Selco Genesis 200 AC-DC Repair Manual
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Selco Genesis 200 AC-DC Repair Manual

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REPAIRS MANUAL
Genesis
200 AC-DC
Genesis
E
N
G
L
I
S
H
200 TLH
WU 15

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Summary of Contents for Selco Genesis 200 AC-DC

  • Page 1 REPAIRS MANUAL Genesis 200 AC-DC Genesis 200 TLH WU 15...

  • Page 2: Table Of Contents

    Tel. +39 049 9413111 Fax +39 049 9413311 e-mail: service.dept@selco.it All rights reserved. Copyright Selco s.r.l.. No part of this manual may be translated, reproduced or adapted by any means (including photocopying, filming and microfilming) without the written permission of Selco s.r.l.

  • Page 3: Guarantee Conditions

    Selco for relevant work. The purchaser is obliged to comply with the directions contai- ned in the manual. Failure to do so will result in Selco decli- ning all liability. Guarantee conditions - Purpose of the manual...

  • Page 4: Warnings, Precautions, General Information On Executing Repairs

    3) WARNINGS, PRECAUTIONS, GENERAL - Moving parts: INFORMATION ON EXECUTING REPAIRS WARNING!: Keep your hands well away from the fan when the machine is connected to the power lmminent danger of serious bodily harm and dange- supply. Make sure that the power plug is removed rous behaviours that may lead to serious bodily and that the fan is idle before replacing it.

  • Page 5: Diagnostics And Repair Instruments And Tools

    4) DIAGNOSTICS AND REPAIR INSTRUMENTS 4.3) Conventions AND TOOLS We have adopted a convention whereby, when you are asked 4.1) Instruments for basic diagnostics to take a measurement between two points, such as a the tip of the arrow always indicates where to apply the mul- You will need: timeter's red probe (a), whilst the black probe is applied to the other end (b).

  • Page 6: Wiring And Connection Diagrams

    5) WIRING AND CONNECTION DIAGRAMS 5.1) WU15 Wiring diagram (fig. 1) Review 28-04-98 QUESTO DISEGNO E' DI PROPRIETA' SELCO. SONO PROIBITE LA RIPRODUZIONE E LA DIFFUSIONE NON AUTORIZZATE. Wiring and connection diagrams...
  • Page 7 5.4) Connectors (fig. 5) Review 17-03-00 QUESTO DISEGNO E' DI PROPRIETA' SELCO. SONO PROIBITE LA RIPRODUZIONE E LA DIFFUSIONE NON AUTORIZZATE. Wiring and connection diagrams...
  • Page 8 5.5) Connections for central adapter and remote control connector (fig. 5 ) FRONT VIEWS CENTRAL TORCH ADAPTER REMOTE CONTROL 3 - 5 = Torch trigger A = EXT +V B = EXT GND C = EXT RIF D = - (not connected) E = - (not connected)
  • Page 9 5.5) RC12 - RC16 remote control wiring diagrams (fig. 6 ) RC12 Wiring diagram RC16 Wiring diagram Wiring and connection diagrams...

  • Page 10: Description Of Machine's Component Parts

    6) DESCRIPTION OF MACHINE'S PARTS (fig. 7) 6.1) x) front panel board (15.14.236) [FP122 for G200 AC-DC, In terms of electrics, power source Genesis 200 (AC-DC FP106 for G200 TLH] and TLH) is made up of the following parts: y) output resistor z) remote control connector a) master switch b) connector for cooling unit WU15...
  • Page 11 (fig. 8 ) 6.2) In terms of electrics, cooling unit WU15 is made up of the following parts. a) connector for connection to power source G200 b) 230Vac motor-powered fan c) 230Vac pump Description of machine's component parts...

  • Page 12: Description Of Diagnostic Indications

    7) DESCRIPTION OF DIAGNOSTIC INDICATIONS 7.1) EXTERNAL DIAGNOSTIC INDICATIONS FP 122 - GENESIS 200 AC-DC (fig. 9) FP 106 - GENESIS 200 TLH (fig. 10) Description of diagnostic indications...
  • Page 13 The front panel controls the status of the actual equipment, which is reported to the operator via the LEDs and display. See the owner's manual for meanings and use of the various controls as this section deals with diagnostic signals only. Power LED (GREEN) Indicates machine on/off status.
  • Page 14 If error code E10 appears, also check the three thermal cutout capsules illustrated in the following figures (fig. 11-12-13). Board 15.14.250 (fig. 11) Description of diagnostic indications...
  • Page 15 Board 15.14.256 (only for G 200 AC-DC) (fig. 12) G 200 TLH (fig. 13) Description of diagnostic indications...
  • Page 16 7.2) INTERNAL DIAGNOSTIC INDICATIONS Board 15.14.250 (fig. 14) Description of diagnostic indications...
  • Page 17 Internal diagnostic messages are supplied by the LEDs on board 15.14.250. The LEDs indicate operating status of the relevant part, as described in the table below: Meaning Status (in regular operating conditions) -15 Vdc supplied by 15.14.250 for 15.14.250 control section +15 Vdc supplied by 15.14.250 for 15.14.250 control section +5 Vdc supplied by 15.14.250 for 15.14.250...

  • Page 18: Set-Up Parameters

    8) SET-UP PARAMETERS Front panel settings are complemented by others that can be edited in the Setup, which is accessed as follows (also see fig. 9 and fig. 10 in sect. 7.1): - Switch unit off; wait a while (at least 10 seconds). - Switch unit on.

  • Page 19: Description Of Boards

    9) DESCRIPTION OF BOARDS The following sections illustrate regular work conditions of boards making up the power source, and furnish standard values for the electrical measurements that can be taken at the main points of said boards. All measurements indicated can be taken with a digital multimeter. Remember that testing should always start with a VISUAL INSPECTION! Visual inspection reduces the time spent troubleshooting and points any subsequent steps in the direction of the dama- ged part!
  • Page 20 9.2) MAIN-BOARD 15.14.250 (fig. 16) This board features the following circuits - UPFR preregulator - switching power supply - power inverter - welding current control Description of boards Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly...
  • Page 21 9.2.1) BOARD 15.14.250 "UPFR SECTION" (fig. 17) UPFR preregulator: supplies stabilized voltage (approx. 385Vdc) to electrolytic capacitors to power the power inverter. In addi- tion, this stage sees that current absorbed from the supply mains is sinusoidal (power factor = 0.99). Toroidal inductor L1 is also included in this stage (see point "f"...
  • Page 22 9.2.2) BOARD 15.14.250 "POWER SUPPLY SECTION" (fig. 18) Switching power supply: supplies auxiliary voltage required for the whole machine to work. Generally, the various voltages power circuits that are electrically insulated from each other (there is no ground shared by the whole machine). WARNING: before taking measurements described, open solder-jumper K2 with the machine unplugged! Power source / Mode Component...
  • Page 23 9.2.3) BOARD 15.14.250 "POWER INVERTER SECTION" (fig. 19) Full-bridge power inverter WARNING: before taking measurements described, open solder-jumper K2 with the machine unplugged! Note: solder-jumper K2 causes a break in the inverter's power supply circuit and is normally closed (it may be opened to test the power source;...
  • Page 24 9.2.4) BOARD 15.14.250 "WELDING CURRENT CONTROL SECTION" (fig. 20) Analogue adjustment circuits: control welding current (relevant logic system is located in panel board 15.14.236). WARNING: before taking measurements described, wait 5 minutes after switching off the power source and - with the machine unplugged - close solder-jumper K2! Note: solder-jumper K2 enables a limitation of the power source's open circuit voltage OCV, and is normally open (can be fac- tory set only).
  • Page 25 9.2.5) ASSEMBLY DIAGRAM FOR KIT 15.18.017 (BOARD 15.14.250 + POWER COMPONENTS) (fig. 21) WARNING! 1) Components sensitive to electrostatic discharges. 2) Torque wrench settings: FASTENING ON HEAT SINK = MAX 1.5 Nx m / 13 lb x in BOARD FASTENING = MAX 1.5 Nx m / 13 lb x in 3) Use layer of thermal grease 9.3) POWER INVERTER CAPACITORS BOARD 15.14.288 (fig.
  • Page 26 9.4) SECONDARY POWER UNIT 9.4.1) SECONDARY POWER UNIT G 200 AC- DC (fig. 24) This unit handles secondary power rectifying and AC switching. WARNING!: Before commencing the measurements described, make sure the HF board is disconnected from the bus board! Power source / Mode Test point Value...
  • Page 27 9.4.2) SECONDARY POWER UNIT G 200 TLH (fig. 25) This unit handles secondary power rectifying. WARNING!: Before commencing the measurements described, make sure the HF board is disconnected from the bus board! Power source / Mode Test point Value WARNING! +0.3 Vdc 1) Components sensitive to electrostatic discharges.
  • Page 28 9.5) AC STAGE CLAMP BOARD 15.14.256 (FOR G200 AC/DC ONLY) (fig. 26) This circuit is a filter for the AC stage. Description of boards Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly...
  • Page 29 9.6) BOARD BUS 15.14.285/15.14.315 (fig. 27) This is an interconnection board. F1 = 3.15A T 250Vac cooling unit protection (pump + fan) F2 = 3.15A T 250Vac superimposition board and HF board protection F3 = 2.5A T 250Vac fan protection CN1: wire n°...
  • Page 30 9.7) SUPERIMPOSITION AND AC CONTROL BOARD 15.14.253 (FOR G200 AC-DC ONLY) (fig. 28) This board generates superimposing and controls AC switching of the secondary IGBT module. Note (valid only for board 15.14.253 version 6 and higher): - solder-jumpers K1, K2 are closed (can be factory set only) - solder-jumper K3 is open (can be factory set only) WARNING: perform checks following steps 1 and 2 in the given order! WARNING: measurements indicated in the following table should be taken with board 15.14.253 disconnec-...
  • Page 31 This board generates series of very fast high-voltage pulses to facilitate TIG striking. Power source Genesis 200 TLH WHITE Genesis 200 AC-DC WHITE WARNING: perform checks following steps 1 and 2 in the given order! WARNING: measurements indicated in the following table must be taken directly on bus board 15.14.285 /15.14.315 once HF board 15.14.286 has been removed from the machine!
  • Page 32 9.9) OUTPUT FILTER BOARD 15.14.238 (fig. 30) This board performs filtering on the secondary to achieve EMC (just like the input board does on the primary - see section 9.1) and also filters out any disturbance from the torch trigger command owing to HF . Description of boards Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly...
  • Page 33 9.10) FRONT PANEL BOARD 15.14.236 (fig. 31) This pair of interconnected boards acts as a user interface, gives the gas solenoid valve and HF striking command, and provides operating logic and microprocessor control of the whole machine. Panel boards 15.14.236 have different factory settings depending on the version of the panel they are fitted on (FP106 for G200 TLH or FP 122 for G200AC/DC);...
  • Page 34 ENGLISH 10) FINAL INSPECTION OF POWER SOURCE 10.3) Check UPFR section on main-board 15.14.250 AND SETTINGS Conditions - Machine connected to 230Vac power supply, ON/OFF Precautions (also see chapter 3) switch set to "I". 1) live parts (bare wires, HF terminals, …) 2) moving parts (fan …) Checks 3) parts that get hot (heat sinks …)
  • Page 35 10.7) 10.9) Functional MMA tests Checking current delivered Conditions Conditions - Power source powered, MMA mode - Ammeter clamped on earth lead. - Electrode holder and earth lead connected - Power source on, set to TIG DC mode. - Welding circuit not connected to protection earth potential. Checks Checks - Perform various welding tests in TIG mode, making sure the...
  • Page 36 DEUTSCH 10) ENDPRÜFUNG DES GENERATORS UND Generator / Modus Farbe Status EIN /WIG* L1, L2, L3, L4, L5, L6, L7 Grün LEUCHTET EICHUNGEN EIN /WIG* L8, L9, L12 LEUCHTET Vorsichtsmaßnahmen (siehe auch Kapitel 3) NICHT 1) unter Spannung stehende Teile (blanke Leiter, HF- EIN /WIG* Grün BLINKT...
  • Page 37 - Den Verbinder CN5 von der Karte 15.14.250 (Thermostat Elektrodentyp grün grün T1) abtrennen und das Ansprechen des Wärmeschutzes Durchmesser überprüfen: Stromrichtung DC Aufleuchten der gelben Alarm-LED am vorderen Schaltfeld; Dauerstrom Alarmanzeige "E10" am Display; Pulsiert keine Leerlaufspannung im Ausgang. Mittelfrequenz Ja - CN5 wieder anschließen und prüfen, ob die Funktionalitäten Stromstärke...
  • Page 38 FRANÇAIS 10) ESSAI FINAL DU GÉNÉRATEUR ET RÉGLAGES Générateur/ Mode Couleur Etat ALLUME / TIG* L1, L2, L3, L4, L5, L6, L7 Verte ALLUMEE Précautions à prendre (voir également au chapitre 3) ALLUME / TIG* L8, L9, L12 Rouge ETEINTE 1) parties sous tension (conducteurs sans gaine, cos- ALLUME / TIG* Verte...
  • Page 39 - Débrancher le connecteur CN5 de la carte 15.14.250 (ther- Type d'électrode rouge rouge verte verte mostat T1) et vérifier s'il y a intervention de la protection Diamètre thermique: Polarité allumage de la DIODE jaune "Alarme" sur le panneau frontal; Cour.
  • Page 40 ESPAÑOL 10) PRUEBA FINAL DEL GENERADOR Y CALIBRACIONES Generador / Modo Color Estado ENCENDIDO/TIG * L1, L2, L3, L4, L5, L6, L7 Verde ENCENDIDO Precauciones (ver también el capítulo 3) ENCENDIDO/TIG * L8, L9, L12 Rojo APAGADO 1) partes bajo tensión (conductores pelados, termi- ENCENDIDO/TIG * L10 Verde RELAMPAGUEA...
  • Page 41 - Desconectar el conector CN5 de la tarjeta 15.14.250 (ter- Tipo electrodo Rojo Rojo Verde Verde mostato T1) y verificar la intervención de la protección tér- Diámetro mica: Polaridad encendido LED amarillo "Alarma" en el panel frontal; Corr. constante SÍ SÍ...

  • Page 42: Available Spare Parts

    11) AVAILABLE SPARE PARTS 11.1 GENESIS 200 AC-DC (fig. 32) Available spare parts...
  • Page 43 Available spare parts...
  • Page 44 11.2 GENESIS 200 TLH (fig. 33) Available spare parts...
  • Page 45 Available spare parts...
  • Page 46 WU 15 (fig. 34) ITALIANO ENGLISH DEUTSCH POS.DESCRIZIONE CODICE POS.DESCRIPTION CODE POS.BESCHREIBUNG CODE Pannello laterale destro 01.03.027 Right side panel 01.03.027 Seitenteil re 01.03.027 Pannello laterale sinistro 01.03.026 Left side panel 01.03.026 Seitenteil l' 01.03.026 Innesto rapido H2O 19.50.043 Quick coupling H2O 19.50.043 Schnellkupplung H2O 19.50.043...
  • Page 47 GENERATOR TROLLEY 1 CYLINDER (fig. 35) ITALIANO ENGLISH DEUTSCH POS.DESCRIZIONE CODICE POS.DESCRIPTION CODE POS.BESCHREIBUNG CODE Carrello portageneratore GT 18 71.03.019 Generator trolley GT 18 71.03.019 Gerätewagen GT 18 71.03.019 Fondo completo carrello GT 18 02.07.040 Bottom GT 18 02.07.040 Unterteil GT 18 02.07.040 Ruota fissa PBF 180 04.04.003...

  • Page 48: Technical Dates

    12) TECHNICAL DATES TECHNICAL CHARACTERISTICS G 200 TLH G 200 AC/DC Supply voltage (50/60 Hz) 1x230V ± 15% 1x230 V ± 15% 4.9 kW 5.3 kW Max. absorbed power in TIG (x=40%) Max. absorbed current in TIG (x=40%) 21.8 A 23.4 A Absorbed current in TIG (x=100%)

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