Selco Genesis 240 Repair Manual

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REPAIRS MANUAL

Genesis

240 TLH

240

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Summary of Contents for Selco Genesis 240

Page 1 REPAIRS MANUAL Genesis Genesis 240 TLH...
Page 2: Guarantee Conditions
1) GUARANTEE CONDITIONS. SELCO s.r.l. INDEX : 1) GUARANTEE CONDITIONS 2) PURPOSE OF THE MANUAL 3) MACHINE TECHNICAL SPECIFICATIONS 4) DESCRIPTION OF MACHINE PARTS 5) DESCRIPTION OF MACHINE OPERATION LAY-OUTS OF CARDS 6) DESCRIPTION OF DIAGNOSTIC INDICATIONS : - EXTERNAL...
Page 3: Purpose Of The Manual
3) MACHINE TECHNICAL SPECIFICATIONS . 2) PURPOSE OF THE MANUAL GENESIS 240 NOTE * GENESIS 240 TLH * NOTE : does not WU15...
Page 4: Description Of Machine Parts
FIG. 1 4) DESCRIPTION OF MACHINE PARTS. (see fig. 1)
Page 5 FIG. 2 (see fig. 2)
Page 6: Description Of Machine Operation
FIG. 3 5) DESCRIPTION OF MACHINE OPERATION. NOTE : 5.1) (see fig. 3-4) IMPORTANT !: When accessing parts inside the machine, remember that turning off the switch will not prevent the danger of electric shocks. We the- refore advise you to remove the power plug.
Page 7 FIG. 4 NOTE :...
Page 8 FIG. 5 5.2) (see fig. 5-6)
Page 9 FIG. 6...
Page 10 FIG. 7 5.3) (see fig. 7-8)
Page 11 FIG. 8...
Page 12: See Fig.
FIG. 9 5.4) in TIG (LIFT) : (see fig. 9-10) in MMA :...
Page 13 FIG. 10 in MMA : in TIG (lift) : in TIG (H.F.) :...
Page 14 FIG. 11 5.5) (see fig. 11-12)
Page 15 FIG. 12 Parameter Note predef.
Page 17 FIG. 13 5.6) (see fig. 13)
Page 18 FIG. 14 5.7) (see fig. 14)
Page 19 FIG. 15 5.8) (see fig. 15-16-17)
Page 20 FIG. 16 FIG. 17...
Page 21 NOTE : FIG. 18 FIG. 19 15.14.240...
Page 22 LAY-OUTS OF CARDS...
Page 23 Card 15.14.233 (Fig. 20)
Page 24 Card 15.14.236 side A (Fig. 21)
Page 25 Card 15.14.236 side B (Fig. 22)
Page 26 Card 15.14.236 side C (Fig. 23)
Page 27 Card 15.14.254 side A (Fig. 24)
Page 28 Card 15.14.254 side B (Fig. 25)
Page 29 Card 15.14.254 side C (Fig. 26)
Page 30 Card 15.14.254 side D (Fig. 27)
Page 31 Card 15.14.192 (Fig. 28)
Page 32 Card 15.14.239 (Fig. 29)
Page 33 Card 15.14.240 (Fig. 30)
Page 34: Description Of Diagnostic Indications
FIG. 31 6) DESCRIPTION OF DIAGNOSTIC INDICATIONS. YELLOW led: 6.1) see fig. n°31 Position Colour Status under Meaning normal then either conditions GREEN LED: then then either...
Page 35 FIG. 32 (see fig. 32) Code Meaning Position Colour Status under Meaning normal conditions then then either...
Page 36 Card 15.14.254 (FIG. 33) 6.2) L2 : if then IMPORTANT!: these indications are present only from version 2 onwards of board 15.14.254 which can be identified by following the instructions in point 10.2. then see fig. n°33 Position Status in normal Meaning L3 : if conditions...
Page 37: Available Spare Parts
TAB. 01 GENESIS 240 SPARE PARTS 7) AVAILABLE SPARE PARTS Pos. Description Code (see TAB. 01) NOTES :...
Page 38 TAB. 02 (see TAB. 02) GENESIS 240 TLH SPARE PARTS Pos. Description Code NOTES :...
Page 39: Warnings, Precautions, General Information On Executing Repairs
8) WARNINGS, PRECAUTIONS, GENERAL 9) DIAGNOSTICS AND REPAIR INSTRUMENTS INFORMATION ON EXECUTING REPAIRS. AND TOOLS. 9.1) 9.1.1) NOTE : NOTE : IMPORTANT!: When accessing parts inside the machine, remember that turning off the switch will not prevent the danger of electric shocks. We the- 9.1.2) refore advise you to remove the plug and wait for about a minute before attempting any job.
Page 40: Diagnosis Procedure
For G 240 and G 240 TLH, with reference to the SELCO normalised loads (see TAB. 03), loads 3, 4, 5, 6 and 8 are required selected, depending on current, accor- 10.2)
Page 41 15.14.234. For the machines in this batch the procedure does not apply: they must be sent to SELCO for repair. The board code is given on the board itself in the area indi- cated in figure 34.
Page 42 Card 15.14.254 (soldering side) FIG. 35A Card 15.14.254 (soldering side) FIG. 35B...
Page 43: Level
10.3) (see from fig. 36 to 43 ) G 240 : (level 1 and 2) NOTE : secondary power diodes checking procedure. NOTE :...
Page 44 power supplies checking procedure power inverter checking procedure (Important! Red cable to screw + and black cable to screw -). current adjustment circuits checking procedure.
Page 45 G 240 TLH : NOTE :...
Page 47 power supplies checking procedure power inverter checking procedure Important! Red cable to + screw and black cable to -screw power inverter checking procedure secondary power diodes checking procedure IMPORTANT! When taking this measurement, make sure that MMA operating mode has been selected. The TIG H.F.
Page 48 Check procedure for power inverter. NOTE: does not always accurate visual check level 2 diagnostics IMPORTANT!: breakage of the inverter can cause breakage of the input rectifier bridge and you are therefore advi- sed to follow the diagnostic phases in the sequence given in this manual. (level 1) (level 2) NOTE :...
Page 49 Check procedure of secondary power diodes. (level 1 and 2)
Page 50 Check procedure for power supplies G 240 : (level 1 and 2) Position Status in normal Meaning conditions...
Page 51 G 240 TLH : Position Status in normal Meaning conditions...
Page 52 Check procedure for current control circuits G 240 : (level 1 and 2) Selector in TIG Selector in MMA mode mode Colour Normal status Meaning Position Status in normal Meaning conditions (Caution: in the static load test the load must be adapted to the different currents. Adaptation to currents below 30A is difficult)
Page 53 power supplies checking procedure (level 2)
Page 55 G 240 TLH : (level 1 and 2) Colour Status in normal Meaning conditions Position Status in normal Meaning conditions NOTE power supplies checking procedure...
Page 56 (level 1 and 2)
Page 57 H.F. generation circuit checking procedure (level 1 and 2)
Page 58 J9 connector (frontal side) FIG. 36 Card 15.14.192 (FIG. 37)
Page 59 FIG. 38 Card 15.14.233 FIG. 39...
Page 60 Card 15.14.254 version 1 - soldering side (FIG. 40A)
Page 61 Card 15.14.254 version 2 - soldering side (FIG. 40B) soldering side view...
Page 62 Card 15.14.236 (FP106) FIG. 41...
Page 63 H.F. 15.14.192 wring diagrama (FIG. 42) FIG. 43...
Page 64 Oscillogram 1 Oscillogram 2...
Page 65 Oscillogram 3 Oscillogram 4...
Page 66 Oscillogram 5 Oscillogram 6...
Page 67 Oscillogram 7 Oscillogram 8...
Page 68 Oscillogram 9 Oscillogram 10...
Page 69 Oscillogram 11...
Page 70 11) PARTS DISMANTLING AND RE-INSTALLATION 11.6) PROCEDURE . (see fig. 44 a 48) G 240 : 11.7) 11.1) IMPORTANT ! : Don't forget to fix the yellow-green cable to the cover before refitting the cover definitively. 11.2) IMPORTANT! When replacing the metal base, ensure that you fit the plastic protection between the rectifier unit radiator and the base itself.
Page 71 11.9) 11.14) 11.10) 11.15) IMPORTANT! To insert the component correctly as indicated in point 14, the component terminals must be correctly identified using a tester set to diode 11.16) testing. NOTE : 11.11) 11.17) 11.12) 11.18) 11.13) 11.19) 11.20)
Page 72 G 240 TLH : 11.21) 11.22) IMPORTANT! When mounting the front nipple, use only LOCTITE 577 joint sealing compound or ordinary TEFLON sealing tape. 11.23)
Page 73 FIG. 44...
Page 74 FIG. 45...
Page 75 FIG. 46 FIG. 47...
Page 76 FIG. 48...
Page 77 12) OPERATING TESTS AND SETTINGS. G 240 : 12.1) 12.2) IMPORTANT ! : When you have executed a setting (e.g. of minimum current), make sure that the other setting (maximum current) is constantly maintained at the set value. A couple of checks are usually enough to consider setting completed.
Page 78 G 240 TLH : 12.1) 12.2) 12.3)
Page 79 Card 15.14.239 (FIG. 49)
Page 80 Card 15.14.254 (FIG. 50)
Page 81 FP106 (FIG. 51)
Page 82 13) TELEPHONE ASSISTANCE REQUEST PROCEDURE...

Selco Genesis 240 Repair Manual

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