Selco Genesis 90 Repair Manual
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Selco Genesis 90 Repair Manual

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REPAIRS MANUAL
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  • Page 1 REPAIRS MANUAL Genesis...

  • Page 2: Table Of Contents

    All translation, reproduction and adaptation rights, total or partial and by any means (including photostat copies, films and micro films), are reserved and forbidden without the written authorisation of Selco S.r.l. INDEX : 1) PURPOSE OF THE MANUAL ............. . .3 2) WARNINGS, PRECAUTIONS AND GENERAL NOTICES FOR PERFORMING REPAIRS .

  • Page 3: Purpose Of The Manual

    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 dama- ge to things that may occur during performance of repairs, even after reading or practical application of this manual.

  • Page 4: Warnings, Precautions And General Notices For Performing Repairs

    2) WARNINGS, PRECAUTIONS AND GENERAL Moving parts: CAUTION ! Keep your hands well away from the NOTICES FOR PERFORMING REPAIRS fan when the machine is connected to the power supply. Ensure that the machine is unplugged and Repairs must be performed by qualified personnel only. that the fan is at a standstill before replacing it.

  • Page 5: Instruments And Conventions For Performing Diagnosis And Repair

    3) INSTRUMENTS AND CONVENTIONS FOR PERFOR- 3.3) Grid load MING DIAGNOSIS AND REPAIR Use of grid load can speed up fault tracing and machine testing. Just remember that a fixed power resistor applied to machine's 3.1) Instruments for basic diagnosis output is somewhat equivalent to a welding arc, but only inside of a narrow output voltage range, whose center value can be The following are required:...
  • Page 6 In the event of difficulty, con- tact Selco Service. Remember that the first of the tests to be perfor- med is the VISUAL CHECK!

  • Page 7: Description Of Operation Of The Power Sources

    4) DESCRIPTION OF OPERATION OF THE POWER SOURCES Use and routine maintenance (excerpt from the "Instructions for use" manual provided with each power source). 4.1 SAFETY WARNING 4.1.3 Protection against fumes and gases Prior to performing any operation on the machine, make sure that you Fumes, gases and powders produced during the welding (cutting) have thoroughly read and understood the contents of this manual.
  • Page 8 4.2 ELECTROMAGNETIC COMPATIBILITY (EMC) WARNING This device is built in compliance with the indications contained WELDING AND CUTTING CABLES in the harmonized standard EN60974-10, to which the opera- The welding (cutting) cables must be kept as short as possible, tor must refer for the use of this apparatus. positioned near one another and laid at or approximately at - lnstall and use the apparatus keeping to the instructions ground level.
  • Page 9 The Genesis ying the set current. Vice versa if you begin cutting within 5 60 and Genesis 90 are provided with an automatic pilot arc re- sec., the voltage is displayed during the entire cutting opera-...
  • Page 10 The equipment is provided with a single electric connection with a 5m cable positioned in the rear part of the power source. Fig.2 Size table of the power source input cables and fuses: Power source GENESIS 90 4.4.3 Technical characteristics Rated voltage 400 V ±15% Voltage range...
  • Page 11 4.6.2 Connecting the equipment components 7. Press for a moment the torch button so as to generate the pilot arc; release the control, checking the machine is cor- Keep to the safety regulations contalned in sec- rectly operating with the display panel. It is advisable not to tion “4.1SAFETY”.
  • Page 12 4.8.2 Possible electrical failures 4.10 THEORETICAL OUTLINE OF PLASMA CUTTING Fault Cause A gas assumes the plasma state when it is brought to an extre- Apparatus fails to come on - Incorrect mains supply mely high temperature and ionizes wholly or partly, thus beco- (Yellow LED L1 off) ming electrically conductive.
  • Page 13 GENESIS 90 MILD STEEL Thickness (mm) Current (A) Speed (mm/min) 3400 12000 3300 1550* 20000 6300 Fig. 6 3200 1500 650* 400* 250* STAINLESS STEEL Thickness (mm) Current (A) Speed (mm/min) 2500 14000 3200 1200* 21000 Fig. 7 7200 3200...
  • Page 14 A-90 TORCH Tip diameter Range of current usable Tip Ø 1.1 22÷60A 4.13 TECHNICAL CHARACTERISTICS Tip Ø 1.4 40÷90A Tip Ø 1.7 80÷140A Principle of operation Ignition of pilot arc with high Tab. 1 Choice of appropriate tip frequency Version Monogas (air or nitrogen) 4.16 USING THE TORCH Protection device...

  • Page 15: Operating Principle - Block Diagram

    5) OPERATING PRINCIPLE - BLOCK DIAGRAM General overview EMI input filter Three phases input rectifier Smoothing capacitor Quasi-resonant full bridge inverter Snubbing inductor Primary current transformer Resonant inductor Power transformer Secondary power rectifier Pilot arc IGBT Hall effect probe (cutting current) Output filter Auxiliary multi-output switching power supply Resonant inverter logic...
  • Page 16 Quasi-resonant full bridge power inverter * Note: due to resonant topology of primary power inverter, - 30kHz switching frequency* switching frequency is not constant: it varies in [27 ... 33]kHz Fast response welding current loop range, depending on actual output power; due to full bridge High stability welding arc topology, secondary rectifier works at double inverter frquency, that is 55...65kHz, thus allowing a very precise arc...

  • Page 17: Wiring And Connection Diagram

    6) WIRING AND CONNECTION DIAGRAM 6.1) Genesis 90...
  • Page 18 6.2) Connections for torch FRONT VIEW torch cap protection common (protection and torch button) trigger 7, 8 pilot arc Wiring and connection diagrams...

  • Page 19: Pc Boards' Location

    7) PC BOARDS’ LOCATION PC boards’ location...
  • Page 20 PC boards’ location...

  • Page 21: 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. The Genesis 90 automatically compensates for the variations in power supply voltage, i.e. variations of ±15% with respect to the rated power supply voltage do not produce significant variations in the cutting current.
  • Page 22 D1/D2 Display At switch-on, the power source performs an autotest during which the D2 display shows the size of the power source "90"; imme- diately after, the D2 display briefly indicates the software version installed (e.g. 1.0). The D1 display indicates the cutting current required by the operator and immediately after striking of the arc goes to reading mode, providing the actual value of the current or the voltage delivered.
  • Page 23 8.2) Internal diagnostic indications Meaning Status under normal conditions +30Vdc Torch protection and button circuit supply +24Vdc Power supply (not used) -24Vdc Power supply (not used) +26Vdc Main positive auxiliary power supply +10Vdc µP logic power supply -20Vdc Main negative auxiliary power supply +12VAUX +12Vdc Primary Logic power supply Alarm: phase lack!
  • Page 24 8.3) Thermal devices connectors locations Description of diagnostic indications...
  • Page 25 Description of diagnostic indications...

  • Page 26: Setup Parameters

    9) SETUP PARAMETERS The settings on the front panel of G90 are increased by the settings in Setup which can be accessed in the following way (see also figure in section 8.1): - Switch on the unit. - The machine performs a self-test during which only the supply green LED stays on, then the generator's type is displayed ("Gen 90") followed by the panel's software version (i.e.

  • Page 27: Description, Testing And Replacement Of The Electronic Boards, Current Calibration

    10) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS, CURRENT CALIBRATION Introduction Malfunctioning of a machine can be due to various causes. Firstly you should check that the machine has been correctly installed and connected to the power supply (use of motor genera- tor, extensions, plugs, presence of other large-size equipment that can interfere with the electrical power supply, etc.).
  • Page 28 Remember that the first test to be performed is the VISUAL CHECK! The visual check reduces troubleshooting times and directs any subsequent tests towards the damaged part! In general, points to be visually checked are: - input filter area - traces of smoke on the inside of the bonnet - power and signal connections - overall condition of the boards Caution: when the machine is connected to the power supply, the main switch is live, regardless of its status (open or...

  • Page 29: Input Filter Pc Board 15.14.269

    10.1) Input filter PC board 15.14.269 This board performs the following functions: - EMC input filter - power input rectifier - power source voltages supervision - isolated auxiliary power sources for the various machine circuits (see table on following page) - fan and gas solenoid valve power supply - the signals for the Hall probe and torch button pass through this board.
  • Page 30 Functional part Generator/Mode Component Test point Value Notes Input rectifier PR1 / PR2 PZ_U + 0.5Vdc PZ_V + 0.5Vdc PZ_W + 0.5Vdc PZ_U + 0.5Vdc PZ_V + 0.5Vdc PZ_W + 0.5Vdc + 0.7Vdc + 0.6Vdc Input voltage PZ_U PZ_V 400Vac ± 15% PZ_U PZ_W 400Vac ±...

  • Page 31: Power Supply Pc Board 15.14.271

    10.2) Power supply PC board 15.14.271 This board performs the following functions: - auxiliary power supplies of all the boards = HF PC board power supply CN2/1 = synchronization signal from main clock generator PZGNDL = ground connection to Input Filter PC Board, well tighten screw needed Fusible Value Protected circuit...
  • Page 32 Functional part Generator/Mode Component Test point Value Notes Input fuse 0 Ω 2A 250Vac GT * Output fuses 0 Ω 1A 250Vac T 0 Ω 1A 250Vac T 0 Ω 1A 250Vac T 0 Ω 1A 250Vac T 0 Ω 1A 250Vac T 0 Ω...

  • Page 33: Power Inverter Pc Board 15.14.176

    10.3) Power inverter PC board 15.14.176 This board performs the following functions: - power inverter Power IGBT module (IG1 & IG2) replacing instructions: - MOUNTING & TERMINALS: use torque screw driver @ 3 Nxm (26 lbxin) - use thermal grease as necessary. Anyway, in case of inverter failure use of replacement kit 14.60.069 is suggested (see also "PC Boards location"...
  • Page 34 Functional part Generator/Mode Component Test point Value Notes Full bridge inverter C2-E1 0.40 Vdc C2-E1 0.40 Vdc 10kΩ 10kΩ C2-E1 0.40 Vdc C2-E1 0.40 Vdc 10kΩ 10kΩ Resonant snubber 0.40 Vdc 0.40 Vdc 0.40 Vdc 0.40 Vdc 0.40 Vdc 0.40 Vdc MF1 (G CN6/5 CN6/6...
  • Page 35 CHECKING THE INVERTER AND SECONDARY RECTIFIER OPERATION To test the operation of the inverter and secondary power rectifier safely, follow the following procedure: - disconnect the power cables from C1 ("+" red) and E2 ("-" black) of IG2 and tighten the screws again - isolate the 2 free connections coming from the levelling capacitor - power the inverter power stage with an insulated external power supply source at low voltage and limited current (protected against short circuits)

  • Page 36: Resonant Inverter Control Pc Board 15.14.152

    10.4) Resonant inverter control PC board 15.14.152 This board performs the following functions: - resonant inverter control logic - welding current reading Soldered jumpers (factory setted): Dip-switch (factory setted): K1 = OPEN DS1 G90 Functional part Generator/Mode Componente Test point Valore Note Aux.

  • Page 37: Inveter Driver Pc Board 15.14.200

    10.5) Inveter driver PC board 15.14.200 This board performs the following functions: - driving of resonant inverter power components Soldered jumpers (factory setted, all located on solder side of PC Board): K1 = CLOSED K2 = CLOSED K3 = CLOSED K4 = CLOSED K5 = CLOSED K6 = CLOSED...

  • Page 38: Output Filter Pc Board 15.14.276

    10.6) Output filter PC board 15.14.276 This board contains a series of EMC filters, the Hall-effect current probe and two interface relays for the RL1 torch button and RL2 torch protection. WARNING! PZ_PE must always be earthed! Functional part Generator/Mode Component Test point Value...

  • Page 39: Secondary Rectifier And Pilot Arc Pc Board 15.14.277

    10.7) Secondary rectifier and pilot arc PC board 15.14.277 Power diodes module and IGBT replacing instructions : - MOUNTING COMPONENTS ON HEATSINK: use torque screw driver @ 1.7 Nxm (15 lbxin) - PC BOARD MOUNTING: use torque screw driver @ 1.5 Nxm (13 lbxin) - use thermal grease as necessary.

  • Page 40: Hf Pc Board 15.14.192

    10.8) HF PC board 15.14.192 This board generates HF high voltage impulses to strike the pilot arc. Functional part Generator / Mode Component Test point Value Notes Auxiliary power +0.5Vdc supplies 10kΩ 10Ω HF output 25Ω +0.5Vdc Power supply CN2/1 CN2/4 +250Vdc voltage...

  • Page 41: Control Panel Pc Board 15.22.131 (15.14.259 Pc Board + Fp131)

    10.9) Control panel PC board 15.22.131 (15.14.259 PC board + FP131) This board performs the following functions: - microprocessor control of all the machine - air pressure control (board-mounted pressure switch) CAUTION! - PZ2 must always be electrically connected to protection earth! Dip-switch (factory setted): DS1 G90 NOTE:...
  • Page 42 Functional part Generator / Mode Component Test point Value Notes Auxiliary power CN6/2 CN1/12 +10Vdc supplies L1 = LIT CN1/12 +5Vdc F1 = 1AT CN1/1 CN1/12 +15Vdc CN1/7 CN1/12 -15Vdc CN1/12 +5Vdc Alarm power supplies L5 = OFF (overvoltage, undervoltage, L5 = LIT in alarm no phase)

  • Page 43: Output Current Calibration (Delivered And Displayed)

    10.10) Output current calibration (delivered and displayed) WARNING! Calibration of the generator's output current must be performed preferably with a static load! The generator can also be calibrated while cutting but in this case two people are needed: spark on a 4-5mm thick suitably sized piece of iron and continue cutting at a moderate and regular speed;...
  • Page 44 To perform calibration of the power source, follow the procedure below: 1. Be sure to have correctly replaced the damaged part and that the unit has been correctly repaired & tested (if replacing the reso- nant logic board 15.14.152, check correct setting of the dip switches DS1). 2.

  • Page 45: Available Spare Parts

    11) AVAILABLE SPARE PARTS 56.01.090 GENESIS 90 Available spare parts...
  • Page 46 Available spare parts...
  • Page 47 SELCO s.r.l. - Via Palladio, 19 - 35010 ONARA DI TOMBOLO (PADOVA) ITALY Tel. +39 049 9413111 - Fax +39 049 9413311 - http://www.selcoweld.com - E-mail:info@selco.it SELCO 2 - Via Macello, 61 - 35013 CITTADELLA (PADOVA) ITALY...

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