Selco Genesis 35 Repair Manual
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Selco Genesis 35 Repair Manual

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REPAIRS MANUAL
Genesis 35
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Summary of Contents for Selco Genesis 35

  • Page 1 REPAIRS MANUAL Genesis 35...

  • Page 2: Table Of Contents

    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: Purspose 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 damage 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 NO- TICES 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: Instruments And Conventions For Performing Diagnosis And Repair

    3) INSTRUMENTS AND CONVENTIONS FOR PER- 3.3) CONVENTIONS. By convention, when a measurement has to be taken between two FORMING DIAGNOSIS AND REPAIR 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: PLASMA CUTTING: = 80 + 0.04 x I...

  • Page 7: Use And Routine Maintenance Of Power Sources And Accessories And Technical Dates

    4) USE AND ROUTINE MAINTENANCE OF POWER SOURCES AND ACCESSORIES, TECHNICAL DATES Use and routine maintenance (excerpt 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: Machine Description

    L6: low air pressure alarm. in the thickness of the metal to be cut. The Genesis 35 is equipped Means that the pressure of compressed air is below 3.5 bar, with an automatic circuit for the reignition of the pilot arc, that al- too low for proper functioning.
  • Page 10 5.6.2) Commissioning Fig. 3 - Genesis 35 socket panel A1: torch fitting. Permits connection of the PLASMA torch. Fig. 4 - SP45 torch P1: earth socket.
  • Page 11 5.6.3) Using the torch * Check the temperature of the component and make sure that they are not overheated. 5.6.3.1) Inclination and speed of the torch during cutting * Always use gloves in compliance with the safety standards. The torch is generally held perpendicular to the workpiece during * Use suitable spanners and tools.
  • Page 12 5.7) TECHNICAL SPECIFICATIONS 5.7.1) Generator Power supply voltage (50/60 1x30V Release the hose clamp (G) and pull out the hose. Delayed fuse Rated power 3.75kW Cutting current 35 A (x=35%) 5 A (x=100%) Cutting voltage (x=100%) No-load voltage 53V Pilot arc current Remove the cable clamp and gus- Operating pressure 5 bar...

  • Page 13: Description Of Generator Functioning (Block Diagram)

    6) DESCRIPTION OF GENERATOR FUNCTIONING (BLOCK DIAGRAM) Genesis 35 block diagram a) Master switch b) Input filter c) Varistor d) Rectifier bridge e) Bus capacitor f) Power stage ( Zero Voltage Switching full bridge inverter) g) Power transformer h) Output rectifier...
  • Page 14 6.1) INPUT FILTER WARNING The single-phase power supply voltage 30Vac – 50/60Hz is fed to the input filter board 15.14.371. A varistor is inserted between the two phases, i.e. an electronic com- When accessing parts inside the machine, remember that ope- ponent which when an instantaneous voltage of a value higher than ning the circuit-breaker does not prevent the danger of electric 75V appears on its terminals, starts to conduct extremely quickly,...
  • Page 15 6.2) RECTIFIER BRIDGE 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 16 The inverter provided by Selco for the Genesis 35 machines is a resonant inverter of the Zero Voltage Switching type. Therefore, the...
  • Page 17 6.4) OUTPUT STAGE The AC voltage/current generated by the inverter stage and supplied to the secondary are fed to a rectifier which carries out the final AC/DC power conversion. The power is now available for the cutting process and during the operation the current is keeping costant to set value until power supply is in the nominal range.
  • Page 18 6.5) SWITCHING FEEDER The mainboard 15.14.370 has a switching power supply in Flyback configuration, which generates DC supply voltages for the different boards. The following voltages are generated: +4Vdc, +15Vdc, +1Vdc, -15Vdc. The power supply input voltage is a continuous DC LINK voltage of +35Vdc.

  • Page 19: Wiring And Connectin Diagram

    7) WIRING AND CONNECTION DIAGRAM...
  • Page 22 N° Filo Descrizione Description Wire Fase U Phase U Neutro N Neutral N ALT1 Fase U dopo l’interruttore Phase U after switch ALT Neutro N dopo l’interruttore Neutral N after switch ALT11 Fase U dopo il filtraggio Phase U after input filter ALT Neutro N dopo il filtraggio Neutral N after input filter...

  • Page 23: Description Of Diagnostic Indications

    8) DESCRIPTION OF DIAGNOSTIC INDICATIONS 8.1) EXTERNAL DIAGNOSTIC INDICATIONS ALIMENTAZIONE ALLARME POTENZA D’USCITA (POWER SUPPLY) (ALARM) (OUTPUT POWER ENABLE) ALLARME TERMICO (THERMAL ALARM) ALLARME PROTEZIONE CAPPUCCIO TORCIA (TORCH PROTEC- TION ALARM) LED PULSANTE TEST GAS ALLARME PRESSIONE ARIA (LED GAS TEST PUSH BUTTON) (LOW AIR PRESSURE ALARM) POWER SUPPLY LED (GREEN) Indicates the on/off status of the machine.
  • Page 24 8.1) INTERNAL DIAGNOSTIC INDICATIONS L1 - +24V voltage supply LED L4 - -15V voltage supply LED Indicates the presence of +4V voltage power supply generates Indicates the presence of -15V voltage power supply generates by by switching feeder. switching feeder. L2 - +15V voltage supply LED L5, L6, L7 ed L8 - Driver switching feeder LED.

  • Page 25: Description, Testing And Replacement Of The Electronic Boards, Current Calibration

    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 26 9.1) INPUT FILTER BOARD 15.14.371 DESCRIPTION This board filters the input power supply for the purpose of EMC and contains the varistor, which protects the electronics from input over- voltage. The DC LINK voltage-balancing capacitors are also mounted on this board. INSTRUMENTS REQUIRED - Set of screwdrivers - Multimeter...
  • Page 27 9.2) ISOTOP BOARD 15.14.418 DESCRIPTION The board has two primary side inverter diodes, which are contained inside a power module connected to the dissipator. INSTRUMENTS REQUIRED - Set of screwdrivers - Multimeter BOARD Functional part Generator/ Component Test Point Value Type of Note Mode...
  • Page 28 9.3) MAINBOARD 15.14.370 DESCRIPTION The following circuit are present on this board: - Input rectifier bridge. - Switching feeder to generate the following DC voltage -15Vdc, +5Vdc, +15Vdc e +4Vdc. - Power inverter. - Output rectifier bridge (test it on board 15.14.404) - Control logic of the inverter.
  • Page 29 R4/2 R4/1 R10/1 R10/2 ALT10 ALT20 PTC1 PTC2 Gate resistance L7 L8 ed R...
  • Page 30 This measures must be done with generator OFF Functional part Generator/ Component Test Point Value Type of Notes mode measure Rectifier bridge ALT10 +0.4Vdc ALT0 +0.4Vdc ALT10 +0.4Vdc ALT0 +0.4Vdc Inverter 4.7kohm 4.7kohm 4.7kohm 4.7kohm +0.4Vdc +0.4Vdc +0.4Vdc +0.4Vdc PTC1 PTC1/1 PTC1/ 75ohm...
  • Page 31 This measures must be done with generator OFF Functional part Generator/ Component Test point Value Type of Note Mode measure Voltage supply ALT10 ALT0 30Vac + 15% DC LINK +35Vdc + 15% Power supplies L1 = ON +4Vdc voltage supply LED +15Vdc_ISO volta- L= ON ge supply LED...
  • Page 32 R4/1 R4/2 R10/1 R10/2...
  • Page 34 ISTRUzIONE D’USO DEI KIT INSTRUCTIONS FOR USE OF KITS (Sostituzione del diodo secondario e monoscheda) (Replacement of secondary rectifier diode) ATTENzIONE CAUTION - COMPONENTI SENSIBILI ALLE SCARICHE ELETTROSTATI- - COMPONENTS SENSITIVE TO ELECTROSTATIC DISCHARGE CHE! - WHENEVER YOU DISSAMBLE THE MAINBOARD FROM DIS- - OGNI VOLTE CHE SI SMONTA LA MONOSCHEDA DAL DIS- SIPATOR, REPLACE THE THERMIC INTERFACE WITH A NEW SIPATORE, SOSTUIRE L’INTERFACCIA TERMICA CON UNA...
  • Page 36 Flat 1 FLAT 2 SENSORE DI CORRENTE CURRENT SENSING...
  • Page 37 ATTENzIONE CAUTION 1) Rimuovere le viti S1,S,S3,……..,S13. 1) Remove the screws S1, S, S3,…..,S13 ) Non togliere le torrette T1, T, T3 e T4, ) Not remove the tower T1,T,T3 and T4. 3) La scheda mandata in riparazione deve avere i flat, i ponti a dio- 3) The board sends in repair must have flat, bridge rectifier, power di, modulo di potenza e le quattro torrette T1, T, T3 e T4.
  • Page 38 b) Montaggio Scheda Snubber (Assemble Snubber Board). Filo corto dell’induttanza The shortest wire of in- ductor Secondario trasforma- tore Secondary side of tran- sformer 1) Inserire il filo corto dell’induttanza attraverso il gommino e posi- 1) Insert the shortest wire from inductor and position it in the tower zionarlo sulla torretta del modulo.
  • Page 40 Far passare il cavo primario corto del trasformatore attraverso il Insert the short primary conductor across the current sensor and fix sensore e fissarlo al mprsetto. it on the terminal. Fissare l’altro primario e fascettare Fix another primary conductor and wrap it.
  • Page 41 9.4) SNUBBER BOARD 15.14.404 DESCRIPTION This board contains the snubber diodes to limit the power dissipation. Moreover, in this board there is the output shunt realized with four 10mohm resistence connected in parallel mode for an equivalent resistence of .5mohm. INSTRUMENTS REQUIRED - Set of screwdrivers - Multimeter...
  • Page 42 9.5) PRIMARY INDUCTOR BOARD 15.14.403 DESCRIPTION This board contains the primary inductor of the inverter. INSTRUMENTS REQUIRED - Set of screwdrivers - Visual analysis BOARD...
  • Page 43 9.6) PILOT ARC BOARD 15.14.405 DESCRIPTION This board contains the electronic circuitry for controlling the pilot arc current. A sensor reads the flow of current circulating inside the torch during the striking phase and, when an electronic switch is shut off, it communicates the information to the microprocessor system on the mainboard.
  • Page 44 9.7) OUTPUT FILTER BOARD 15.14.406 DESCRIPTION This board contains the secondary side EMC filter. INSTRUMENTS REQUIRED - Set of screwdrivers - Multimeter BOARD Functional part Generator/ Component Test Point Value Type of Notes Mode measure Resistences R1/1 R1/ .ohm R/1 R/ .ohm Note:...
  • Page 45 9.8) FRONT PANEL BOARD 15.14.385 DESCRIPTION This microprocessor board with segnalling and interaction function with users. On the front there are the visualizazion LED and the poten- tiometer to set up the cutting current. INSTRUMENTS REQUIRED - Set of screwdrivers - Multimeter - Visual analysis BOARD...
  • Page 46 9.9) PROCEDURE FOR CALIBRATING THE OUTPUT CURRENT MAXIMUM CURRENT CALIBRATION 1 On the front panel, set a current of 35A. . Attach the amp clamp meter to the negative cable. 3. Start cutting. 4. Calibrate the trimmer P1 on the board 15.14.385 to bring the output current value at 35A ± 1A. PRESSURE LIMITER CALIBRATION 1.

  • Page 48: 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 49 10.1 - POWER SUPPLY UNIT FAILED OPERATION FLOW SIGNAL The welding machine is connected to the 30Vac 50/60Hz single-phase network. When the input switch is closed, the phase and neutral are connected to the filter board 15.14.371. Between phase and neutral there is a varistor, which is a device protecting the downstream electronics from overvoltages.
  • Page 50 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 power supply but this voltage found between terminals ALT1 ALT, check the input switch and the power cable.
  • Page 51 10.2 - FAN OPERATION FLOW SIGNAL The fan is controlled by means of PWM modulation to reduce acoustic noise and the infiltration of dust inside the generator. When the temperature limit is reached, as shown by the NTC mounted below the mainboard 15.14.370, the microprocessor on the front panel board 15.14.385 generates the command signal for the mainboard.
  • Page 52 Fault Possible problem Suggestions The fan does not activate 1. Fan faulty At maximum fan speed (achieved by discon- necting the NTC) a difference of potential of 4Vdc is detectable between terminals CN/1 CN/. If this voltage is sup- plied but the fan does not work, replace the .
  • Page 53 10.3 - SOLENOID VALVE OPERATION FLOW SIGNAL The electrovalve is controlled by the microprocessor system on the front panel board 15.14.385. The command signal activates a low power inverter on the mainboard 15.14.370, which generates the alternate supply voltage of 4Vac - 50Hz for the electrovalve, enabling the gas to flow for the required amount of time.
  • Page 54 10.4 - POWER OUTPUT ENABLE OPERATION FLOW SIGNAL When the torch switch is pressed, the generator provides power. The red LED diode lights up on the front panel. The four green LED diodes corresponding to the inverter command light up on the mainboard. BLOCK DIAGRAM Fault Possible problem...
  • Page 55 10.5 TORCH BUTTON OPERATION FLOW SIGNAL When the torch switch is pressed, this is detected by pilot arc board 15.14.405. After isolation by means of an opto-isolator, the torch switch signal is sent to the front panel and supplied to the microprocessor system. BLOCK DIAGRAM Fault Possible problem...
  • Page 56 10.6 - OPEN CIRCUIT VOLTAGE OPERATION FLOW SIGNAL The Genesis 35 generator used for the plasma cutting process gives an open-circuit voltage of +54Vdc when the torch switch is pressed. Fault Possible problem Suggestions Open-circuit voltage zero 1. Secondary diodes faulty...

  • Page 57: Spare Parts List

    11) SPARE PARTS LIST 56.01.003 GENESIS 35 Lista ricambi, Spare parts list, Ersatzteilverzeichnis, Liste de pièces détachées, Lista de repuestos, Lista de peças de reposição, Reserveonderdelenlijst, Reservdelslista, Liste med reservedele, Liste over reservedeler, Varaosaluettelo,...
  • Page 59 82.20.039 SP45 Lista ricambi, Spare parts list, Ersatzteilverzeichnis, Liste de pièces détachées, Lista de repuestos, Lista de peças de reposição, Reserveonderdelenlijst, Reservdelslista, Liste med reservedele, Liste over reservedeler, Varaosaluettelo,...

  • Page 61: Nominal Data

    12) NOMINAL DATA 12.1 Generator Power supply voltage (50/60 1x30V Delayed fuse Rated power 3.75kW Cutting current 35 A (x=35%) 5 A (x=100%) Cutting voltage (x=100%) No-load voltage 53V Pilot arc current Operating pressure 5 bar Flow rate 115 l/min Protection class IP3S Insulation class...
  • Page 63 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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