) Uz2
X17-1 (-)

TR2
T15 T18
TR1

D28 T14 T19

X2-5
R78
X2-6

RE2
-Uz
X19-4
+24Vext.
X19-3
X5-2
Si1 +24V Si2
19V
+24Vext.
X5-1 X3-12
+16V +5V X3-9

Si3
X5-3
+60V +3,3V
42V X5-4 +Uz Uz2

X13-3
Si4 +16Vprim. µP
11V X13-1
+3,3V
-Uz
-Uz

*the connector X19 was later renamed to X2

Fuses DRV15
designation value
Si1 (24V) 6.3 A
Si2 (24V ext.) 1.5 A
Si3 (60V) 6.3 A
Si4 (16V) 0.63 A

page 21
Pc-Board DRV07 / DRV17
The pc-board DRV07 is the primary driver board of the MicorMIG 500.
Since week18 2017 the DRV07 was replaced by the DRV17. For details see page 27.

Functions
- primary driving of the transformer
- capture primary input current
- measuring temperatures
- generating internal supply voltages
- driving fans
- switching power-up relays
- PE monitoring
- coding power unit
- monitoring mains voltage
- monitoring bus voltage

LEDs
LED state designation
1 (red) blinking (1 Hz) normal operation
blinking (3 Hz) when switching off the machine (no mains voltage present)
lit weak DSP not programmed
off 3.3V supply voltage is missing

Measuring points
designation measuring point result
bus voltage X21 +Uz ca. +580 V DC
(from rectifier) X24 -Uz
supply voltage +24V X6-2, X7-2, X11-2, X8-2 + +24V DC
X6-1, X7-1, X11-1, X8-1 -
supply voltage +16V X2-1 + +16V DC
X2-2 -
supply voltage +16V (primary) X14-2 + +16V DC
X24 -Uz
supply voltage +60V X1-5 + +60V DC
X1-6 -

page 22
Picture pc-board DRV17
SI3 SI1

X13

X15
X6 X11 X7

X16
X12
X1 X14

X9
X5 X8
SI4
X3

X4
DIP1
X19 LED1

X21
X2 +Uz
X17

X31 1
X30 2
X26

+Uz Uz/2

A A-B
B-A
B

-Uz Uz/2

X29 3
X20 4

X18 X24
-Uz

page 23
Schematic
DRV17

+Uz

2
X30
T13 T16
X31

X21 (+) T12 T17

(A)
Uz2
(B)
X24 (-)
4
X20
T15 T18
X29

3
X17-1
T14 T19
X17-3

-Uz X2-5
X2-6

X19-4
Si1 +24V Si2
+24Vext.
X5-2
19V
+24Vext.
X5-1 X19-3
+16V +5V
X3-12
Si3
X5-3 X3-9
+60V +3,3V
42V X5-4 +Uz Uz2

X13-3
Si4 +16Vprim. µP
11V X13-1
+3,3V
-Uz
-Uz

Fuses DRV17
designation value
Si1 (24V) 6.3 A
Si3 (60V) 6.3 A
Si4 (16V) 0.63 A

page 24
Overview DRV versions

In the past the software of the primary processor on the pc-board DRV was changed and improvments had been
implemented. The different versions were marked manually on the grey bus-voltage foil capacitors.

marking description
none initial version

“S” - useage since week 21 2014

- power-up phase stabilized (switching of power-up relays)

“R17” - useage since week 11 2015

- quicker balancing of bus-voltages
- automatic reset of overvoltage error message

page 25
marking description
“R32” - useage since week 40 2016
- modification of filter for bus-voltage measuring

“V1.08” - useage since week 18 2017

“V1.10” - multivoltage (3-phase 230V / 400V)
- preparation for generator use

“V1.11R” - useage since week 30 2018

- fully fit for generator use

- since week 40 2018: new terminals for transformer wires and supply

page 26
Change from pc-board DRV0x toe DRV1x
Since week 18 2017 the new DRV boards are used in the MicorMIG series. To ensure the multivoltage function
and generator useage, not only the hard and software of the DRV were changed, also the software of the MAPRO
board (version 2.02 for Master and Process firmware) needed to be changed.
That is why the new DRV boards are NOT compatible with the MAPRO software 1.xx.

If a “old” DRV0x board needs to be replaced by a “new” DRV1x board, it is absolutely necessary that
the MAPRO needs to be updated to minimum version 2.02!!!

previous board replaced by new part no.

DRV03 DRV13 981.1219.0
DRV05 DRV15 650.5645.5
DRV07 DRV17 650.5647.5

page 27
Pc-Board DC01
The pc-board DC01 is the secondary board for wiring the secondary diodes at the MicorMIG 300 and 350.

Functions
- wiring secondary diodes
- connecting resonance capacitors
- providing output voltage for measuring

Measuring points
designation measuring result
point
output voltage X2-5 + +80V DC*
X2-1 -
*only at machines with no VRD, at machines with activated VRD, the VRD voltage is measured.

Picture pc-board DC01

X2

X1

Schematic

Rshunt

X2
X1 5 4 3 2 1

MAPRO

page 28
Pc-Board DC03
The pc-board DC03 is the secondary board for wiring the secondary diodes at the MicorMIG 400.

Functions
- wiring secondary diodes
- connecting resonance capacitors
- providing output voltage for measuring

Measuring points
designation measuring result
point
output voltage X2-5 + +80V DC*
X2-1 -
*only at machines with no VRD, at machines with activated VRD, the VRD voltage is measured.

Picture pc-board DC03

X2

X1
PE

Schematic
DC03
Rshunt

X2

1 2 3 4 5 X1

MAPRO

page 29
Pc-Board DC04
The pc-board DC04 is the secondary board for wiring the secondary diodes at the MicorMIG 500.

Functions
- wiring secondary diodes
- connecting resonance capacitors
- providing output voltage for measuring

Measuring points
designation measuring result
point
output voltage X2-5 + +80V DC*
X2-1 -
*only at machines with no VRD, at machines with activated VRD, the VRD voltage is measured.

Picture pc-board DC04

X2
X1

D6

D7

D8

D9

page 30
Pc-Board MAPRO04
The pc-board MAPRO04 is the main control logic of the MicorMIG machines.

Functions
- welding process control
- weld sequence control
- fan control
- open circuit voltage generator
- temperature monitoring
- monitoring primary input current
- monitoring welding- current/voltage
- communication operating elements (front panel, remote control)

Picture pc-board MAPRO04

X2 X7 X1 X6

X8

X4

X5

Change MAPRO04 since July 2015

X1
X6

X2 X7

X8

X4

X5

Overview connectors pc-board MAPRO04

connector designation
X1 connector flat ribbon cable to pc-board DRV
X2 connector flat ribbon cable to dront panel
X5 connector shunt resistor and pc-board DC0x
X6 connector water-sensor (only at version with 2-pin X6 connector)
X7 connector to pc-board DRV
X8 LorchNet

page 31
Pc-Board DMR-RT3
The pc-board DMR-RT3 is the wire feed control of the MicorMIG machines.

Functions
- driving and monitoring the wire feed motor
- monitoring torch trigger switch
- communication PowerMaster torch

LEDs
LED status designation
1 (red) off until software version 1.11: normal operation
from software version 1.12 on : micorprocessor not working
blinking until software version 1.11: malfunction LorchNet (CAN bus)
from software version 1.12 on : normal operation
lit weak micro processor not programmed
on micro processor detected a fault
2 (green) on 5V supply voltage ok
off 5V supply voltage missing
3 (green) on wire retract active
off normal wire feed

Picture pc-board DMR-RT3

X13

X14

LED2
LED2 +5V

LED3 LED3
retract LED1
LED1 error

X9 X9

X3
X12
X8

X4 X5 X1 X20 X7 X6
X11 X10

! CAUTION ! the cable-bridge on connector X13 pins 5 and 11 must always be present.

page 32
Pc-Board DMRPP05
The pc-board DMRPP05 is the control unit for Push-Pull torches and the NanoFeeder.
In case of a Push-Pull application the DMRPP05 replaces the standard motor control pc-board DMR-RT3.
it consists of two pc-boards that are connected via flat ribbon cables:
- pc-board DMRPP-P: power board containing the motor driver circuits
- pc-board DMRPP-C05: control logic

Functions
- driving and monitoring the normal wire feed motor as well as the Push-Pull motor
- driving the solenoid valve
- monitoring control elements (front panel, torch trigger switch)

LEDs
LED state designation
1 (red) off DSP is ok
lit bright pc-board is in programming “flash” mode (DIP switch 1 is set to “ON”
lit weak DSP is not programmed
2 (green) on +5V supply voltage ok
off +5V supply voltage is missing
3 (green) blinking DSP is working
lit continously wrong configuration (if DIP switch 2 ios set to “ON”

DIP switch
DIP switch setting function
1 ON programming mode active
OFF “normal” operation
2 ON configuration “intermediate feeder” (not supported by MicorMIG)
OFF configuration Push-Pull / NanoFeeder

page 33
Picture pc-board DMRPP05
LED2 LED1 LED3

X14 X15

X2 X17

LED3

X13

X3
LED1

X16
LED2 S1

X9

X18

X8
X10
X11

X12 X4 X5 X1 X20
X6

X1 X2

page 34
page 35
Pc-Board SF18
The pc-board SF18 was the control logic of the water cooling unit. Since September the 16th 2015 it was replaced
by the pc-board SF24.

LEDs
LED state designation
1 (red) lit weak microprocessor not programmed
blinking irregular LorchNet (CAN-bus) error
blinking synchronous with LED2 flowrate too low (<0.3 l/min)
2 (green) off status not ok
blinking Status: blinking with 1Hz
if pump off, LED is blinking with short pulses
if pump on, LED is blinking with long pulses
3 (green) on 5V supply voltage ok
off 5V supply voltage missing

Picture pc-board SF18

X9 X10
X4
X5

X2

X3

LED3
+5V
X6

X8 X1 X7

LED1 LED2
Err Status

page 36
Schematic pc-board SF18

P
M
SF18
X5 X4

X9-2
X9-1
X10-6
RE1
X10-2
Si4
Si5 2.5A
1A
400V
X2 X10-3 0

X10-5 230
Si6
1A
400V
X3 X10-1 400

+24V +5V
RE1
X7-1 gnd
X7-2
X7-3
X7-4 CAN uP

+5V X1-1
X1-2
X1-3
X1-4

!!! CAUTION !!!

Because the pc-board SF18 is no longer produced and not available as spare part, the pc-board
SF23 is used instead in case of a repalcement.
The pc-board SF23 is the standard control board for the water cooling unit of the Robo-MicorMIG and
is also part of the retrofit kit “Water-Detection MicorMIG” (570.8066.0)

page 37
Pc-board SF23
The pc-board SF23 is the standard control of the Robo-MicorMIG. It is also used as replacement pc-board for the
SF18 as well as in the retrofit kit, to retrofit the water monitoring in machines build before 2016.

Picture pc-board SF23

X9 X10
X4 X5 X3 X2

LED4

X6 X11

LED1 LED6

X8 X1 X7

LED2

LEDs
LED state designation
1 (red) off status ok
on (weak) processor not programmed
blinking iregularly LorchNet error
blinking synchronous to LED2 coolant flowrate too low (<0.3 l/min)
2 (green) off status not ok
blinking status: blinking with 1 Hz
if pump off, LED is blinking with short pulses
if pump on, LED is blinking with long pulses
4 (green) on +5V supply ok
6 (green) on +10V supply ok

page 38
Schematic pc-board SF23
P
M
SF23
X5 X4

X9-2
X9-1
X10-6
RE1
X10-2
SI1
SI2 2.5A
1A
400V
X2 X10-3 0

X10-5 230

400V
X3 X10-1 400

+24V +5V
RE1
X7-1 gnd
+10V
X7-2
X7-3
X7-4 CAN uP

+5V

X1-1
X1-2
X1-3
X1-4

Connector Function
X1-1 +5V DC supply
X1-2 sensor input
flow rate < 0.3 liter/minute : pins X1-2 and X1-3 are open (error message E05)
flow rate > 0.3 liter/minute : pins X1-2 and X1-3 are closed
X1-3 gnd
X1-4 activation sensor input with +5V (bridge to X1-1) the sensor input (X1-2) is active

Picture water sensor

page 39
Pc-board SF24
The pc-board SF24 is replacing the pc-board SF18. Since serial number 40xx-2538-0001-x. the SF24 is the
standard control board for the water cooling unit of the MicorMIG. At the same time the pc-board DRV was
changed (implementation of connector X19) to drive the relay on the SF24.
Since January 14th 2016 (with the introduction of cooling water detection) the SF24 was replaced with the pc-
board SF27.

Picture pc-board SF24

X9 X10
X4 X5

X2 X3

X7

Schematic pc-board SF24

P
M
SF24
X5 X4
X9-2
X9-1

X10-6
RE1
X10-2
Si1
Si2 2.5A
1A
400V
X2 X10-3 0

X10-5 230

400V
X3 X10-1 400

+24V
X7-4
X7-3 RE1
X7-2
X7-1

page 40
Pc-board SF27
The pc-board SF27 is the actual control board for the water cooling unit with water flow detection. The sensor can
only detect if water is flowing or not. It cannot measure the flow rate.

Picture pc-board SF27

X9 X10
X3

X4
X5
X2

X6

X8 X7

Schematic pc-board SF27

P
M
SF27
X5 X4
X9-2
X9-1

X10-6
RE1
X10-2
Si1
Si2 2.5A
1A
400V
X2 X10-3 0

X10-5 230

400V
X3 X10-1 400

+24V
X7-4 +15V
X7-3 RE1

X6-1
X8-1
X8-3
X6-2

page 41
Pc-board SF37
Since 07/15/2020 (from serial number 4xxx-3029-xxxx-x), the SF37 is used as a standard pc-board used for water
cooling. The threshold value for detection of water flowing / water not flowing has been raised by 10 Kelvin. Fur-
thermore, the fuse SI2 has been changed: 1.25A (instead of 1A) because at the same of the switch to SF37, the
autotransformer was changed to a stronger version.

Schematic pc-board SF37

P
M
SF37
X5 X4

X9-2
X9-1
X10-6
RE1
X10-2
Si1
Si2 2.5A
1.25A
400V
X2 X10-3 0

X10-5 230

400V
X3 X10-1 400

+24V
X7-4 +15V
X7-3 RE1

X6-1
X8-1
X8-3
X6-2

1.25A

page 42
Transformer 400V/230V

At the same time as the switch to the SF37 board, a more powerful transformer was used.
A retrofit kit is available for older systems: 981.8131.0
This includes an adapter plate (adaptation to the hole pattern of the old transformer) and the 1.25A fuse for the
SF27 pc-board.

old transformer new transformer

655.8106.0 655.8109.0

page 43
Connection cooling unit

At machines with internal water cooling, the pc-board SF18 was the main control board of the cooling unit. It has a
microprocessor and was connected via the internal CAN-bus (LorchNet) to the pc-board DRV (x6 or X7, X11).
Since September 16th 2015 the pc-board Sf18 was replaced by the pc-board SF24, without microprocessor. it
was still connected to the pc-board DRV, but not to the CAN bus any more. It must be connected to the separate
X19 connector.
Since January 28th 2016 all MicorMIG machine are equipped with a water flow sensor for monitoring the cooling
unit. For this the SF24 was replaced by the SF27. On the pc-board SF27 is a new connector for the water flow
sensor.

Connection SF18 / SF23

Connection
SF24 / SF27
SF37

!! CAUTION !!
It is important not to mix up the connections X19 and X6, this could lead to a damage on the DRV or
SF- pc-board.

page 44
Control of the water cooling unit

Connection diagram water cooling unit SF18/SF23

P
M
SF18
X5 X4

X9-2
X9-1
X10-6
RE1
X10-2
Si4
Si5 2.5A
1A
400V
X2 X10-3 0

X10-5 230
Si6
1A
400V
X3 X10-1 400

+24V +5V
RE1
X7-1 gnd
MAPRO DRV X7-2
X8-3 X2-7 X6-3 X7-3
DSP CAN X8-4 X2-8 X6-4 X7-4 CAN uP

X7-3
X7-4 +5V X1-1
X1-2
X11-3 X1-3
X11-4 X1-4

Connection diagram water cooling unit SF24

P
M
SF24
MAPRO DRV X5 X4

X9-2
X9-1
+24V X10-6
RE1
X19-4 X7-4 X10-2
X19-3 X7-3 RE1
Si1
2.5A
X1-12 X3-12 X10-3 0
FPGA
Si2 1A
400V
X2 X10-5 230

X1-9 X3-9
400V
X3 X10-1 400

Connection diagram water cooling unit SF27

P
M
SF27
MAPRO DRV X5 X4
X9-2
X9-1

+24V X10-6
RE1
X19-4 X7-4 X10-2
X19-3 X7-3 RE1
Si1
2.5A
X1-12 X3-12 X10-3 0
FPGA
Si2 1A
400V
X2 X10-5 230

X1-9 X3-9
400V
X3 X10-1 400

X6-1 X6-1
DSP X8-1
X8-3
X6-2 X6-2

page 45
Temperature monitoring
Schematic MicorMIG 300/350

TM1
µP

ϑ
X2-3 X7-4

RS485

RS485
X2-4 X7-5 FPGA
-Uz
+3.3V

TM2

X3-16 X1-16
DSP
ϑ X3-10 X1-10

DRV -Uz MAPRO

X4-1

X4-2

ϑ
10kΩ : 25°C

Schematic MicorMIG 400/500

+3.3V
µP

X2-3 X7-4
RS485

RS485

X2-4 X7-5 FPGA

-Uz

+3.3V

X3-16 X1-16
DSP
X3-10 X1-10

DRV MAPRO
X18-1

X18-2

X4-1

X4-2

ϑ ϑ
10kΩ : 25°C

page 46
The temperature sensors are temperature dependant NTC resistors. As soon as one of the sensors is measur-
ing a too high temperature, the machine stops with E01 “Overtemperature”. The sub-code indicates which sensor
detected the overtemperature. The fans keep running to cool down the machine. If the temperature drops below
55°C, the error code disappears and the machine can be used again.

The middle heat sink temperature is calculated over a longer period of time. The effective limit is depending on
the actual current setting, that means if the machine is used with a welding current below the 100% duty cycle, the
E01-04 can never come up.

sensor code limit monitoring

output diodes E01-01 ca. 80°C MAPRO
primary modules E01-02 ca. 70°C DRV
middle heatsink temperature E01-04 current depending MAPRO

If one of the sensors should be faulty or disconnected from the measuring circuits, the machine will stop with the
error code E13 “Error Temperature Sensor”.
The sensors have a resistance value of about 10kΩ at 25°C.

code sensor
E13-01 at output diodes
E13-02 inside primary modules (MicorMIG 300/350) / MOSFETs and IGBTs (MicorMIG 400/500)

page 47
Monitoring bus voltage
Right from switching on the machine, the bus voltage is monitored directly by the DSP of the DRV.
The actual value of the bus voltage is send from the DSP of the DRV to the MAPRO.
As soon as the voltage gets too high, the machine stops with E02 “Overvoltage”. In this case the power-up relays
on the DRV are switched off, so that the power-up resistors are active again, lowering the input voltage.
If the minimum value of 390V DC is not reached during startup (switching on), the machine stops with E22-03
“Undervoltage Startup”.

Schematic
RE2 DRV

1 +Uz2
X17

TM2
3 -Uz2

2
+Uz1
TM1
4
-Uz

MAPRO

RE1 X2-3* X7-4

RS485

RS485
DSP X2-4* X7-5 FPGA

*(at the DRV05 the connector designation X19 was later renamed into X2)

In general the values of both bus voltages at the power modules TM1 and TM2 are equal (symmetrical). If there
should be a difference >60V, the machine stops with E33-01 Unsymmetrical bus voltage.
If a difference >60V is detected during startup, the machine stops with E33-02 Unsymmetrical bus voltage Startup.
As soon as the difference gets below 60V, the error code is reset.

Code Cause
E02-02 During startup the maximum limit of 700V DC was exceeded.
E02-04 The maximum limit of 750V DC (or 400V DC at the modules) was exceeded during operation.
E02-05 The FPGA measured a too high bus voltage (>400V DC) at the modules.
E22-03 During startup the minimum limit of 390V DC was not reached.
E33-01 The difference between the bus voltages of module 1 and 2 is greater 60V.
E33-02 The difference between the bus voltages of module 1 and 2 is greater 60V at startup.

page 48
PE (Protective Earth) -Protection
The PE monitoring is a standard feature in every machine. As soon as a current >15A is
flowing via the PE wire of the mains cable, a reed-contact opens up and the machine stops with E04-01 PE-moni-
toring.

Schematic
DRV
+3.3V

X15-1 PE
DSP

-Uz X15-2

Cooling unit
Since January 14th 2016 the water cooled machines of the MicorMIG series are equiped with a water monitoring.
A sensor is mounted in the water tank, that is washed around by the cooling water of the return-flow. The sensor
is a “self-heating” sensor: the temperature is decreasing as soon as the water is flowing over it. If the water is not
flowing, the temperature of the sensor is kept stable.
If the pump is running and a flow of the water cannot be detected for longer than seven seconds, the machine
stops with the error message E05.

Schematic
SF27 MAPRO
X6-1 X6-1
X8-1 DSP
sensor
X8-3
X6-2 X6-2

tank

pump

hose connector blue

hose connector red

cooler

Since November 2017 with the software release 2.09 the water surveilance time was enhanced from
7 seconds to 10 seconds.

page 49
Monitoring Output Voltage
The output-/welding voltage is measured directly by the DSP of the MAPRO. If a voltage >100V DC is measured
for longer than 100ms, the machine stops with E06-00 “Overvoltage secondary”.
In case that the FPGA is measuring the too high voltage, the machine stops with E06-01 “Overvoltage secondary
FPGA”. The output voltage is measured directly at the secondary diodes (via X5-7 of the MAPRO).

Schematic
RSHUNT

X2-1

X2-5

DC0x
X1
X2-2
X2-3
X2-4
X5-8
X5-6
X5-7

MAPRO
OCV

DSP FPGA

When switching on the machine the power unit is activated shortly and the output voltage is measured. If there is
no output voltage during driving the power unit, the machine stops with E12-00 “Power unit error Startup”.
The reason can be a fault in the measuring path or a fault in the primary driver (e.g. interchanged transformer
wires at the pc-board SF02).

If a machine is used too far off the “normal” welding characteristic, it will stop after the machine recognizes a too
high output voltage for a longer period of time. This will overload the machine at it protects itself by stopping with
the error code E18-01 “Overload”. In such situations it is very likely that the temperature of the power unit gets
very high in a short time and maybe also reach the maximum allowed temperature, stopping with E01.

page 50
Open Circuit Voltage Generator & VRD
The open circuit voltage of the MicorMIG machines is not produced via the power unit, it is a DC signal voltage
generated by the MAPRO. At machines with active VRD, the VRD voltage is programmed with a lower voltage
(like 24V) instead of 80V.
When the machine is switched on, the MAPRO is activating the open circuit voltage for a short time to check its
function. If no voltage is measurable, the machine stops with E25-01 “Error voltage generator”.

Since software version 1.12 the display of the error message is suppressed, when at switching on
the machine. If a short circuit at the output is present (torch is laying on the work table, wire is touch-
ing the ground), the E25-1 is NOT displayed at the front panel. In this situaton (as long as the short
circuit is still present), the wire inching button is not working. As soon as the short circuit is removed
(taking the torch away from the work table), tha machine functions normally.

When switching between to a different welding mode like MMA (stick electrode) or TIG, the open circuit voltage
generator is stopped and started again. If no voltage is measurable after the re-start, the machine stops with the
error code E25-02.

Monitoring welding current

The welding current is measured directly via the DSP of the MAPRO using a shunt resistor. Parallel to this, the
FPGA of the MAPRO is also monitoring the voltage across the shunt resistor via an A/D converter.
When the machine is not welding, the voltage across the shunt resistor is 0V. If a voltage is measured anyway
(voltage offset), the machine stops with the error code E15-01 “current offset FPGA”.
In case of a contact problem between MAPRO and shunt resistor, the machine stops with the error code E15-00.

Schematic
MAPRO

A/D FPGA

X5-1 DSP
X5-2

RSHUNT

New Shunt resistor

Since May 2020 (from serial number 4xxx-3019-xxxx-x) a new shunt resistor is used where the connecting wires
are now directly soldered to the shunt. Also new spare part kits were generated (including a mounting instruction):
MicorMIG 300/350/400: 666.0012.0
MicorMIG 500: 666.0015.0

old shunt new shunt

page 51
Monitoring and driving the wire feed motor
The wire feed motor is driven and monitored by the pc-board DMR-RT3. If the current consumption of the motor is
too high, the machine stops with the error code E08 “Motor overcurrent”.

Motor identification
The pc-board DMR-RT3 is also used in other machines with other motors, not only at the MicorMIG. Because
of this, a identification (cable-bridge at connector X13, pins 5 and 11) is needed to indicate that the DMR-RT3 is
used in a MicorMIG machine. This cable must always be present at every MicorMIG machine.

Schematic
DMR-RT3
X9-2
+24V
X9-1
X13-5 X9-4 wire
identification
MicorMIG X13-11 X9-3 retract
X9-6 wire
X9-5 inching

X4-1 wire
X20-1 X4-2 inching
X20-2
+24V
X20-3 X1-1 torch
X20-4 X1-2 trigger

X8-1 µP X5-1
+5V
X8-2 Tacho-ON X5-4
X8-3 Tacho-Signal X5-2
X8-4 CAN X5-3
G
X8-5
+60V +60V
X8-6 X11
M
X8-7
X8-8 X10
+24V
DRV

+5V
+24V
RE1

LED2 LED1
LED3

page 52
Schematic DMRPP05
Schweiß-
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
Drahteinlauf
10 6
Kaltdraht-
+24V
Sensor Gas- Ausblaß- Draht- Draht- Lüfer Drahtende-
X1 Gastest
13 4
ventil ventil rückzug einlauf Sensor
Gastest
gnd 1
Brenner- 12 12
data 2 interface
Kollisionsschutz 16 5
Kollisionsschutz
X18 14 14
1 8 3
2
analog Eingang
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 9 9
G
10
6 15 digital2
G PushPull
X20
1 5 11 digital1
gnd 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
Strom Strom
Koffer aktiv
7 Vorschub- PushPull gnd Vorschub Motor
8
temp. motor motor 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

In case of a installed Push-Pull option, instead of the DMR-RT3 the pc-board DMRPP05 is present. An additional
menu item is available where the Push-Pull torch type can be selected. The normale wire feed motor as well as
the Push-Pull motor is controlled by the DMRPP05.

page 53
Supply Voltages
The MAPRO is supplied with 16V from the DRV. If the voltage gets below 12V, the machine stops with E14-00
“Undervoltage”.

Schematic MicorMIG 300/350

NEFI
DRV
1 5
L1
+3.3V prim.
2 6
L2
3 7
L3 Si4
X1-1 X13-3 +16V prim. X15-1
11V X13-1 -Uz X15-2 PE-mon.
X1-3

4A
500V X5-3 DMR
Si3 +60V X1-5 X8-5
42V
X5-4 X1-6 X8-6
X5-2
Si1 +24V Si2 +24Vext. X1-8 X8-8
19V
X5-1 X1-1 X8-1
X1-2 X8-2

X11-1
MAPRO X11-2 CAN
X7-2 X2-1 +16V
X7-6 X2-2 X7-1
X7-2 CAN
X9-1
X9-2 +5V X6-1
X12-1 X6-2 CAN
fan X12-2
X16-1
X16-2 +3,3V

Schematic MicorMIG 400/500

NEFI
DRV
1 5 X14-2
L1
+3.3V prim.
2 6 X18-1
L2
X18-2 temp. prim.
3 7
L3 Si4
X1-1 X13-3 +16V prim. X15-1
11V X13-1 -Uz X15-2 PE-mon.
X1-3

4A
500V X5-3 DMR
Si3 +60V X1-5 X8-5
42V
X5-4 X1-6 X8-6
X5-2
Si1 +24V Si2 +24Vext. X1-8 X8-8
19V
X5-1 X1-1 X8-1
X1-2 X8-2

X11-1
MAPRO X11-2 CAN
X7-2 X2-1 +16V
X7-6 X2-2 X7-1
X7-2 CAN
X9-1
X9-2 +5V X6-1
X12-1 X6-2 CAN
fan X12-2
X16-1
X16-2 +3,3V

page 54
Machine Configuration
The hardware configuration is saved internally inside the machine. When switching on, the MAPRO is reading the
configuration and compares it with the actual present hardware identifications of the DRV, the actual software ver-
sion and the identification of the front panel.
If the configuration does not match the actual hardware configuration or if the configuration could not be read cor-
rectly, the machines stops with E30 “Configuration”.

code designation cause

E30-04 configuration primary the measured bus voltages do not match the actual saved configuration
E30-05 error configuration error when reading the configuration: no valid data present or data is corrupted
E30-06 configuration software the actual software does not fit to the hardware

R25 R26 R27 configuration DIP1 DIP2 configuration

X X 300 / 350 OFF OFF 3-phase 400V
X 400 OFF ON 3-phase 230V
X X 500 ON OFF multivolt (selection switch 230V / 400V)

Configuration resistors DRV13 DRV15

R27
R26
R27
R26 R25
R25

DIP
DIP

Configuration resistors DRV17

DIP

R25
R26
R27

page 55
Monitoring Primary Input Current
The current consumption of the machine is monitored by the DSP and the FPGA. As soon as the input current
is getting too high, the machines stops with the error code E32-01 “Overcurrent FPGA” or E32-04 “Overcurrent
IPMax”.

Schematic MicorMIG 300/350

DRV13
Uz2
SF02

TM1 TR2 3

2
1

-Uz

MAPRO

X2-5 X7-7 FPGA

X2-6 X7-8
DSP

Schematic MicorMIG 400

DRV15

Uz2

X2
T15 T18
X21

MAPRO
T14 T19
X2-5 X7-7 FPGA
-Uz X2-6 X7-8
DSP

Schematic MicorMIG 500

DRV17

Uz2

T13 T16
1

X17-1 MAPRO
X17-3
T12 T16
X2-5 X7-7 FPGA
-Uz X2-6 X7-8
DSP

page 56
If no current zero crossing is measured after a certain time when activating the welding transformer (polarity rever-
sal of the full bridge inverter), the system stops with E32-02 “Timeout”.
Especially with the MicorMIG 500, the current direction of the primary current sensor must be set to the correct
mounting position:

The black connecting lead of the sensor must point in the direction of the cable shoe of the transformer lead. If the
sensor is mounted incorrectly (rotated by 180 °), this would also result in fault message E32-02.

page 57
Fan Control
The cooling fans of the machine are driven and monitored directly by the MAPRO. The MicorMIG 300/350 have
two fans, the MicorMIG 400/500 have three fans. As soon as the current consumption of the fans is getting too
high, the machine stops with the error code E34-00 “error fan current”.

machine max. current

MicorMIG 300/350 2.5A for longer than 0.9 seconds
MicorMIG 400/500 3.5A for longer than 0.9 seconds

Schematic

MAPRO DRV

DRV
shunt
+16V +16VDRV 1
X9
X12 M
(X16)
X1-13 X3-13 „I“ 2
DSP
X1-14 X3-14

Mains Monitoring
The three mains phases are monitored by the DSP on the DRV. If during welding the mains cannot be detected,
the machine stops with the error code E41-01 “mains loss”.

Schematic

NEFI

1 5
L1
2 6
L2
DRV
3 7
L3 +3.3V

14 X14-3
DSP
12 X17 “-“
-Uz

page 58
LorchNet-Remote
LorchNet-Remote is the optional remote control interface of the MicorMIG.
It is connected to the power source via the 4-pin socket “LorchNet” at the rear-side, where also the “LorchNet
Connect” can be plugged in.
If the start contact (pins 1 and 2) is closed during the time the machine is switched on, the error message E25-01
is displayed at the front panel.

Schematic

LorchNet-Remote
start AMP14
1
2
wh 1
pot. 3 br
+10V +24V 2
4 gr 3
CAN ye
5 µP 4

6
„external“ 7
„2-T“ 8

9
I>0
„arc established“ 10

+12V

signal pin description

start 1 and 2 as soon as pins 1 and 2 are closed, the machine starts the welding process (like pressing the trigger
switch at the torch)
energy setting 4 analog input for setting the welding energy (e.g. via a potentiometer)
0V = min. energy setting of the actual selected welding program
10V = max. setting of the actual selected welding program
! CAUTION : the analog input is only valid, when the identification “external” at the pins 6 and 7 is ac-
tive !
identification “external” 6 as soon as pin 6 is closed to pin 7 (gnd), the analog input (pin 4) is active and the remote control LED
at the front panel is lit
identification “2-T” 8 as soon as pin 8 is closed to pin 7 (gnd), the machine switches automatically to 2-stroke mode (2-T)
when the start signal is given
arc established (I>0) 9 and 10 as soon as welding current is flowing, the potential free relay contact is closed
max. contact load: 1A

page 59
LorchNet Connect
To connect a computer to a MicorMIG machine, a LorchNet-Connect adapter box (570.4030.0) is necessary. It
provides the LorchNet interface potentially separated for “external” use.
With the software tool “Lorch System Manager” software updates can be made or the list of the last error mes-
sages can be read out.

LorchNet
Connect

CAN
Dongle MicorMIG

page 60
Measuring CAN bus
The CAN bus is easily checked at each pc-board by measuring the resistance value between CAN-low and
CAN-high against GND (ground). Before measuring, disconnect the pc-board completely from the machine.
If the measuring result is too low (1k ohm or lower), the CAN controller chip is damaged and the pc-board must be
exchanged.

Measuring the CAN bus at the MAPRO

Result: about 60k ohm each

CAN_HIGH GND
CAN_LOW

Measuring the CAN bus at the front panel

Result: 50k ohm - 60k ohm each

CAN_LOW
CAN_HIGH GND

Measuring the CAN bus at the DMR-RT3

Result: about 490k ohm each

GND CAN_LOW
CAN_HIGH

Measuring the CAN bus at the DMRPP05 (Push-Pull DMR) is different, there the result is about 0.9k
ohm by standard. A faulty CAN controller chip may not be directly detecable.

Since week12 2017, CAN controllers with a higher dielectric strength are used on all pc-boards.

page 61
Reading out machine data
Since the software version 1.12 from the 30th November 2015 it is possible to read out machine data using a
smartphone. Depending on the existing front panel the data can be transferred with different methods:
front panel read out via
Basic, BasicPlus NFC
ControlPro NFC, QR-code

The following data can be read out:

- software versions
- information- and error messages
- operating hour counters
- machine configuration
- actual settings and welding parameters

Read out via NFC

A smartphone with NFC functions is required. To read out the data follow these steps:
Basic/BasicPlus:
- switch off the machine
- press the menu button (upper-left button) and keep it pressed
- switch on the machine
- release the menu button
ControlPro:
- switch off the machine
- press the menu button A50 and keep it pressed
- switch on the machine with the button pressed
- release the menu button A50

The machine shows “nFc Act” at the front panel.

In this condition a smartphone with NFC functions must be held to the front panel. The
machine transfers the data to the smartphone and accesses a Lorch web site automati-
cally that displays the data:

The email address of the user/technician can be put into the field “E-Mail” and hit the
button “Send E-Mail”. A PDF with the data is then send to the e-mail address that was
entered.

page 62
Read out via QR-code
With a ControlPro front panel the machine data can be transferred via QR-code. A smartphone with installed QR-
code scanner app is required for this. To read out the data follow these steps:
- switch off the machine
- press the menu button and keep it pressed
- switch on the machine
- release the menu button
The QR-code is displayed at the front and can be scanned with a smartphone.

Since software version 2.02, the start-menu can also be accessed without switching off the machine:
- press and hold the keys A2 and A32
- after about 3 seconds the start-menu is displayed

page 63
Information Messages
Information messages are malfunctions that are not blocking the welding functions in general. If a information
message is displayed at the front panel, it must be acknowledged with the “Exit” key.
Welding is still possible but maybe with some restrictions.
code designation cause remarks
H30-02 configuration calibration data no valid calibration data could be found Standard calibration data are used instead,
this can result in a difference between the dis-
played current value and the real current value.
H30-03 configuration maximum no valid data for the maximum current could be Standard values are used instead, it can hap-
current found pen that the machine is not able to reach the
maximum current.
H30-04 configuration duty-cycle no valid data for the duty cycle could be found Standard values are used instead, it can hap-
pen, that the machine has a less duty cycle
than normal.
H31-07 Communication DMR The internal CAN bus communication between - check CAN bus wires between DMR-RT3
MAPRO and DMR-RT3 is blocked or interfered. (X8) and DRV (X1)
- check CAN bus wires between DRV (X2) and
MAPRO (X7)
nFc-H01 Read/write error Cancel, faulty saving Present card again
nFc-H02 NFC card invalid No valid Lorch NFC card Use suitable NFC card
nFc-H03 Connection interrupted Interruption on removing the NFC card Present card again
nFc-H10 NFC card used NFC card has already been used -
nFc-H11 Incorrect serial number Not intended for this welding device Use a suitable NFC card
Action was interrupted during installation on Complete the installation operation on the
nFc-H12 NFC card blocked
another system other system
Code input incorrectly, incorrect input values
Check the input on the TAN server Check the
nFc-H13 Incorrect TAN code on the TAN website. (e.g.: Swap: "b" and "6" or
TAN web address.
missing ".")
nFc-H15 Decryption error Incorrect data, card not from Lorch Use a suitable NFC card
nFc-H16 Invalid signature Data error, no valid Lorch signature Use a suitable NFC card
nFc-H30 Upgrade already installed Update already performed -
nFc-H31 Invalid customer number Welding program created for another customer Use a suitable NFC card
NFC card not suitable for this product family/
nFc-H32 Invalid product family Use a suitable NFC card
series
Lorch authorisation card must be used first, or
nFc-H33 Authorisation required Perform authorisation again
time run out
nFc-H34 Insufficient user level e.g. action not available for WPS welder Contact welding supervisor
Are all preconditions fulfilled (card label/order
nFc-H35 Condition failed General conditions are not fulfilled
data). Have the card checked
nFc-H40 Activation error Data error on the card or function not supported Have the card checked
nFc-H41 Inconsistent data Data error on the card Have the card checked
Re-write job card or change the compensation
nFc-H46 Wrong job card contents Job card does not fit to compensation mode
mode to “cable length”
Missing NFC-card informa-
nFc-H59 Incompatible front panel firmware Make software update to power source and
tion or decryption error
front panel (with LSM)
nFc-H61 NFC card invalid Invalid card type
nFc-H62 NFC card invalid Wrong card type for this TAN process request a new card
Incompatible front panel for Make software update to power source and
nFc-H63 Incompatible front panel firmware
this process front panel (with LSM)
nFc-H64 Inconsistent data Data error on card Let card check by Lorch
noP-H20 Function upgrade missing e.g. read NFC not updated
e.g. CrNi job loaded to device but device with-
noP-H21 Material upgrade missing
out CrNi upgrade
e.g. SpeedArc job loaded to device but device Perform the necessary upgrade first
noP-H22 Process upgrade missing
without SpeedArc upgrade
Job with welding program number not available
noP-H23 Welding program missing
on device
noP-H24 Incorrect software Incompatible software version SW update (Master, control panel)

page 64
Error codes
As soon as the machine is detecting a malfunction, the power unit is stopped immediately (welding process is in-
terrupted) and the corresponding error code is displayed at the front panel. Every recognized error code together
with the actual operation hour counter is written into the list of last error messages (error memory). A maximum of
16 error codes can be saved.
Using a computer with CAN interface and LorchNet Connect adapter, the error memory can be read out via the
program “Lorch System Manager”.

Code designation cause remarks

E01-01 Overtemperature diodes The maximum temperature was ex- fans keep running to cool down the ma-
ceeded. chine
E01-02 Overtemperature primary modules
for details see page 46
E01-04 Overtemperature middle heatsink temp.
E02-02 Overvoltage startup The DRV measured a too high bus volt- - check mains and bus voltage
age during startup. - check wiring between DRV and MAPRO
- check flat ribbon cable between DRV and
E02-04 Overvoltage primary The DRV measured a too high bus volt-
MAPRO
age during operation.
for details see page 48
E02-05 Overvoltage FPGA The FPGA on the MAPRO measured a
too high bus voltage.
E04-01 PE-monitoring A current >15A was flowing via the PE - check machine for short circuits to the
wire of the mains cable. housing
- check wiring of the reed contact at con-
nector X15 of the DRV
for details see page 49
E05-00 Cooling unit A flow of the cooling liquid could not be - check coolant and cooling unit
detected. - check fuses on pc-board SF 18/23/24/27
- check step-down transformer 400V/230V
- check wiring of pump and sensor
for details see page 49 and page 45
E06-00 Overvoltage secondary The DSP of the MAPRO measured a too - check wiring of the power unit to pc-board
high output voltage (>100V). DC0x (X2)
- check wiring between MAPRO (X5) and
E06-01 Overvoltage secondary FPGA The FPGA of the MAPRO measured a
DC0x (X2)
too high output voltage (>100V).
- check flat ribbon cable between DRV and
MAPRO
for details see page 50
E07-01 EEPROM initialisation error Error during reading of the error memory, Switch machine off and on again. At a
accessing the EEPROM memory is not permanent fault, the MAPRO needs to
possible (hardware failure). be exchanged.
E08-00 Wire feed The wire feed motor draws too much - check motor and its wiring
current. - check wiring of the DMR
for detail see page 51
E08-01 Motor overvoltage The voltage at the motor is too high - check motor and its wiring
(>100V). - check DMRPP05 and its wiring
for details see page 53
E08-02 Motor supply The supply voltage of the motor (60V DC)
is too high (>75V).
E08-03 Motor overcurrent 1 The wire feed motor draws too much cur-
rent (>12A).
E08-04 Motor overcurrent 2 The Push-Pull motor draws too much
current.
E08-05 Tachometer motor 1 The tacho encoder of the wire feed motor
is not connected or faulty.
E08-06 Tachometer motor 2 The tacho encoder of the Push-Pull mo-
tor or NanoFeeder is not working.
E08-10 Torch connection At the torch trigger wires a voltage > 2.5V check torch trigger wires for short circuits to
was measured. other wires
E12-00 Power unit startup When testing the power unit during ini- - check wiring of the power unit to pc-board
tialisation (switching on the machine) no DC0x (X2)
output voltage could be measured. - check wiring between MAPRO (X5) and
DC0x (X2)
- check flat ribbon cable between DRV and
MAPRO
for details see page 50

page 65
Code designation cause remarks
E13-01 Temperature sensor diodes After a certain time, no rise of the tem- - check sensor and its connection at DRV
perature could be measured. - check wiring between DRV (X6) and
E13-02 Temperature sensor primary modules
Sensor faulty or disconnected (loose MAPRO (X7)
connection) - check flat ribbon cable between DRV and
MAPRO
for details see page 46
E14-00 Supply undervoltage The 16V supply voltage of the MAPRO is - check mains supply
too low (<12V) - check wiring between NEFI, control trans-
former, DRV and MAPRO
- check fans
for details see page 54
E15-00 Current offset Contact problem between MAPRO and - check shunt and its wiring
shunt resistor or shunt wires not con- - check torch and central connector (trigger
nected wires to power cable)
- replace shunt resistor if necessary
E15-01 Current offset FPGA The offset voltage across the shunt resis-
for details see page 51
tor is too high.
E18-01 Overload The power unit was overloaded (unusual Let the machine cool down (in case of E01),
operation from the characteristic). An E01 switch off and on again.
is likely to appear in this condition. for details see page 50
E22-03 Undervoltage Startup During startup the bus voltage didn’t - check mains and bus voltage
reach the minimum limit of 390V DC. - check wiring between DRV (X6) and
MAPRO (X7)
for details see page 48
E25-01 OCV generator Startup No open circuit voltage could be meas- - check for short circuits at the output
ured during startup. sockets
- check wiring of power unit and DC0x (X2)
The start contact at the LorchNet-Remote
- check between DC0x (X2) and MAPRO
interface was active during switching on
(X5)
of the machine.
- check LorchNet-Remote
E25-02 OCV generator No open circuit voltage could be meas- - check torch and central connector
ured when switching to MMA or TIG for details see page 51
E27-00 No program or missing process Welding programs are not present or reprogram the machine, exchange MAPRO
missing. if necessary
E30-04 Configuration primary The measured bus voltages are not - check wiring at X17 of the DRV
matching the actual configuration. - check configuration resistors on DRV
for details see page 55
E30-05 Configuration machine The data of the machine configuration Switch the machine off and on again, con-
could not be read or is corrupted. tact Lorch Service if necessary.
E30-06 Configuration software The actual software is not compatible to Re-program the machine with the correct
the machine hardware. software.
E30-07 Configuration VRD The VRD voltage setting was changed This is only a status message in the list of
(reprogrammed). the last error codes to indicate that the VRD
voltage setting was changed.
E31-04 Communication FPGA-DSP The FPGA doesn’t recoginze any activity Switch the machine off and on again, if the
of the DSP. error is permanently, the MAPRO should be
exchanged.
E31-05 Communication primary DSP Malfunction in the communication be- - Switch the machine off and on again
tween the primary DSP on the DRV and - check the flat ribbon cable between
the DSP of the MAPRO. MAPRO and DRV
E31-06 Communication primary DSP Startup When switching on the machine, there
was no signal received by the MAPRO
ffrom the primary DSP (DRV).
E32-01 Overcurrent FPGA A primary input current >80A was meas- - check secondary diodes
ured. - check primary modules
- check wiring between DRV (X6) and
E32-04 Overcurrent IPmax A primary input current >60A was meas-
MAPRO (X7)
ured.
- check the flat ribbon cable between
MAPRO and DRV
for details see page 56
E32-02 Timeout When driving the power unit, after some - check wiring between DRV (X6) and
time a zero-crossing (polarity change) of MAPRO (X7)
the current could not be detected. - MicorMIG 500: check current sensor
for details see page 56

page 66
Code designation cause remarks
E33-01 Unsymmetrical bus voltage The difference between the bus voltages - check power modules
of the power modules 1 and 2 is >60V. - check the flat ribbon cable between
MAPRO and DRV
E33-02 Unsymmetrical bus voltage Startup The difference between the bus voltages
- check connector X17 on DRV
of the power modules 1 and 2 is >60V at
for details see page 48
startup.
E34-00 Fan current The current consumption of the fans is - check fans and their wiring
too high. for details see page 58
E41-01 Mains loss The primary DSP couldn’t detect a mains - check mains supply
supply. - check wiring between NEFI and DRV
(X14)
for details see page 58
E48-00 End of Demo mode The maximum test time of the demonstra- Restart the machine
tion mode has ended.
Lines in display “= = =” CAN bus connection between front panel - Check CAN bus connection/wires
and MAPRO is jammed. - measure the CAN bus (see page 61)
- replace MAPRO and/or front panel if
necessary

page 67
Lorch Schweißtechnik GmbH Im Anwänder 24-26 71549 Auenwald Germany
Tel. +49 (0)7191 503-0 Fax +49 (0)7191 503-199 info@lorch.eu www.lorch.eu