Selco GENESIS 145 Repair Manual
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Selco GENESIS 145 Repair Manual

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REPAIRS MANUAL
Genesis 145
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  • Page 1 REPAIRS MANUAL Genesis 145...
  • Page 2 Via Palladio, 19 I - 35019 ONARA DI TOMBOLO (PD) TEL. +39 049 9413111 FAX. +39 049 9413311 email: service.dept@selcoweld.com How to contact Selco Service Department.: SELCO s.r.l Service Department c/o SELCO 2 Via Macello, 61 I - 35010 CITTADELLA (Padova) Italy Tel.
  • Page 3 In order to avoid serious injury to persons or damage to things, this manual must be used only by qualified technicians. Selco S.r.l. accepts no liability for any injury to persons or damage to things that may occur during performance of repairs, even after reading or practical application of this manual.
  • Page 4 2) WARNINGS, PRECAUTIONS AND GENERAL NOTICES FOR PERFORMING REPAIRS Repairs must be performed by qualified personnel only. Before performing the repair, you should read and assimilate the contents of this manual, in particular the safety precautions. Avoid performing repairs without the presence of another person able to provide help in the event of an accident.
  • Page 5 3) INSTRUMENTS AND CONVENTIONS FOR PER- 3.3) CONVENTIONS FORMING DIAGNOSIS AND REPAIR By convention, when a measurement has to be taken between two points, for example a b, the arrow point indicates where to apply the red tip of the multimeter (a),while the black tip is applied 3.1) INSTRUMENTS FOR BASIC DIAGNOSIS at the other end (b).
  • Page 6 3.4) STATIC LOAD. Use of grid load can speed up fault tracing and machine testing. Just remember that a fixed power resistor applied to machine’s ou- tput is somewhat equivalent to a welding arc, but only inside of a narrow output voltage range, whose center value can be determined by the formula: STICK WELDING: V OUT = 0 + 0.04 x I OUT...
  • Page 7 4) USE AND ROUTINE MAINTENANCE OF POWER SOURCES AND ACCESSORIES, TECHNICAL DATES Use and routine maintenance (extract from the “Instructions for use” manual provided with each power source). CAUTION 4.1) SAFETY - Do not perform welding or cutting operations on closed contai- ners or pipes.
  • Page 8 4.2) ELECTROMAGNETIC COMPATIBILITY (EMC) CAUTION This device is built in compliance with the indications contained in EARTHING THE WORKPIECE the harmonized standard EN60974-10, to which the operator must When the workpiece is not earthed for electrical safety reasonsor refer for the use of this apparatus. due to its size and position, the earthing of the workpiece may re- - lnstall and use the apparatus keeping to the instructions given in duce the emission.
  • Page 9 5) MACHINE DESCRIPTION 5.2) REAR CONTROL PANEL (FIG. 2) These constant current inverter power sources are able to perform * I1: Off/On switch the following types of welding with excellent results: Turns on the electric power to the welder. - MMA, It has two positions, “O”...
  • Page 10 5.4) TRANSPORT - UNLOADING CAUTION Never underestimate the weight of the equipment * The electrical system must be made by skilled technicians with the specific professional and technical qualifications and in compliance with the regulations in force in the coun- Never make the cargo pass or leave it suspended try where the equipment is installed.
  • Page 11 Connection for TIG welding (Fig. 4) 5.6.2 Possible faults in the TIG welding Fault Cause - Separately connect the torch gas pipe connector to the gas distri- Oxidations 1) lnsufficient gas. bution. ) No protection on the rever- The protection gas flow is adjusted using the tap normally located on the torch.
  • Page 12 6) DESCRIPTION OF GENERATOR FUNCTIONING (BLOCK DIAGRAM) Block diagram of Genesis 145 a) Master switch b) Varistor c) EMI input filter board d) Input rectifier e) DC LINK capacitor f) Power stage (Forward converter) g) Power transformer h) Output rectifier...
  • Page 13 6.1) INPUT FILTER WARNING The 30Vac - 50/60Hz single phase voltage is supplied to the input filter board 15.14.43. Between phase and neutral there is a varistor, which is an electronic When accessing parts inside the machine, remember that ope- component which, when a voltage of around 500V appears on its ning the circuit-breaker doesn’t prevent the danger of electric terminals, becomes conductive extremely rapidly, absorbing a cur-...
  • Page 14 6.2) RECTIFIER BRIDGE AND DC LINK The rectifier bridge has the job of making the first power conversion and in particular of making an AC/DC conversion. The sinusoidal input voltage is rectified by a Graetz bridge rectifier which feeds a bank of smoothing capacitors. Thus, the capacitor bank forms a DC LINK or a connection between the rectifier stage and the inverter stage on which a constant voltage difference is present.
  • Page 15 The Forward converter made by Selco provides a suitable transfor- mer resetting circuit in order to improve the performance of the sy- stem and to have better control of the output current.
  • Page 16 6.4) SWITCHING FEEDER The switching feeder is provided by a DC/DC Flyback converter. The Flyback stage is supplied by the +35Vdc voltage present on the BUS and makes it possible to obtain the -1Vdc, +1Vdc, +15Vdc and +5Vdc voltages required to supply the various boards. The electronic switch of the feeder is a MOSFET.
  • Page 17 7) WIRING AND CONNECTION DIAGRAM...
  • Page 20 Filo/ Descrizione Description Wire Fase U Phase U Fase U dopo l’interruttore Phase U after switch Neutro N Neutral N Neutro N dopo l’interruttore Neutral N after switch GND_BUS GND_BUS +18Vdc +18Vdc +5Vdc +5Vdc...
  • Page 21 8) DESCRIPTION OF DIAGNOSTIC INDICATIONS For the meaning and use of the various controls, please refer to the respective user manuals; only the diagnostic indications are described in this section. 8.1) EXTERNAL DIAGNOSTIC INDICATIONS OF GENESIS 145 ALLARME ALIMENTAZIONE (ALARM) (POWER SUPPLY) The welding control logic present on board 15.14.43 and the power stage control logic present on board 15.14.44 monitor the state of...
  • Page 22 9) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS, CURRENT CALIBRATION The normal working conditions of the boards making up the generator are illustrated in the following sections and the standard values are given for the electrical parameters found at the main points of the boards themselves. All the measurements indicated can be made with a digital multimeter.
  • Page 23 9.1) INPUT FILTER AND WELDING LOGIC 15.14.243 DESCRIPTION This board contains the overcurrent protection devices (varistor), EMC filter circuitry, the electronic welding logic and the switching power supply INSTRUMENTS REQUIRED - Multimeter - Set of screwdrivers BOARD M2/1 M2/2 M1/1=U M1/2=N JUMPER...
  • Page 24 Functional part Generator/ Component Test Point Value Type of Note Mode measure Supplies voltage M1/1 M1/ 30Vac + 15% 30Vac + 15% Fan supply CN6/1 CN6/ +15Vdc voltage Supplies voltage CN8/1 CN8/3 +35Vdc CN8/4 CN8/3 +18Vdc CN8/5 CN8/3 +5Vdc LEDs L1 = ON -1Vdc power...
  • Page 25 9.2) POWER BOARD 15.14.244 DESCRIPTION This PC board contains the input rectfier bridge, the forward converter and the control logic. The main switch of forward power stage is implemented with eight MOSFET connected in paralleling (MF1,MF,MF3,MF4,MF6,MF7,MF8 and MF9). The MOSFET MF5 is the active clamp of the forward converter to get a quickly reset of the transformer and to better the performance of the power stage.
  • Page 26 Functional part Generator/ Component Test Point Value Type of Note Mode measure DC LINK R11/1 R11/ +35Vdc MOSFET +0.4Vdc FORWARD 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm +0.4Vdc 1kohm MOSFET +0.4Vdc 10kohm Pre-load relay Listen to the preloading relay tripping with a...
  • Page 27 RECTIFIER BRIDGE 14.10.150 REPLACEMENT PROCEDURE WARNING: Work with the power supply plug disconnected from the mains. If the rectifier bridge is found to have failed, it is recommended when replacing it: 1) Remove the filter board 15.14.43 2) Remove the power board 15.14.44 3) Remove the sheet of SILPAD insulation underneath the MOSFET MF5 (WARNING: The sheet of SILPAD insulation can NOT be re- used).
  • Page 28 POWER BOARD 15.14.244 REPLACEMENT PROCEDURE 1) Remove board 15.14.43 2) Remove screws S1, S, S3, S4, S5, S6, S7, S8, S9 and S10 which fix the power components and the rectifier bridge to the heat sink 3) Disconnect all the connected cables, paying special attention to remembering how they are connected. 4) Remove the board from the plastic support.
  • Page 29 9.3) SECONDARY BOARD 15.14.245 DESCRIPTION This board contains the secondary rectifier. INSTRUMENTS REQUIRED - Multimeter - Set of pipe spanners for exagonal nuts - Set of screwdrivers BOARD NOTE: Resistance R is not supplied with the 15.14.45 board. If board 15.14.43 is replaced, unsolder resistence R from the secondary board not in operation and solder it onto the new board...
  • Page 30 Functional part Generator/ Component Test Point Value Type of Note Mode measure Diodes +0.4Vdc With board removed +0.4Vdc With board +0.4Vdc removed +0.4Vdc +0.4Vdc With board +0.4Vdc removed With board +0.4Vdc removed +0.4Vdc Diode +0.4Vdc Resistence R 470ohm Notes: * Unless specified otherwise, all the measurements can suffer a variation + 10% ** The diode measurements on this board are made with the board disconnected from the rest of the circuit.
  • Page 31 9.4) DOUBLER BOARD 15.14.376 DESCRIPTION This board doubles the output voltage to optimise dynamic control of the arc and to ensure excellent arc striking in all welding conditions. INSTRUMENTS REQUIRED - Multimeter - Set of pipe spanners for exagonal nuts - Set of screwdrivers BOARD Functional part...
  • Page 32 9.5) FRONT PANEL BOARD 15.14.246 DESCRIPTION This board contains the switch to select MMA or TIG mode, the power supply led (green), the thermal protection led (yellow) and the po- tentiometer to adjust the output current beetween 0A and 145A. INSTRUMENTS REQUIRED - Multimeter - Set of pipe spanners for exagonal nuts...
  • Page 33 This voltage difference, of a few dozen mV, is proportional to the output current and is processed by the control logic present on board 15.14.43 to generate the reference signals for the power stage. The shunt of the Genesis 145 generator is illustrated in the figure below. Negative terminal of the SH-...

  • Page 34: Troubleshooting

    10 - TROUBLESHOOTING This section of the repair manual gives assistance with locating and repairing possible malfunctions in the welding machine. This can be done by following this simple procedure: 1) LOCATE THE PROBLEM: The FAULT column in the various tables describes possible malfunctions of the welding machine. The first step is to identify the description which is closest to the problem you have.
  • Page 35 10.1 - POWER SUPPLY UNIT FAILED OPERATION FLOW SIGNAL The welding machine is connected to the 30Vac 50/60Hz single-phase mains. When the input switch is closed, phase and neutral are connected to the welding logic and filter board 15.14.43. A varistor is connected between phase and neutral, i.e. a device protecting the downstream electronics against overvoltages.
  • Page 36 Fault Possible problem Suggestions The machine will not switch on 1. Faulty power supply cable or switch If the generator is connected to the 30Vac single-phase mains but this vol- tage is not found between input terminals M1/1 M1/, check the input switch, the terminal strip connections and the sup- ply cable.
  • Page 37 10.2 - FAN OPERATION FLOW SIGNAL The machine is cooled by a ventilation system consisting of a fan which runs constantly. The fan is supplied by a +15Vdc voltage provided by the switching feeder. BLOCK DIAGRAM Fault Possible problem Suggestions The fan will not start 1.
  • Page 38 10.3 - THERMAL ALARM OPERATION FLOW SIGNAL The generator is equipped with temperature control based on a temperature device T1. When the limit temperature is reached, the device opens the circuit and the machine enters the temperature alarm state with yellow LED illuminated and no power released. If the temperature device is broken, the machine remains in a temperature alarm state.
  • Page 39 10.4 - OPEN CIRCUIT VOLTAGE OPERATION FLOW SIGNAL The welding machine has a no-load voltage of about 50Vdc + 5Vdc. If this is not the case, the problem could lie in the feedback control. BLOCK DIAGRAM Fault Possible problem Suggestions Incorrect no-load voltage Lack of feedback signal If the control system does not read the ou-...
  • Page 40 10.5 - POWER PARTS CONTROL OPERATION FLOW SIGNAL The mainboard 15.14.44 contains the input rectifier bridge and the forward power converter. OPERATION FLOW SIGNAL Fault Possible problem Suggestions The main switch cuts off Rectifier bridge is broken Check the rectifier bridge according to the procedure on page 5.
  • Page 41 11) SPARE PART LIST...
  • Page 43 12) NOMINAL DATA Power supply voltage 50/60Hz 1x30Vac + 15% Max. absorbed power (x=35%) 4.65kW Max. absorbed current (x=35%) 31.1A Absorbed current (x=100%) 18.6A Absorbed current .50 (80A@40%) 9.A Absorbed current with 3.5 electrode (110 A @ 40%) Absorbed current with 17.8A 4.00 electrode (140 A @ 40%) Efficiency (x=100%)
  • Page 45 Selco s.r.l. – Via Palladio, 19 35010 Onara di Tombolo(Padova) – Italy Tel. +39 049 9413111 – Fax. +39 049 9413311 e-mail: info@selcoweld.com...

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