Selco Genesis 1700 AC/DC, Genesis 2200 AC/DC Repair Manual

Download

Page 1

Genesis 1700 AC/DC Genesis 2200 AC/DC

MANUALE DI RIPARAZIONE REPAIR MANUAL

Page 2

Cod. 92.08.067 Data/Date 17/11/11 Rev.

SELCO s.r.l.

Via Palladio, 19 35019 ONARA DI TOMBOLO (PD) TEL. +39 049 9413111 FAX. +39 049 9413311 email: service@selcoweld.com

Come contattare l’Assistenza Tecnica Selco/ How to contact Service Department:

SELCO s.r.l Service Department c/o SELCO 2

Via Macello, 61 35010 CITTADELLA (Padova) Italy Tel. +39 049 9413988 Fax. +39 049 9413335 email: service@selcoweld.com

Prima di iniziare qualsiasi operazione siate sicuri di aver ben letto e compreso questo manuale. Non apportate modifiche e non eseguite manutenzioni non descritte. Per ogni dubbio o problema circa l’utilizzo della macchina, anche se qui non descritto, consultare personale qualificato.

La SELCO s.r.l. si riserva il diritto di apportare modifiche in qualsiasi momento e senza alcun preavviso.

Quanto esposto è di vitale importanza e pertanto necessario affinchè le garanzie possano operare. Nel caso l’operatore non si attenesse a quanto descritto, il costruttore declina ogni responsabilità.

I diritti di traduzione, di riproduzione e di adattamento, totale o parziale e con qualsiasi mezzo (compresi le copie fotostatiche, i film ed i microfilm) sono riservati e vietati senza l’autorizzazione scritta della SELCO s.r.l.

Before performing any operation on the machine, make sure that you have thoroughly read and understood the contents of this booklet. Do not perform modifications or maintenance operations which are not prescribed. Do consult qualified personnel for any doubt or problem concerning the use of the machine, even if not described herein.

SELCO s.r.l. reserves the right to modify this booklet at any time without notice.

The directions provided herewith are of vital importance and therefore necessary to ensure the warranties. The manufacturer accepts no liability in case of misuse or non-application of the directions by the users.

All rights of translation and total or partial reproduction by any means whatsoever (including photocopy, film, and microfilm) are reserved and reproduction is prohibited without the explicit written consent of SELCO s.r.l.

ITALIANO ................................................................................................................................................................................3

ENGLISH ..............................................................................................................................................................................113

17) Targa dati, Rating plate..................................................................................................................................................221

18) Significato targa dati del generatore, Meaning of power source rating plate ..............................................................222

19) Schemi elettrici e di collegamento, Wiring diagrams and connection ........................................................................223

20) Connettori, Connectors .................................................................................................................................................228

21) Lista ricambi, Spare parts list ........................................................................................................................................230

Page 3

113

ENGLISH

INDEX

SYMBOLS

Imminent danger of serious body harm and dangerous behaviours that may lead to serious body harm

Important advice to be followed in order to avoid minor injuries or damage to property

Technical notes to facilitate operations

1 WARNING ...........................................................114

1.1 Work environment .......................................114

1.2 User's and other persons' protection.............114

1.3 Protection against fumes and gases ..............115

1.4 Fire/explosion prevention .............................115

1.5 Prevention when using gas cylinders ............115

1.6 Protection from electrical shock ...................115

1.7 Electromagnetic fields & interferences ..........116

1.8 IP Protection rating ......................................116

2 INSTALLATION.....................................................117

2.1 Lifting, transport & unloading ......................117

2.2 Positioning of the equipment .......................117

2.3 Connection ..................................................117

2.4 Installation ..................................................117

3 SYSTEM PRESENTATION ......................................118

3.1 General........................................................118

3.2 FP216 Front control panel ...........................118

3.3 Starting Screen .............................................118

3.4 Main Screen ................................................119

3.5 Set up ..........................................................120

3.6 Programs screen ...........................................122

3.7 Interface personalisation ..............................124

3.8 Lock/unlock .................................................124

3.9 External controls management .....................124

3.2 FP279 front control panel ............................125

3.3 Main Screen ................................................125

3.4 Set up ..........................................................126

3.5 Programs screen ...........................................129

3.6 Interface personalisation ..............................130

3.7 Interface personalisation ..............................131

3.8 Lock/unlock .................................................131

3.9 External controls management .....................132

3.10 Guard limits ...............................................132

3.11 Alarms screen ............................................133

3.12 Rear panel ................................................134

3.13 Sockets panel ............................................134

4 ACCESSORIES ......................................................134

4.1 General........................................................134

4.2 RC 100 remote control ................................134

4.3 RC 120 pedal remote control unit

for TIG welding ..................................................134

4.4 RC 180 remote control ................................134

4.5 RC 200 remote control ................................135

4.6 ST... series torches ........................................135

4.7 ST...U/D series torches .................................135

4.8 ST...DIGITIG series torches ...........................135

4.8.1 General.....................................................135

5 MAINTENANCE ....................................................135

6 TROUBLESHOOTING ..........................................135

7) PURSPOSE OF THE MANUAL .............................138

8) WARNINGS, PRECAUTIONS AND ......................139

GENERAL NOTICES FOR PERFORMING REPAIRS ...139

9) INSTRUMENTS AND CONVENTIONS FOR ........140

PERFORMING DIAGNOSIS AND REPAIR ................140

9.1) Instruments for basic diagnosis ....................140

9.2) Repair tools ................................................140

9.3) Conventions................................................140

9.4) Static load ...................................................141

10) DESCRIPTION OF THE BLOCK DIAGRAM .......142

10.1) Input filter .................................................143

10.2) PFC rectifier ..............................................144

10.3) Inverter stage ............................................145

10.4) Output stage .............................................146

10.5) Switching power supply ............................147

10.6) WU cooling group ....................................148

11) START-UP INDICATION ...................................149

11.1) External diagnostic indications .................149

11.2) Mechanical inidication ..............................151

11.2.1 Panels identification ................................151

11.2.2 Opening instruction ................................152

11.3) Elements location and description section .153

11.3.1 Left view .................................................153

11.3.2 Right view ...............................................154

12) DESCRIPTION, TESTING AND REPLACEMENT

OF THE ELECTRONIC BOARDS ..............................155

12.1) Input filter pcb ref. 15.14.443 ...................156

12.2) Power inverter-pfc pcb ref. 15.18.035

(schede 15.14.422 e 15.14.423) ........................160

12.3) Genesis 1700-2200 AC/DC

secondary power module and diodes ................175

12.4) Thermic caps inverter side ........................177

12.5) Thermic caps secondary side ....................179

12.6) Switching power supply pcb ref. 15.18.034

(15.14.42901+15.14.439) .................................181

12.7) Digital card pcb ref. 15.14.415 ................187

12.8) Analog signal pcb ref. 15.14.419 ...............192

12.9) Superimposition pcb ref. 15.14.435 ..........194

12.10) H.F. Generator pcb ref. 15.14.430 ..........196

12.11) Output module AC-DC driver pcb

ref. 15.14.434 ..................................................199

12.12) Control panel pcb

ref. 15.14.343 & 15.14.342 ..............................201

12.13) Control panel LCD 3.5” pcb

ref. 15.14.517 (spare order ref. 15.22.273) ........202

12.14) Bus pcb ref. 15.14.431 ...........................204

12.15) Output filter pcb ref. 15.14.444 ..............209

13) CALIBRATIONS .................................................212

13.1) Offset calibration

(only for unit with FP 15.22.279) ......................212

13.2) Current calibration

(to be done after 704 calibration).......................212

14) ALARMS TROUBLESHOOTING ......................213

14.1) Guard limits code .....................................216

15) ADVANCED SET-UP (COD. 358 MENU' SERV) ..217

15.1) List of set up parameters (MMA) ...............217

15.2) List of set up parameters (TIG) ..................218

15.3) “INFO” screen ..........................................219

16) TECHNICAL SPECIFICATIONS ..........................220

Page 4

114

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).

1 WARNING

Before performing any operation on the machine, make sure that you have thoroughly read and understood the contents of this booklet. Do not perform modifications or maintenance

operations which are not prescribed. The manufacturer cannot be held responsible for damages to persons or property caused by misuse or non-application of the contents of this booklet by the user.

Please consult qualified personnel if you have any

doubts or difficulties in using the equipment.

1.1 Work environment

• All equipment shall be used exclusively for the operations for

which it was designed, in the ways and ranges stated on the rating plate and/or in this booklet, according to the national

and international directives regarding safety. Other uses than the one expressly declared by the manufacturer shall be considered totally inappropriate and dangerous and in this case the manufacturer disclaims all responsibility.

• This equipment shall be used for professional applications

only, in industrial environments.

The manufacturer shall not be held responsible for any dam-

ages caused by the use of the equipment in domestic environments.

• The equipment must be used in environments with a tem-

perature between -10°C and +40°C (between +14°F and +104°F).

The equipment must be transported and stored in envi-

ronments with a temperature between -25°C and +55°C (between -13°F and 131°F).

• The equipment must be used in environments free from dust,

acid, gas or any other corrosive substances.

• The equipment shall not be used in environments with a rela-

tive humidity higher than 50% at 40°C (104°F).

The equipment shall not be used in environments with a rela-

tive humidity higher than 90% at 20°C (68°F).

• The system must not be used at an higher altitude than 2,000

metres (6,500 feet) above sea level.

Do not use this machine to defrost pipes. Do not use this equipment to charge batteries and/ or accumulators. Do not use this equipment to jump-start engines.

1.2 User's and other persons' protection

The welding process is a noxious source of radia-

tion, noise, heat and gas emissions.

Wear protective clothing to protect your skin from

the arc rays, sparks or incandescent metal.

Clothes must cover the whole body and must be:

- intact and in good conditions

- fireproof

- insulating and dry

- well-fitting and without cuffs or turn-ups Always use regulation shoes that are strong and

ensure insulation from water.

Always use regulation gloves ensuring electrical and thermal insulation.

Position a fire-retardant shield to protect the surrounding area from rays, sparks and incandescent slags. Advise any person in the area not to stare at the arc or at the incandescent metal and to get an adequate protection.

Wear masks with side face guards and a suitable protection filter (at least NR10 or above) for the eyes.

Always wear safety goggles with side guards, especially during the manual or mechanical removal of

welding slag.

Do not wear contact lenses!.

Use headphones if dangerous noise levels are reached during the welding. lf the noise level exceeds the limits prescribed by law, delimit the work area and make sure that anyone getting near it is protected with headphones or earphones.

• The systems must not undergo any kind of modification.

• Always keep the side covers closed while welding. Avoid touching items that have just been welded:

the heat could cause serious burning or scorching.

• Follow all the precautions described above also in all opera-

tions carried out after welding since slag may detach from the items while they are cooling off.

• Check that the torch is cold before working on or maintaining it. Ensure the cooling unit is switched off before disconnecting the pipes of the cooling liquid. The hot liquid coming out of the pipes might cause burning or scorching.

Keep a first aid kit ready for use. Do not underestimate any burning or injury.

Page 5

115

Before leaving work, make the area safe, in order to avoid accidental damage to people or property.

1.3 Protection against fumes and gases

• Fumes, gases and powders produced during the welding process can be noxious for your health.

Under certain circumstances, the fumes caused by welding

can cause cancer or harm the foetus of pregnant women.

• Keep your head away from any welding gas and fumes.

• Provide proper ventilation, either natural or forced, in the work area.

• In case of poor ventilation, use masks and breathing apparatus.

• In case of welding in extremely small places the work should be supervised by a colleague standing nearby outside.

• Do not use oxygen for ventilation.

• Ensure that the fumes extractor is working by regularly checking the quantity of harmful exhaust gases versus the values stated in the safety regulations.

• The quantity and the danger level of the fumes depends on the parent metal used, the filler metal and on any substances used to clean and degrease the pieces to be welded. Follow the manufacturer's instructions together with the instructions given in the technical sheets.

• Do not perform welding operations near degreasing or painting stations.

Position gas cylinders outdoors or in places with good ventila-

tion.

1.4 Fire/explosion prevention

• The welding process may cause fires and/or explosions.

• Clear the work area and the surrounding area from any flammable or combustible materials or objects.

Flammable materials must be at least 11 metres (35 feet) from

the welding area or they must be suitably protected.

Sparks and incandescent particles might easily be sprayed

quite far and reach the surrounding areas even through minute openings. Pay particular attention to keep people and property safe.

• Do not perform welding operations on or near containers under pressure.

• Do not perform welding operations on closed containers or pipes.

Pay particular attention during welding operations on pipes

or containers even if these are open, empty and have been cleaned thoroughly. Any residue of gas, fuel, oil or similar materials might cause an explosion.

• Do not weld in places where explosive powders, gases or vapours are present.

• When you finish welding, check that the live circuit cannot accidentally come in contact with any parts connected to the earth circuit.

• Position a fire-fighting device or material near the work area.

1.5 Prevention when using gas cylinders

• Inert gas cylinders contain pressurized gas and can explode if the minimum safe conditions for transport, storage and use are not ensured.

• Cylinders must be secured in a vertical position to a wall or other supporting structure, with suitable means so that they cannot fall or accidentally hit anything else.

• Screw the cap on to protect the valve during transport, commissioning and at the end of any welding operation.

• Do not expose cylinders to direct sunlight, sudden changes of temperature, too high or extreme temperatures. Do not expose cylinders to temperatures too low or too high.

• Keep cylinders away from naked flames, electric arcs, torches or electrode guns and incandescent material sprayed by welding.

• Keep cylinders away from welding circuits and electrical circuits in general.

• Keep your head away from the gas outlet when opening the cylinder valve.

• Always close the cylinder valve at the end of the welding operations.

• Never perform welding operations on a pressurized gas cylinder.

1.6 Protection from electrical shock

• Electric shocks can kill you.

• Avoid touching live parts both inside and outside the welding system while this is active (torches, guns, earth cables, electrodes, wires, rollers and spools are electrically connected to the welding circuit).

• Ensure the system and the welder are insulated electrically by using dry bases and floors that are sufficiently insulated from the earth.

• Ensure the system is connected correctly to a socket and a power source equipped with an earth conductor.

• Do not touch two torches or two electrode holders at the same time.

lf you feel an electric shock, interrupt the welding operations

immediately.

The arc striking and stabilizing device is designed for manual or mechanically guided operation.

Increasing the length of torch or welding cables more than 8 m will increase the risk of electric shock.

Page 6

116

1.7 Electromagnetic fields & interferences

• The welding current passing through the internal and external system cables creates an electromagnetic field in the proximity of the welding cables and the equipment itself.

• Electromagnetic fields can affect the health of people who are exposed to them for a long time (the exact effects are still unknown).

Electromagnetic fields can interfere with some equipment like

pacemakers or hearing aids.

Persons fitted with pacemakers must consult their doctor before undertaking arc welding or plasma cutting operations.

EMC equipment classification in accordance with EN/IEC 60974-10 (See rating plate or technical data)

Class B equipment complies with electromagnetic compatibility requirements in industrial and residential environments, including residential locations where the electrical power is provided by the public low-voltage supply system. Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

Installation, use and area examination

This equipment is manufactured in compliance with the requirements of the EN60974-10 harmonized standard and is identified as "CLASS A" equipment. This unit must be used for professional applications only, in industrial environments. The manufacturer will accept no responsability for any damages caused by use in domestic environments.

The user must be an expert in the activity and as such is responsible for installation and use of the equipment according to the manufacturer's instructions. lf any electromagnetic interference is noticed, the user must solve the problem, if necessary with the manufacturer's technical assistance. In any case electromagnetic interference problems must be reduced until they are not a nuisance any longer.

Before installing this apparatus, the user must evaluate the potential electromagnetic problems that may arise in the surrounding area, considering in particular the health conditions of the persons in the vicinity, for example of persons fitted with pacemakers or hearing aids.

Mains power supply requirements (See technical data) High power equipment may, due to the primary current drawn form the mains supply, influence the power quality of the grid. Therefore connection restrictions or requirements regarding the maximum permissible mains impedance (Zmax) or the required minimum supply capacity (Ssc) at he interface point to the public grid (point of common coupling, PCC) may apply for some types of equipment (see technical data).

In this case it is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may be connected.

In case of interference, it may be necessary to take further precautions like the filtering of the mains power supply. lt is also necessary to consider the possibility of shielding the power supply cable.

Welding cables

To minimise the effects of electromagnetic fields follow the following instructions:

- Where possible, collect and secure the earth and power cables together.

- Never coil the welding cables around your body.

- Do not place your body in between the earth and power cables (keep both on the same side).

- The cables must be kept as short as possible, positioned as close as possible to each other and laid at or approximately at ground level.

- Position the equipment at some distance from the welding area.

- The cables must be kept away from any other cables.

Earthing connection

The earth connection of all the metal components in the welding equipment and in the close aerea must be taken in consideration. The earthing connection must be made according to the local regulations.

Earthing the workpiece

When the workpiece is not earthed for electrical safety reasons or due to its size and position, the earthing of the workpiece may reduce the emissions. It is important to remember that the earthing of the workpiece should neither increase the risk of accidents for the user nor damage other electric equipment. The earthing must be made according to the local regulations.

Shielding

The selective shielding of other cables and equipment present in the surrounding area may reduce the problems due to electromagnetic interference. The shielding of the entire welding equipment can be taken in considered for special applications.

1.8 IP Protection rating

IP23S

- Enclosure protected against access to dangerous parts by fingers and against ingress of solid foreign bodies with diameter greater than/equal to 12.5 mm

- Enclosure protected against rain at an angle of 60°.

- Enclosure protected against harmful effects due to the ingress of water when the moving parts of the equipment are not operating.

Page 7

117

2 INSTALLATION

Installation should be performed only by expert personnel authorised by the manufacturer.

During installation, ensure that the power source is disconnected from the mains.

The multiple connection of power sources (series or parallel) is prohibited.

2.1 Lifting, transport & unloading

- The equipment is provided with a handle for hand transportation.

- Use a fork lift truck paying attention during operations in order to prevent the generator from tipping over.

Do not underestimate the weight of the equipment: see technical specifications.

Do not move or position the suspended load above persons or things.

Do not drop or apply undue pressure on the equipment.

2.2 Positioning of the equipment

Keep to the following rules:

- Provide easy access to the equipment controls and connections.

- Do not position the equipment in very small spaces.

- Do not place the equipment on surfaces with inclination exceeding 10° from to the horizontal plane.

- Position the equipment in a dry, clean and suitably ventilated place.

- Protect the equipment against pouring rain and sun.

2.3 Connection

The equipment is provided with a power supply cable for connection to the mains. The system can be powered by:

- single-phase 115V

- single-phase 230V

CAUTION: to prevent injury to persons or damage to the equipment, the selected mains voltage and fuses must be checked BEFORE connecting the machine to the mains. Also check that the cable is connected to a socket provided with earth contact.

Operation of the equipment is guaranteed for voltage tolerances up to ±15% with respect to the rated value.

In order to protect users, the equipment must be correctly earthed. The power supply voltage is provided with an earth lead (yellow - green), which must be connected to a plug provided with earth contact.

The electrical connections must be made by skilled technicians with the specific professional and technical qualifications and in compliance with the regulations in force in the country where the equipment is installed.

The power source supply cable is provided with a yellow/ green wire that must ALWAYS be earthed. This yellow/green wire shall NEVER be used with other voltage conductors.

Verify the existence of the earthing in the equipment used and the good condition of the sockets.

Install only certified plugs according to the safety regulations.

2.4 Installation

Connection for MMA welding

The connection shown in the figure produces reverse polarity welding. To obtain straight polarity welding, reserve the connection.

- Connect (1) the earth clamp to the negative socket (-) (2) of the power source.

- Connect (3) the electrode holder to thpositive socket (+) (4) of the power source.

Page 8

118

Connection for TIG welding

- Connect (5) the earth clamp to the positive socket (+) (6) ofthe power source.

- Connect the TIG torch coupling (7) to the torch socket (8) ofthe power source.

- Connect the gas hose from the cylinder to the rear gas connection.

- Connect the signal cable of the torch to the appropriate connector (9).

- Connect the gas hose of the torch to the appropriate union/ connection (10).

- Connect the red colored

water pipe of the torch to the

inlet quick connector of the cooling unit.

- Connect the blue colored

water pipe of the torch to the

outlet quick connector of the cooling unit.

3 SYSTEM PRESENTATION

3.1 General

The Genesis 1700 AC/DC - Genesis 2200 AC/DC are constant current inverter power sources developed for electrode (MMA), TIG DC (direct current) and TIG AC (alternating current) welding. They are fully digital multiprocessor systems (data processing on DSP and communication over CAN-BUS), capable of meeting the various requirements of the welding world in the best possible way.

3.2 FP216 Front control panel

1 Power supply

Indicates that the equipment is connected to the mains and is on.

2 General alarm

Indicates the possible intervention of protection devices such as the temperature protection.

3 Power on

Indicates the presence of voltage on the equipment outlet connections.

4 7-segment display

Allows the general welding machine parameters to be

displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

5 LCD display

Allows the general welding machine parameters to be

displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

Allows all the operations to be displayed instantaneously.

6 Main adjustment handle.

Allows entry to set up, the selection and the setting of the welding parameters.

7 Processes/functions

Allow the selection of the functions provided on the

system to which the remote control is connected.

3.3 Starting Screen

When switched on, the generator performs a succession of checks in order to guarantee the correct operation of the system and of all the devices connected to it.

1 μP Microprocessor 2 FP Control panel 3 DSP DSP 4 WU Cooling unit 5 RC Remote control

Page 9

119

6 RI Robot interface 7 Software versions 8 ON System operation time 9 WELDING System welding time

At this stage the gas test is also carried out to check the proper connection to the gas supply system.

3.4 Main Screen

Allows the control of the system and of the welding process, showing the main settings.

1 Welding parameters 2 Functions

1 Welding parameters

1a Welding parameters

Select the required parameter by pressing the encoder button. Adjust the value of the selected parameter by rotating

the encoder. 1b Parameter icon 1c Parameter value 1d Unit of measurement of the parameter

The parameters of the main screen can be personalised (consult the “Interface personalisation” section).

2 Functions

Allow the setting of the most important process func-

tions and welding methods.

2a Allows the selection of the welding process

MMA

TIG DC

TIG AC 2b MMA Allows the selection of the welding method

Direct polarity

Reverse polarity

Alternating current

TIG Allows the selection of the welding method

2 Step

4 Step

Bilevel

MMA

Synergy

Allows you to set the best arc dynamics,

selecting the type of electrode used: STD Basic/Rutile CLS Cellulose CrNi Steel Alu Aluminium Cast iron Cast iron

Selecting the correct arc dynamics enables maximum

benefit to be derived from the power source to achieve the best possible welding performances.

Perfect weldability of the electrode used is not guaran-

teed (weldability depends on the quality of the consumables and their preservation, the operating and welding conditions, the numerous possible applications, etc.).

TIG DC Current pulsation

CONSTANT current

PULSED current

Fast Pulse

TIG AC Current pulsation

CONSTANT current

PULSED current

AC/DC mix

Allows the storage and management of 60 welding programs which can be personalised by the operator.

(Consult the “Programs screen” section).

Page 10

120

3 Measurements During the welding operation, the real current and volt-

age measurements are shown on the LCD display.

3a Welding current 3b Welding voltage

3.5 Set up

Permits set up and adjustment of a series of additional parameters for improved and more accurate control of the welding system. The parameters present at set up are organised in relation to the welding process selected and have a numerical code.

Entry to set up: by pressing the encoder key for 3 sec. Selection and adjustment of the required parameter: by

turning the encoder until displaying the numerical code relating to that parameter. If the encoder key is pressed at this point, the value set for the parameter selected can be displayed and adjusted. Exit from set up: to quit the "adjustment" section, press the encoder again. To exit the set up, go to parameter "O" (save and quit) and press the encoder.

List of set up parameters (MMA) 0 Save and quit

Allows you to save the changes and exit the set up.

1 Reset

Allows you to reset all the parameters to the default values.

3 Hot start

Allows adjustment of the hot start value in MMA. Permits an adjustable hot start in the arc striking phases,

facilitating the start operations. Parameter set as a percentage (%) of the welding current. Minimum Off, Maximum 500%, Default 80%

7 Welding current

Permits adjustment of the welding current.

Parameter set in Amps (A).

Minimum 3A, Maximum Imax, Default 100A

8 Arc force

Allows adjustment of the Arc force value in MMA.

Permits an adjustable energetic dynamic response in

welding, facilitating the welder's operations.

Parameter set as a percentage (%) of the welding current. Minimum Off, Maximum 500%, Default 30%

312 Arc detachment voltage

Allows you to set the voltage value at which the electric arc switch-off is forced. It permits improved management of the various operating conditions that occur. In the spot welding phase, for example, a low arc detachment voltage reduces re-striking of the arc when moving the electrode away from the piece, reducing spatter, burning and oxidisation of the piece.

If using electrodes that require high voltages, you are

advised to set a high threshold to prevent arc extinction during welding.

Never set an arc detachment voltage higher than the no-load voltage of the power source.

Parameter set in Volts (V). Minimum 0V, Maximum 99.9V, Default 57V 500 Allows the selection of the required graphic interface: XE (Easy Mode) XA (Advanced Mode) XP (Professional Mode)

Allows access to the higher set-up levels: USER: user SERV: service SELCO: Selco

501 Info

Allows the display of a set of information related to the system.

502 Alarm queue

Allows the intervention of an alarm to be indicated and provides the most important indications for the solution of any problem encountered.

(Consult the “Alarms screen” section).

551 Lock/unlock

Allows the locking of the panel controls and the insertion of a protection code (consult the “Lock/unlock” section).

552 Buzzer tone

Permits adjustment of the buzzer tone. Minimum Off, Maximum 10, Default 5

553 Contrast

Permits adjustment of the display contrast. Minimum 0, Maximum 50, Default 25

601 (U/D) Adjustment step

Permits adjustment of the variation step on the updown keys. Minimum Off, Maximum MAX, Default 1

602 CH1, CH2, CH3, CH4 External parameter

Allows the management of external parameter 1 (minimum value, maximum value, default value, parameter selected).

(Consult the “External controls management” section).

751 Current reading

Allow the real value of the welding current to be displayed.

Allows the welding current display method to be set

(consult the “Interface personalisation” section).

752 Voltage reading

Allows the real value of the welding voltage to be displayed.

Allows the welding voltage display method to be set

(consult the “Interface personalisation” section).

Page 11

121

List of set up parameters (TIG) 0 Save and quit

Allows you to save the changes and exit the set up.

1 Reset

Allows you to reset all the parameters to the default values.

2 Pre-gas

Allows you to set and adjust the gas flow prior to striking of the arc.

Permits filling of the torch with gas and preparation of

the environment for welding.

Minimum 0.0sec., Maximum 99.9sec., Default 0.1sec.

3 Initial current

Allows regulation of the weld starting current. Allows a hotter or cooler welding pool to be obtained

immediately after the arc striking. Parameter setting: Amperes (A) - Percentage (%). Minimum 3A-1%, Maximum Imax-500%, Default 50%

5 Initial current time

Allows setting of the time for which the initial current is

maintained. Parameter setting: seconds (s). Minimum off, Maximum 99.9s, Default off

6 Slope-up

Allows you to set a gradual passage between the initial

current and the welding current. Parameter set in sec-

onds (s). Minimum off, Maximum 99.9s, Default off

7 Welding current

Permits adjustment of the welding current.

Parameter set in Amps (A). Minimum 3A, Maximum Imax, Default 100A

8 Bilevel current

Permits adjustment of the secondary current in the

bilevel welding mode. Parameter set in Amps (A). Minimum 3A-1%, Maximum Imax-100%, Default 50%

10 Basic current

Permits adjustment of the basic current in pulsed and

fast pulse modes. Parameter set in Amps (A). Minimum 3A-1%, Maximum Weld current-100%,

Default 50%

12 Pulsed frequency

Allows activation of the pulse mode.

Allows regulation of the pulse frequency. Allows better results to be obtained in the welding of

thin materials and better aesthetic quality of the bead. Parameter setting: Hertz (Hz) - KiloHertz (kHz). Minimum 0.1Hz, Maximum 250Hz, Default off

13 Pulsed duty cycle

Allows regulation of the duty cycle in pulse welding.

Allows the peak current to be maintained for a shorter

or longer time. Parameter setting: percentage (%). Minimum 1%, Maximum 99%, Default 50%

14 Fast Pulse frequency

Allows regulation of the pulse frequency.

Allows focusing action and better stability of the elec-

tric arc to be obtained. Parameter setting: KiloHertz (kHz). Minimum 0.02KHz, Maximum 2.5KHz, Default off 15 Pulsed slopes

Allows setting of a slope time during the pulse operation.

Allows a smooth step to be obtained between the peak

current and the basic current, having a more or less soft

welding arc. Parameter setting: percentage (%). Minimum off, Maximum 100%, Default off

16 Slope-down

Allows you to set a gradual passage between the weld-

ing current and the final current. Parameter set in seconds (s). Minimum off, Maximum 99.9s, Default off

17 Final current

Permits adjustment of the final current.

Parameter set in Amps (A). Minimum 3A-1%, Maximum Imax-500%, Default 50%

19 Final current time

Makes it possible to set the time for which the final cur-

rent is maintained. Parameter setting: seconds (s). Minimum off, Maximum 99.9s, Default off

20 Post-gas

Permits setting and adjustment of the gas flow at the

end of welding. Minimum 0.0s, Maximum 99.9s, Default syn

101 (TIG AC) AC wave form

Allows the selection of the required AC wave form.

Default

102 (TIG AC) AC frequency

Allows regulation of the polarity inversion frequency in

TIG AC welding. Allows focusing action and better stability of the electric

arc to be obtained. Parameter setting: Hertz (Hz). Minimum 20Hz, Maximum 200Hz, Default 100Hz

103 (TIG AC) AC balance

Allows regulation of the duty cycle in TIG AC welding.

Allows the positive polarity to be maintained for a

longer or shorter time. Parameter setting: percentage (%). Minimum 15%, Maximum 65%, Default 35%

104 (TIG AC) Fuzzy logic

Allows regulation of the power delivered by the system

during the arc striking phase by selecting the electrode

diameter used. Makes it possible to suitably heat the electrode and/or

to keep the tip intact. Parameter setting: millimetres (mm). Minimum 0.1mm, Maximum 5.0mm, Default 2.4mm

105 Easy rounding

Allows a greater amount of energy to be delivered dur-

ing the TIG AC arc striking phase. Allows the rounding of the electrode in a uniform and

regular manner. The function is automatically disabled after the arc has

been struck. The power delivered depends on the electrode diam-

eter set on the fuzzy logic. Default off

107 AC - DC time mix

Allows adjustment of the welding time in direct current

when the AC MIX function is enabled. Parameter setting: seconds (s). Minimum 0.02s, Maximum 2.00s, Default 0.24s

Page 12

122

108 AC - AC time mix

Allows regulation of the welding time in alternating cur-

rent when the AC MIX function is enabled. Parameter setting: seconds (s). Minimum 0.02s, Maximum 2.00s, Default 0.24s

203 Tig start (HF or LIFT)

Allows selection of the required LIFT START, HF START,

Default HF START arc striking modes.

HF Default 204 Spot welding

Allows you to enable the "spot welding" process and

establish the welding time. Allows the timing of the welding process. Parameter setting: seconds (s).

205 Restart

Allows the activation of the restart function.

Allows the immediate extinguishing of the arc during

the down slope or the restarting of the welding cycle. Default on

206 (TIG DC) Easy joining

Allows striking of the arc in pulsed current and timing

of the function before the automatic reinstatement of

the pre-set welding conditions. Allows greater speed and accuracy during tack welding

operations on the parts. Parameter setting: seconds (s).

Minimum 0.1s, Maximum 99.9s, Default off 207 (TIG AC) Extra energy

Allows balancing of the current in positive polarity com-

pared with that in negative polarity. Makes it possible to obtain greater cleanness of the base

material or greater welding capacity while keeping the

average current value unchanged. Parameter setting: percentage (%).

Minimum 1%, Maximum 200%, Default 100% 312 Arc detachment voltage

Allows you to set the voltage value at which the electric

arc switch-off is forced.

It permits improved management of the various oper-

ating conditions that occur. In the spot welding phase,

for example, a low arc detachment voltage reduces

re-striking of the arc when moving the electrode away

from the piece, reducing spatter, burning and oxidisa-

tion of the piece.

Never set an arc detachment voltage higher than the no-load voltage of the power source.

Minimum 0.0V, Maximum 99.9V, Default 45V 500 Allows the selection of the required graphic interface: XE (Easy Mode) XA (Advanced Mode) XP (Professional Mode)

Allows access to the higher set-up levels: USER: user SERV: service SELCO: Selco

501 Info

Allows the display of a set of information related to the

system.

502 Alarm queue

Allows the intervention of an alarm to be indicated and

provides the most important indications for the solution

of any problem encountered. (Consult the “Alarms screen” section).

551 Lock/unlock

Allows the locking of the panel controls and the insertion of a protection code (consult the “Lock/unlock” section).

552 Buzzer tone

Permits adjustment of the buzzer tone. Minimum Off, Maximum 10, Default 5

553 Contrast

Permits adjustment of the display contrast. Minimum 0, Maximum 50, Default 25

601 (U/D) Adjustment step

Permits adjustment of the variation step on the updown keys. Minimum Off, Maximum MAX, Default 1

602 CH1, CH2, CH3, CH4 External parameter

Allows the management of external parameter 1 (minimum value, maximum value, default value, parameter selected).

(Consult the “External controls management” section).

606 U/D torch

Allows the management of the external parameter (CH1) (parameter selected).

751 Current reading

Allow the real value of the welding current to be displayed.

Allows the welding current display method to be set

(consult the “Interface personalisation” section).

752 Voltage reading

Allows the real value of the welding voltage to be displayed.

Allows the welding voltage display method to be set

(consult the “Interface personalisation” section).

3.6 Programs screen

1 General

Allows the storage and management of 60 welding pro-

grams which can be personalised by the operator.

1 Process of the selected program 2 Welding methods 3 Current pulsation 4 Number of the selected program 5 Main parameters of the selected program 6 Description of the selected program

2 Program storage

Page 13

123

Enter the “program storage” menu by pressing button

(4)

for at least 1 second.

Select the required program (or the empty memory) by

rotating the encoder.

Program stored

Memory empty

Cancel the operation by pressing button (2)

Save all the current settings on the selected program by

pressing button (3) .

Introduce a description of the program.

- Select the required letter by rotating the encoder.

- Store the selected letter by pressing the encoder.

- Cancel the last letter by pressing button (1)

Cancel the operation by pressing button (2)

Confirm the operation by pressing button (3)

The storage of a new program on an already occupied

memory location requires cancellation of the memory location by an obligatory procedure.

Cancel the operation by pressing button (2)

Remove the selected program by pressing button (1)

Resume the storage procedure.

3 Program retrieval

Retrieve the 1st program available by pressing button (4)

Select the required program by pressing button (4) . Select the required program by rotating the encoder.

Only the memories location occupied by a program

are retrieved, while the empty ones are automatically skipped.

4 Program cancellation

Select the required program by rotating the encoder.

Delete the selected program by pressing button (1)

Confirm the operation by pressing button (2)

Confirm the operation by pressing button (1) . Cancel the operation by pressing button (2)

Page 14

124

3.7 Interface personalisation

Allows the parameters to be customized on the main menu.

500 Allows the selection of the required graphic interface: XE (Easy Mode) XA (Advanced Mode) XP (Professional Mode)

3.8 Lock/unlock

Allows all the settings to be locked from the control panel with a security password.

Enter set-up by pressing the encoder key for at least 3 seconds. Select the required parameter (551).

Activate the regulation of the selected parameter by pressing the encoder button.

Set a numerical code (password) by rotating the encoder. Confirm the change made by pressing the encoder button. Save and exit the current screen by pressing button (4)

Cancel the operation by pressing button (3)

The carrying out of any operation on a locked control panel causes a special screen to appear.

- Access the panel functionalities temporarily (5 minutes) by

rotating the encoder and entering the correct password (5).

Confirm the change made by pressing the encoder.

- Unlock the control panel definitively by entering set-up (fol-

low the instructions given above) and bring back parameter 551 to “off”.

3.9 External controls management

Allows the setting of the welding parameters management method by the external devices (RC, torch…).

Enter set-up by pressing the encoder key for at least 3 seconds. Select the required parameter (602). Enter the “External controls management” screen by pressing the encoder button.

Select the required RC remote control output (CH1, CH2, CH3, CH4) by pressing button (1).

Select the required parameter (Min-Max) by pressing the encoder button. Adjust the required parameter (Min-Max) by rotating the encoder. Save and exit the current screen by pressing button (4)

Cancel the operation by pressing button (3)

Page 15

125

3.2 FP279 front control panel

Power supply

Indicates that the equipment is connected to the mains and is on.

2 General alarm

Indicates the possible intervention of protection devices such as the temperature protection (consult the “Alarm codes” section).

3 Power on

Indicates the presence of voltage on the equipment outlet connections.

4 7-segment display

Allows the general welding machine parameters to be

displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

5 LCD display

Allows the general welding machine parameters to be

displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

Allows all the operations to be displayed instantaneously.

6 Main adjustment handle

Allows the welding current to be continuously adjusted. Allows entry to set up, the selection and the setting of the welding parameters.

7 Processes/functions Let you select the various system functions (welding

process, welding mode, current pulse, graphic mode, etc.).

8 Not used

9 Programs

Allows the storage and management of 64 welding programs which can be personalised by the operator.

3.3 Main Screen

Allows the control of the system and of the welding process, showing the main settings.

1 Measurements During the welding operation, the real current and volt-

age measurements are shown on the LCD display.

1a Welding current 1b Welding voltage

2 Welding parameters

2a Welding parameters Select the required parameter by pressing the encoder

button.

Adjust the value of the selected parameter by rotating

the encoder. 2b Parameter icon 2c Parameter value 2d Unit of measurement of the parameter

3 Functions

Allow the setting of the most important process func-

tions and welding methods.

Page 16

3a VRD Voltage Reduction Device

Shows that the no-load voltage of the equipment is controlled.

3b Allows the selection of the welding process

MMA

TIG DC

TIG AC

3c Allows the selection of the welding method

Direct polarity

Reverse polarity

Alternating current

Synergy

Allows you to set the best arc dynamics, select-

ing the type of electrode used: STD Basic/Rutile CLS Cellulose CrNi Steel Alu Aluminium Cast iron Cast iron

Selecting the correct arc dynamics enables maximum

benefit to be derived from the power source to achieve the best possible welding performances.

Perfect weldability of the electrode used is not guaran-

teed (weldability depends on the quality of the consumables and their preservation, the operating and welding conditions, the numerous possible applications, etc.).

3e Allows the selection of the welding method

2 Step

4 Step

Bilevel

3f Current pulsation

CONSTANT current

PULSED current

Fast Pulse

3g Current pulsation

CONSTANT current

PULSED current

AC/DC mix

3.4 Set up

Entry to set up: by pressing the encoder key for 5 sec. Selection and adjustment of the required parameter: by

List of set up parameters (MMA) 0 Save and quit

Allows you to save the changes and exit the set up.

1 Reset

Allows you to reset all the parameters to the default values.

3 Hot start

Allows adjustment of the hot start value in MMA. Permits an adjustable hot start in the arc striking phases,

facilitating the start operations. Parameter set as a percentage (%) of the welding current. Minimum Off, Maximum 500%, Default 80%

7 Welding current

Permits adjustment of the welding current.

Parameter set in Amps (A).

Minimum 3A, Maximum Imax, Default 100A

8 Arc force

Allows adjustment of the Arc force value in MMA.

Permits an adjustable energetic dynamic response in

welding, facilitating the welder's operations. Increasing the value of the arc force to reduce the risks

of sticking of the electrode.

126

Page 17

Parameter set as a percentage (%) of the welding current. Minimum Off, Maximum 500%, Default 30%

204 Dynamic power control (DPC)

It enables the desired V/I characteristic to be selected.

I = C Constant current

The increase or reduction in arc length has no effect on

the welding current required.

Basic, Rutile, Acid, Steel, Cast iron

1÷ 20* Falling characteristic with adjustable slope The increase in arc length causes a reduction in welding

current (and vice versa) according to the value imposed by 1 to 20 amps per volt.

Cellulose, Aluminium

P = C* Constant power The increase in arc length causes a reduction in the

welding current (and vice versa) according to the law: V.I = K.

Cellulose, Aluminium

312 Arc detachment voltage

If using electrodes that require high voltages, you are

advised to set a high threshold to prevent arc extinction during welding.

Never set an arc detachment voltage higher than the no-load voltage of the power source.

Parameter set in Volts (V). Minimum 0V, Maximum 99.9V, Default 57V 500 Allows the selection of the required graphic interface:

XE (Easy Mode) XA (Advanced Mode)

XP (Professional Mode) Allows access to the higher set-up levels:

USER: user SERV: service SELCO: Selco

551 Lock/unlock

Allows the locking of the panel controls and the insertion of a protection code (consult the “Lock/unlock” section).

552 Buzzer tone

Permits adjustment of the buzzer tone. Minimum Off, Maximum 10, Default 5

553 Contrast

Permits adjustment of the display contrast. Minimum 0, Maximum 50, Default 25

601 Regulation step

Allows the regulation of a parameter with a step that can be personalised by the operator.

Minimum 1, Maximum Imax, Default 1

602 CH1, CH2, CH3, CH4 External parameter

Allows the management of external parameter 1 (minimum value, maximum value).

(Consult the “External controls management” section).

751 Current reading

Allow the real value of the welding current to be displayed.

Allows the welding current display method to be set.

752 Voltage reading

Allows the real value of the welding voltage to be displayed.

Allows the welding voltage display method to be set.

List of set up parameters (TIG) 0 Save and quit

Allows you to save the changes and exit the set up.

1 Reset

Allows you to reset all the parameters to the default values.

2 Pre-gas

Allows you to set and adjust the gas flow prior to striking of the arc.

Permits filling of the torch with gas and preparation of

the environment for welding.

Minimum 0.0sec., Maximum 99.9sec., Default 0.1sec.

3 Initial current

Allows regulation of the weld starting current. Allows a hotter or cooler welding pool to be obtained

immediately after the arc striking. Parameter setting: Amperes (A) - Percentage (%). Minimum 3A-1%, Maximum Imax-500%, Default 50%

5 Initial current time

Allows setting of the time for which the initial current is

maintained. Parameter setting: seconds (s). Minimum off, Maximum 99.9s, Default off

6 Slope-up

Allows you to set a gradual passage between the initial

current and the welding current. Parameter set in sec-

onds (s). Minimum off, Maximum 99.9s, Default off

7 Welding current

Permits adjustment of the welding current.

Parameter set in Amps (A). Minimum 3A, Maximum Imax, Default 100A

8 Bilevel current

Permits adjustment of the secondary current in the

bilevel welding mode. On first pressing the torch button, the pre-gas starts, the arc

strikes and the initial current will be used when welding. On first releasing it, the raising ramp of the welding current

“I1” occurs. If the welder now presses and releases the

button quickly, “I2” can be used; by pressing and releasing

it quickly again, “I1” is used again, and so on. If you press the button for a longer time, the lowering ramp

for the current starts, thus reaching the final current. By releasing the button again, the arc goes out and the

gas continues to flow for the post-gas stage. Parameter setting: Amperes (A) - Percentage (%). Minimum 3A-1%, Maximum Imax-500%, Default 50%

127

Page 18

10 Basic current

Permits adjustment of the basic current in pulsed and

fast pulse modes. Parameter set in Amps (A). Minimum 3A-1%, Maximum Weld current-100%,

Default 50%

12 Pulsed frequency

Allows activation of the pulse mode.

Allows regulation of the pulse frequency. Allows better results to be obtained in the welding of

thin materials and better aesthetic quality of the bead. Parameter setting: Hertz (Hz). Minimum 0.1Hz, Maximum 25Hz, Default off

13 Pulsed duty cycle

Allows regulation of the duty cycle in pulse welding.

Allows the peak current to be maintained for a shorter

or longer time. Parameter setting: percentage (%). Minimum 1%, Maximum 99%, Default 50%

14 (TIG DC) Fast Pulse frequency

Allows regulation of the pulse frequency.

Allows focusing action and better stability of the electric

arc to be obtained. Parameter setting: KiloHertz (kHz). Minimum 0.02KHz, Maximum 2.5KHz, Default off 15 Pulsed slopes

Allows setting of a slope time during the pulse operation.

Allows a smooth step to be obtained between the peak

current and the basic current, having a more or less soft

welding arc. Parameter setting: percentage (%). Minimum off, Maximum 100%, Default off

16 Slope-down

Allows you to set a gradual passage between the weld-

ing current and the final current.

Parameter set in seconds (s). Minimum off, Maximum 99.9s, Default off

17 Final current

Permits adjustment of the final current.

Parameter set in Amps (A). Minimum 3A-1%, Maximum Imax-500%, Default 10A

19 Final current time

Makes it possible to set the time for which the final cur-

rent is maintained. Parameter setting: seconds (s). Minimum off, Maximum 99.9s, Default off

20 Post-gas

Permits setting and adjustment of the gas flow at the

end of welding.

Minimum 0.0s, Maximum 99.9s, Default syn

101 (TIG AC) AC wave form

Allows the selection of the required AC wave form.

Default

102 (TIG AC) AC frequency

Allows regulation of the polarity inversion frequency in

TIG AC welding. Allows focusing action and better stability of the electric

arc to be obtained. Parameter setting: Hertz (Hz). Minimum 20Hz, Maximum 200Hz, Default 100Hz

103 (TIG AC) AC balance

Allows regulation of the duty cycle in TIG AC welding.

Allows the positive polarity to be maintained for a

longer or shorter time.

Parameter setting: percentage (%). Minimum 15%, Maximum 65%, Default 35%

104 (TIG AC) Fuzzy logic

Allows regulation of the power delivered by the system during the arc striking phase by selecting the electrode diameter used.

Makes it possible to suitably heat the electrode and/or

to keep the tip intact. Parameter setting: millimetres (mm). Minimum 0.1mm, Maximum 5.0mm, Default 2.4mm

105 Easy rounding

Allows a greater amount of energy to be delivered dur-

ing the TIG AC arc striking phase. Allows the rounding of the electrode in a uniform and

regular manner. The function is automatically disabled after the arc has

been struck. The power delivered depends on the electrode diam-

eter set on the fuzzy logic. Default off

107 AC - DC time mix

Allows adjustment of the welding time in direct current

when the AC MIX function is enabled. Parameter setting: seconds (s). Minimum 0.02s, Maximum 2.00s, Default 0.24s

108 AC - AC time mix

Allows regulation of the welding time in alternating cur-

rent when the AC MIX function is enabled. Parameter setting: seconds (s). Minimum 0.02s, Maximum 2.00s, Default 0.24s

109 (DC) Welding current

Allows adjustment of the welding current in direct cur-

rent when the AC MIX function is enabled. Parameter setting: percentage (%). Minimum 1%, Maximum 200%, Default 100%

203 TIG start (HF)

Allows selection of the required arc striking modes.

On= HF START, Off= LIFT START, Default HF START

204 Spot welding

Allows you to enable the "spot welding" process and

establish the welding time. Allows the timing of the welding process. Parameter setting: seconds (s). Minimum off, Maximum 99.9s, Default off

205 Restart

Allows the activation of the restart function.

Allows the immediate extinguishing of the arc during

the down slope or the restarting of the welding cycle. 0=Off, 1=On, Default On

206 (TIG DC) Easy joining

Allows striking of the arc in pulsed current and timing

of the function before the automatic reinstatement of

the pre-set welding conditions. Allows greater speed and accuracy during tack welding

operations on the parts. Parameter setting: seconds (s).

Minimum 0.1s, Maximum 25.0s, Default off 207 (TIG AC) Extra energy

Allows balancing of the current in positive polarity com-

pared with that in negative polarity. Makes it possible to obtain greater cleanness of the base

material or greater welding capacity while keeping the

average current value unchanged. Parameter setting: percentage (%). Minimum 1%, Maximum 200%, Default 100%

128

Page 19

500 Allows the selection of the required graphic interface:

XE (Easy Mode) XA (Advanced Mode)

XP (Professional Mode) Allows access to the higher set-up levels:

USER: user SERV: service SELCO: Selco

551 Lock/unlock

Allows the locking of the panel controls and the insertion of a protection code (consult the “Lock/unlock” section).

552 Buzzer tone

Permits adjustment of the buzzer tone. Minimum Off, Maximum 10, Default 5

553 Contrast

Permits adjustment of the display contrast. Minimum 0, Maximum 50

601 (U/D) Adjustment step

Permits adjustment of the variation step on the updown keys. Minimum Off, Maximum MAX, Default 1

602 CH1, CH2, CH3, CH4 External parameter

Allows the management of external parameter 1 (minimum value, maximum value, default value, parameter

selected).

(Consult the “External controls management” section).

606 U/D torch

Allows the management of the external parameter (U/D). 0=Off, 1=A

751 Current reading

Allow the real value of the welding current to be displayed.

Allows the welding current display method to be set.

752 Voltage reading

Allows the real value of the welding voltage to be displayed.

Allows the welding voltage display method to be set.

801 Guard limits

Allows the setting of the warning limits and of the guard limits.

Allows the accurate control of the various welding

phases (consult the “Guard limits” section).

3.5 Programs screen

1 General

Allows the storage and management of 64 welding pro-

grams which can be personalised by the operator.

1 Process of the selected program 2 Welding methods 3 Current pulsation 4 Number of the selected program 5 Main parameters of the selected program 6 Description of the selected program 7 Measurements

2 Program storage

Enter the “program storage” menu by pressing button

for at least 1 second.

Select the required program (or the empty memory) by rotating the encoder.

Program stored

Memory empty

Cancel the operation by pressing button (2)

129

Page 20

Save all the current settings on the selected program by

pressing button (3)

Introduce a description of the program.

- Select the required letter by rotating the encoder.

- Store the selected letter by pressing the encoder.

- Cancel the last letter by pressing button (1)

Cancel the operation by pressing button (2) .

Confirm the operation by pressing button (3)

The storage of a new program on an already occupied memory location requires cancellation of the memory location by an obligatory procedure.

Cancel the operation by pressing button (2)

Remove the selected program by pressing button (1)

Resume the storage procedure.

3 Program retrieval

Retrieve the 1st program available by pressing button

Select the required program by pressing button

Select the required program by rotating the encoder.

Only the memories location occupied by a program

are retrieved, while the empty ones are automatically skipped.

4 Program cancellation

Enter the “Program cancellation” screen by pressing the

button for at least 1 seconds.

Select the required program by rotating the encoder. Delete the selected program by pressing button (1)

Confirm the operation by pressing button (2)

Confirm the operation by pressing button (1) .

Cancel the operation by pressing button (2)

3.6 Interface personalisation

1 7 segment display personalisation

Enter set-up by pressing the encoder button for at least

5 seconds.

Select the required parameter by rotating the encoder

until it is displayed within the central quadrant (5).

130

Page 21

Store the selected parameter in the 7 segment display

by pressing button (2)

Save and exit the current screen by pressing button (4)

Default I1

3.7 Interface personalisation

Allows the parameters to be customized on the main menu.

500 Allows the selection of the required graphic interface: XE (Easy Mode) XA (Advanced Mode) XP (Professional Mode)

PROCESS

MMA

TIG DC

TIG AC

MMA

TIG DC

TIG AC

MMA

TIG DC

TIG AC

PARAMETER

3.8 Lock/unlock

Allows all the settings to be locked from the control panel with a security password.

Enter set-up by pressing the encoder key for at least 5 seconds.

Select the required parameter (551) by rotating the encoder until it is displayed within the central quadrant.

Activate the regulation of the selected parameter by pressing the encoder button. Set a numerical code (password) by rotating the encoder. Confirm the change made by pressing the encoder button. Save and exit the current screen by pressing button (4)

The carrying out of any operation on a locked control panel causes a special screen to appear.

- Access the panel functionalities temporarily (5 minutes) by rotating the encoder and entering the correct password.

Confirm the change made by pressing encoder button.

- Unlock the control panel definitively by entering set-up (follow the instructions given above) and bring back parameter 551 to “off”.

Confirm the changes made by pressing button (4)

131

Page 22

3.9 External controls management

Allows the setting of the welding parameters management method by the external devices (RC, torch…).

Enter set-up by pressing the encoder key for at least 5 seconds. Select the required parameter (602) by rotating the encoder until it is displayed within the central quadrant.

Enter the “External controls management” screen by pressing the encoder button. Select the required parameter (CH1, CH2, CH3, CH4) by pressing button (1). Select the required parameter (select the parameter - Min-Max) by pressing the encoder button. Adjust the required parameter (select the parameter - Min-Max) by rotating the encoder.

Save and exit the current screen by pressing button (4)

Cancel the operation by pressing button (3)

3.10 Guard limits

Allows the welding process to be controlled by setting warning limits

and guard limits for the

main measurable parameters :

Welding current

Welding voltage

Automation movement

Enter set-up by pressing the encoder button for at least 5 seconds. Select the required parameter (801).

Enter the “Guard limits” screen by pressing the encoder button. Select the required parameter by pressing button (1)

. Select the method of setting the guard limits by pressing button (2)

/ Absolute value

Percentage value

7 Warning limits line 8 Alarm limits line 9 Minimum levels column 10 Maximum levels column

Select the required box by pressing the encoder key (the selected box is displayed with reverse contrast). Adjust the level of the selected limit by rotating the encoder. Save and exit the current screen by pressing button (4)

Passing one of the warning limits causes a visual signal to appear on the control panel.

Passing one of the alarm limits causes a visual signal to appear on the control panel and the immediate blockage of the welding operations.

It is possible to set start and end of welding filters to prevent error signals during the striking and extinction of the arc (consult the “Set up” section - Parameters 802-803-804).

132

Page 23

3.11 Alarms screen

Allows the intervention of an alarm to be indicated and provides the most important indications for the solution of any problem encountered.

Alarm icon

2 Alarm code

3 Alarm type

Alarm codes

E01, E02, E03 Temperature alarm

E10 Power module alarm

E11, E19 System configuration alarm

E13 Communication alarm (FP)

E14, E15, E18 Program not valid alarm

E17 Communication alarm (μP-DSP)

E20 Memory fault alarm

E21 Data loss alarm

E22 Communication alarm (DSP)

E27 Memory fault alarm ( )

E28 Memory fault alarm ( )

E29 Incompatible measurements alarm

E30 Communication alarm (HF)

E31 Communication alarm (AC/DC)

E38 Undervoltage alarm

E39, E40 System power supply alarm

E43 Coolant shortage alarm

E99 General alarm

Guard limits code

E54 Current level exceeded (Alarm)

E62 Current level exceeded (Warning)

E55 Current level exceeded (Alarm)

E63 Current level exceeded (Warning)

E56 Voltage level exceeded (Alarm)

E64 Voltage level exceeded (Warning)

E57 Voltage level exceeded (Alarm)

E65 Voltage level exceeded (Warning)

E70 Incompatible "WARNING" alarm

E71 Liquid coolant overtemperature alarm

133

Page 24

3.12 Rear panel

1 Power supply cable

Connects the system to the mains.

2 Gas fitting

3 Signal cable (CAN-BUS) input (RC)

4 Off/On switch

Turns on the electric power to the welder.

It has two positions, "O" off, and "I" on.

3.13 Sockets panel

1 Negative power socket

For connection of earth cable in electrode welding or of torch in TIG.

2 Positive power socket

For connection of electrode torch in MMA or earth cable in TIG.

3 Gas fitting

4 Signal cable (TIG Torch) input

4 ACCESSORIES

4.1 General

Operation of the remote control is activated when connected to the Selco power sources. This connection can be made also with the system power on. With the RC control connected, the power source control panel stays enabled to perform any modification. The modifications on the power source control panel are also shown on the RC control and vice versa.

4.2 RC 100 remote control

The RC 100 is a remote control unit designed to manage the display and the adjustment of the welding current and voltage.

“Consult the instruction manual”.

4.3 RC 120 pedal remote control unit for TIG welding

Once the power source has been switched to the EXTERNAL CONTROL mode, the output current is controlled from a minimum to a maximum value (can be entered from SETUP) by varying the foot pressure on the pedal surface. A microswitch provides the start trigger signal at minimum pressure.

4.4 RC 180 remote control

This remote control unit makes it possible to change the output current without interrupting the welding process.

“Consult the instruction manual”.

134

Page 25

4.5 RC 200 remote control

The RC 200 is a remote control unit designed to manage the display and the adjustment of all available parameters of the power source to which it is connected.

“Consult the instruction manual”.

4.6 ST... series torches

“Consult the instruction manual”.

4.7 ST...U/D series torches

The U/D series torches are digital TIG torches allowing the main welding parameters to be controlled:

- welding current

- program recall

(Consult the “Set up” section).

“Consult the instruction manual”.

4.8 ST...DIGITIG series torches

4.8.1 General

The DIGITIG series torches are digital TIG torches allowing the main welding parameters to be controlled:

- welding current

- program recall Parameters 3-4 can be personalised.

(Consult the “Set up” section). “Consult the instruction manual”.

5 MAINTENANCE

Routine maintenance must be carried out on the system according to the manufacturer’s instructions.

Any maintenance operation must be performed by qualified personnel only. When the equipment is working, all the access and operating doors and covers must be closed and locked. Unauthorized changes to the system are strictly forbidden. Prevent conductive dust from accumulating near the louvers and over them.

Disconnect the power supply before every operation!

Carry out the following periodic checks on the power source:

- Clean the power source inside by means of low-pressure compressed air and soft bristle brushes.

- Check the electric connections and all the connection cables.

For the maintenance or replacement of torch components, electrode holders and/or earth cables:

Check the temperature of the component and make sure that they are not overheated.

Always use gloves in compliance with the safety standards.

Use suitable wrenches and tools.

Failure to carry out the above maintenance will invalidate all warranties and exempt the manufacturer from any liability.

6 TROUBLESHOOTING

The repair or replacement of any parts in the system must be carried out only by qualified personnel.

The repair or replacement of any parts in the system by unauthorised personnel will invalidate the product warranty. The system must not be modified in any way.

The manufacturer disclaims any responsibility if the user fails to follow these instructions.

The system fails to come on (green LED off)

Cause No mains voltage at the socket. Solution Check and repair the electrical system as needed. Use qualified personnel only.

Cause Faulty plug or cable. Solution Replace the faulty component. Contact the nearest service centre to have the sys-

tem repaired.

135

Page 26

Cause Line fuse blown. Solution Replace the faulty component.

Cause Faulty on/off switch. Solution Replace the faulty component. Contact the nearest service centre to have the sys-

tem repaired.

Cause Faulty electronics. Solution Contact the nearest service centre to have the sys-

tem repaired.

No output power (the system does not weld)

Cause Faulty torch trigger button. Solution Replace the faulty component. Contact the nearest service centre to have the sys-

tem repaired.

Cause The system has overheated (temperature alarm -

yellow LED on).

Solution Wait for the system to cool down without switching

it off.

Cause Incorrect earth connection. Solution Earth the system correctly. Read the paragraph “Installation “.

Cause Mains voltage out of range (yellow LED on). Solution Bring the mains voltage within the power source

admissible range. Connect the system correctly. Read the paragraph "Connections ".

Cause Faulty electronics. Solution Contact the nearest service centre to have the sys-

tem repaired.

Incorrect output power

Cause Incorrect selection in the welding process or faulty

selector switch. Solution Select the welding process correctly.

Cause System parameters or functions set incorrectly. Solution Reset the system and the welding parameters.

Cause Faulty potentiometer/encoder for the adjustment

of the welding current. Solution Replace the faulty component. Contact the nearest service centre to have the sys-

tem repaired.

Cause Mains voltage out of range Solution Connect the system correctly. Read the paragraph "Connections ".

Cause Faulty electronics. Solution Contact the nearest service centre to have the sys-

tem repaired.

Arc instability

Cause Insufficient shielding gas. Solution Adjust the gas flow. Check that the diffuser and the gas nozzle of the

torch are in good condition.

Cause Humidity in the welding gas. Solution Always use quality materials and products. Ensure the gas supply system is always in perfect

condition.

Cause Incorrect welding parameters. Solution Check the welding system carefully. Contact the nearest service centre to have the sys-

tem repaired.

Insufficient penetration

Cause Incorrect welding mode. Solution Decrease the welding travel speed.

Cause Incorrect welding parameters. Solution Increase the welding current.

Cause Incorrect edge preparation. Solution Increase the chamfering.

Cause Pieces to be welded too big. Solution Increase the welding current.

Tungsten inclusions

Cause Incorrect welding parameters. Solution Decrease the welding voltage. Use a bigger diameter electrode.

Cause Incorrect electrode. Solution Always use quality materials and products. Sharpen the electrode carefully.

Cause Incorrect welding mode. Solution Avoid contact between the electrode and the weld

pool.

Blowholes

Cause Insufficient shielding gas. Solution Adjust the gas flow. Check that the diffuser and the gas nozzle of the

torch are in good condition.

Sticking Cause Incorrect welding parameters. Solution Increase the welding current.

Cause Incorrect welding mode. Solution Angle the torch more.

Cause Pieces to be welded too big. Solution Increase the welding current.

Undercuts

Cause Incorrect welding parameters. Solution Decrease the welding voltage.

Cause Incorrect welding mode. Solution Decrease the side oscillation speed while filling. Decrease the travel speed while welding.

Cause Insufficient shielding gas. Solution Use gases suitable for the materials to be welded.

Oxidations

Cause Insufficient gas protection. Solution Adjust the gas flow. Check that the diffuser and the gas nozzle of the

torch are in good condition.

136

Page 27

Porosity

Cause Grease, varnish, rust or dirt on the workpieces to

be welded.

Solution Clean the workpieces carefully before welding.

Cause Grease, varnish, rust or dirt on the filler material. Solution Always use quality materials and products. Keep the filler metal always in perfect condition.

Cause Humidity in the filler metal. Solution Always use quality materials and products. Keep the filler metal always in perfect condition.

Cause Incorrect arc length. Solution Decrease the distance between the electrode and

the piece.

Cause Humidity in the welding gas. Solution Always use quality materials and products. Ensure the gas supply system is always in perfect

condition.

Cause Insufficient shielding gas. Solution Adjust the gas flow. Check that the diffuser and the gas nozzle of the

torch are in good condition.

Cause The weld pool solidifies too quickly. Solution Decrease the travel speed while welding. Pre-heat the workpieces to be welded. Increase the welding current.

Hot cracks

Cause Incorrect welding parameters. Solution Decrease the welding voltage.

Cause Grease, varnish, rust or dirt on the workpieces to

be welded.

Solution Clean the workpieces carefully before welding.

Cause Grease, varnish, rust or dirt on the filler metal. Solution Always use quality materials and products. Keep the filler metal always in perfect condition.

Cause Incorrect welding mode. Solution Carry out the correct sequence of operations for

the type of joint to be welded.

Cold cracks

Cause Humidity in the filler metal. Solution Always use quality materials and products. Keep the filler metal always in perfect condition.

Cause Particular geometry of the joint to be welded. Solution Pre-heat the pieces to be welded. Carry out post-heating. Carry out the correct sequence of operations for

the type of joint to be welded.

For any doubts and/or problems do not hesitate to contact your nearest customer service centre.

137

Page 28

7) PURSPOSE OF THE MANUAL

This manual is designed to provide authorised service centres with the basic information necessary for performing repairs on the generators Genesis 1700AC/DC and Genesis 2200AC/DC. 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. For a detailed description of the operation, use and ordinary maintenance of the machine, please refer to the "Instructions for use and maintenance manual" which must always accompany the machine. The purchaser must follow the directions contained in the above manual. Failure to do so will exempt Selco from all liability. The operations described in this manual require the use of a digital multimeter, an DC ammeter clamp and a basic knowledge of how the machine works. Basic electrotechnical knowledge is also required.

Repair consists in identification of the faulty part, included in the list of available spare parts, and replacement of it.

In the event of failure of an electronic board, repair entails replacement of the board and not replacement of the faulty electronic component on the board.

Do not carry out modifications or maintenance not scheduled in this manual.

If the problem cannot be solved by following the instructions provided in this manual, contact the Selco Service Department or send the machine to Selco for repair.

138

Page 29

8) 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.

The repair of a machine requires access to its internal parts and consequently removal of some of the protective panels. Additional precautions are therefore necessary with respect to use of the machine for welding in order to prevent possible injury or damage caused by contact with:

- live parts

- moving parts

- parts at high temperature

CAUTION

LIVE PARTS

When handling internal parts of the machine, remember that opening of the switch does not prevent the risk of electric shocks: the machine must be unplugged from the power supply. Wait approx. one minute before carrying out work on the internal parts as the capacitors may be loaded at high voltage.

CAUTION

MEASURING INSTRUMENT LEAD'S LIVE PARTS

When taking measurements, remember that the measuring instruments can be live and you should therefore avoid touching their metal parts.

CAUTION

LIVE ELEMENTS

When TIG operation with HF start is selected in model Genesis 1700AC/DC and Genesis 2200AC/DC its generates a series of high voltage impulses (approx. 10.000V) to strike the welding arc. Consequently, when an arc striking test in TIG with HF discharge is not specifically scheduled in the diagnostic phases, you are advised to disconnect the terminals FN1 and FN2 of the HF board 15.14.430. After performing the repair, remember to reconnect FN1 and FN2 of board 15.14.430 before re-closing the machine, then run a few welding tests, including arc striking in TIG HF mode.

CAUTION

MOVING PARTS

Keep your hands well away from the fan when the machine is connected to the power supply. Ensure that the machine is unplugged and that the fan is at a standstill before replacing it.

CAUTION

PARTS AT HIGH TEMPERATURE

When handling internal parts of the machine, remember that some of them may be very hot. In particular avoid contact with heat sinks.

139

Page 30

9) INSTRUMENTS AND CONVENTIONS FOR PERFORMING DIAGNOSIS AND REPAIR

9.1) Instruments for basic diagnosis

The following are required:

- a multimeter with the following scales: Ohm: from 0 ohm to a few Mohm Diode testing Direct voltage (Vdc): from mVdc to 1000 Vdc Alternating voltage (Vac): from 10 Vac to 700Vac

NOTE: You are advised to use an instrument with automatic scale since it is not theoretically possible to predict the electrical quantity to be measured when the machine has broken down.

SEVERAL MEASURAMENT SHOULD BE PLACED ON CONNECTORS SIDE. PAY PARTICULAR ATTENTION IN ORDER TO AVOID ANY ACCIDENTAL SHORT CIRCUIT BETWEEN CONNECTOR'S PIN OR TEST LEADS. THE USE OF THIN CONDUCTORS AS RESISTANCE LEADS COULD BE HELPFULL ON MEASURAMENT STAGE.

- an AC/DC ammeter clamp at least in class 2.5 with e.o.s.

300A pk.

9.2) Repair tools

- Complete set of fork spanners

- Complete set of pipe spanners for hexagonal nuts

- Complete set of blade screwdrivers

- Complete set of Phillips screwdrivers

- Complete set of Allen keys

- Dynamometric screws driver for fix M3 with adjustable

torque range 1÷3Nxm tolerance 0.1Nxm

- Crimper for insulated wire terminals (blue, red and yellow)

- Pliers for AMP contacts

- Tweezers and cutting nippers - type commonly used for elec-

tronic components

- Tongs (dimensions suitable for closing gas pipe clamps)

- Welder for electronic components, minimum power 50 W

- Portable electric drill

9.3) Conventions

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 at the other end (b). When a double arrow appears between two measuring points (e.g.: c

d), the voltage to be measured is alternating (normally at 50Hz or 60Hz), therefore it does not matter in which order the multimeter terminals are applied. In drawings and tables, when a voltage measurement appears referring to terminals of components such as DIODES, BJT, MOSFET and IGBT, the multimeter is used in "diode test" mode (these measurements are always taken with the machine switched off and normally give values in the range +0.10 … +0.90Vdc). In this case the following symbol is affixed beside the value to be measured:

Junction measurement (multimeter in "diode test"

mode)

The following symbols will be used in the same way:

AC or DC voltage measurement (multimeter in

voltmeter mode)

Resistance measurement (multimeter in ohmmeter

mode)

Current measurement (ammeter clamp or shunt +

multimeter in millivoltmeter mode)

Frequency measurement (multimeter in frequen-

cymeter mode)

The measuring conditions (power source on/off, MMA/TIG operating mode, etc.) are always clearly indicated beside the values to be measured.

The connector terminals are indicated by the name of the connector followed by a slash and the number of the terminal; for example CN1/2 indicates terminal 2 of connector CN1.

Unless otherwise specified, all the measurements must be performed with the boards fitted, together with their connections.

Remember that the first of the tests to be per-

formed is the VISUAL CHECK!

The visual check reduces troubleshooting times and directs any subsequent tests towards the damaged part!

140

Page 31

9.4) 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 output 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

= 20 + 0.04 x I

OUT

DC TIG WELDING: V

OUT

= 10 + 0.04 x I

OUT

If output voltage goes too much above or below the rated value, the generator could either saturate or go into arc force or other special features could be performed (such as anti-flashing): in both cases real output current could be much different from expected value and the generator could even show an intermittent output power.

Grid load resistor's rated power is also important, 'cos a 24Vdc /100A grid load produces 2400W to be dissipated by air cooling.

So, when using grid load, pay attention to both

output current & output voltage and use correct resistance value & power!

141

Page 32

10) DESCRIPTION OF THE BLOCK DIAGRAM

Genesis 1700 AC/DC and 2200 AC/DC - Block diagram

a) Master switch b) Varistor c) Input filter d) PFC inductance e) PFC rectifier (Power Factor Corrector) f) DC LINK g) ZVS (Zero Voltage Switching) inverter h) Power transformer i) Output rectifier j) Superposition switch k) Output inductance l) Output current hall sensor m) Output filter n) Switching power supply o) Driver Inverter p) Microcontroller q) DSP (Digital Signal Processing) r) Superposition driving circuit s) HF unit t) HF transformer u) Primary current hall sensor v) PFC Driver z) Cooling unit

142

Page 33

143

10.1) Filtro d’ingresso

The single-phase power supply voltage 230Vac – 50/60Hz is fed to the input filter board 15.14.443.

Varistors are placed between input phase. They are component that when on their leads an higher thereshold voltage is applied, starts to conduct extremely quickly, absorbing the peak current in order to limit the said overvoltage and thereby protect the other parts of the machine.

This process is not destructive for the component if the energy caused by the voltage peak is modest, as in the case of simple lightning. If however there is a high overvoltage which lasts beyond a certain time, the varistor is unable to withstand this energy and will burn out.

This happen for istance, when equipment is wrongly powered with excessive voltage over the one shown on data or after overvoltages caused by generating sets with an inappropriate and unstabilised output.

The filter circuit consists of passive components such as a toroidal inductor and various capacitors, some of which are earthed. The filter has the twofold job of keeping the radio-frequency emissions of the machine within the regulation limits and of making it immune to interference from the power supply.

When accessing parts inside the machine, remember that opening the circuit-breaker does not prevent the danger of electric shocks.

Therefore: IT IS ADVISABLE TO PULL OUT THE POWER PLUG.

Page 34

144

10.2) PFC rectifier

The stage rectifier has the task to carry out to the first power conversion and particularly carries out with AC/DC commutation.

Stage PFC (Power factor Corrector) allows to rectifier the sinusoidal input voltage and supply on output a constant dc link. All this absorbing a sinusoidal current that allows to reach a power factor P.F. close the unit. In this way, the absorbed current turns out to be reduced to the case of single bridge rectifier with consequent energetic saving.

On the output of PFC stage is present a DC bus capacitors that forms a constant and regulated DC LINK independently from input supply.

Output PFC stage DC value is fix at 385Vdc.

Afterwards the obtained DC voltage will feed the next inverter stage.

Page 35

145

10.3) Inverter stage

The inverter stage is the second power conversion block. This stage carries out the DC/AC conversion allowing an AC voltage to be obtained at a frequency.

The AC voltage is fed to the transformer primary. Since the dimensions of the transformer are inversely proportional to the frequency of the voltage applied, the fact of switching at high frequency makes it possible to have transformers of small dimensions and with lower magnetic losses compared to the 50/60HZ mains frequency transformers.

The transformer, in addition to adapting the voltage and current levels, also allows the galvanic insulation required by the applicable regulations to be obtained between the user and the mains.

The inverter provided by Selco for the Genesis 1700AC/DC and Genesis 2200AC/DC machines is a resonant inverter of the Zero Voltage Switching type. Therefore, the switchings of the electronic switches are made when the voltage is nil, thus reducing the switching losses and increasing the efficiency of the system. The regulation of the output power is done by the Phase Switching technique.

Inverter driver stage and control system are DSP (Digital Signal Processing).

Page 36

146

10.4) Output stage

Output current and voltage on secondary stage are rectifier from full diodes bridge that finally convert into AC/DC charateristic. Up to here the output power is available for welding process and through it, is keep constant, releated to set current value. The power source is AC/DC type and this include a power switch module that invert current sense in both direction. Moreover thanks to superimposition effect, is increase the arc strike as well the currrent though "0" effect. The output current is measured from hall effect while the output voltage is keep from output filter card 15.14.444.

Page 37

147

10.5) Switching power supply

Pcb 15.14.42901 and 15.14.439 are assembled power supply card that realized isolated and multi voltage DC supply. Are generated +24Vdc, +15Vdc, +12Vdc, -15Vdc. The common input power supply is keep from 375Vdc bus.

Page 38

148

10.6) WU cooling group

Genesis 1700AC/DC and Genesis 2200AC/DC source could be connected to water unit group named WU1000. This allows the use of liquid torch and achieve the best performance from Selco unit.

Page 39

149

11) START-UP INDICATION

11.1) External diagnostic indications

1° EDITION (FP216)

2° EDITION (FP279)

Power supply

Indicates that the equipment is connected to the mains and is on.

General alarm

Indicates the possible intervention of protection devices such as the temperature protection (consult the “Alarm codes” section).

Power on

Indicates the presence of voltage on the equipment outlet connections.

7-segment display

Allows the general welding machine parameters to be displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

Page 40

150

LCD display

Allows the general welding machine parameters to be displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms. Allows all the operations to be displayed instantaneously.

Processes/functions

Let you select the various system functions (welding process, welding mode, current pulse, graphic mode, etc.).

Main adjustment handle

Allows the welding current to be continuously adjusted. Allows entry to set up, the selection and the setting of the welding parameters.

"SYN" Not used

"PROG" Programs

Allows the storage and management of 64 welding programs which can be personalised by the operator.

Page 41

151

11.2) Mechanical inidication

11.2.1 Panels identification

Front view Back view

Panels are keeped considering back view.

Left side

Right side

Page 42

152

Left panel view Right panel view

11.2.2 Opening instruction

Unscrew Unscrew

Once panel removed disconnect ground wire.

Disconnect ground wire

Page 43

153

11.3) Elements location and description section

11.3.1 Left view

15.18.035

Power kit group

15.18.034 Front panel (15.14.439 &

15.14.517 FP279 15.14.435 15.14.430 15.14.415 15.14.419 15.14.42901) 15.14.431

15.14.343 FP216 Superposition Pcb HP Pcb Digital Pcb Analog Pcb Power supply Pcb Bus Pcb

15.14.444 11.19.013 05.04.235 05.18.005 15.14.423 15.14.422 15.14.443 Output filter Pcb HALL Sensor Output PFC Driver Power Input filter Pcb inductance inductance Pcb Pcb

Page 44

154

11.3.2 Right view

15.14.434 15.14.461 AC module Secondary 05.03.002 05.02.034 AC comand Pcb Fitting module AC 15.18.036 rectifier HF transformer Power transformer connector Pcb G 1700 AC/DC used 2 diodes G 2200 AC/DC used 4 diodes (diode cod. 14.05.104)

Page 45

155

12) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS

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.

It should be remembered that the first test to be performed is a VISUAL CHECK !

The visual check reduces the fault-finding times and guides any subsequent action towards the damaged part !

In general, the points to be visually checked are:

- Input filter area

- Electrolytic smoothing capacitors

- Any traces of smoke found inside the casing

- Power and signal connections

- Overall state of the boards

CAUTION

When the machine is connected to the mains, the main circuit-breaker is live, independently of its position (open

or closed) ! Therefore, it is advisable to pull out the power plug before touching anything inside the generator ! It is also necessary, because of the possible presence of capacitors charged to a high voltage, to wait for about one minute before being able to work on the internal parts !

Page 46

156

12.1) Input filter pcb ref. 15.14.443

BOARD FUNCTION: the pc board is connected to the input phase AC . As first stage there is a pre-charge through 15ohm resistances that keeps the input power supply from main switch. Initially RL1-2 are contact open ,later via CN1 a signal activate the two relè in order to by-pass the pre loading resistances. Two thoroidal inductors plus passive components realize input EMI filter. The pcb inform via CN2 analog card 15.14.419 on input AC level.

LOCATION: The pc board is one of the first parts after the main switch and before the main PFC bus control. The output go into L1, main input double inductor. Back left side.

DISMANTLING NOTE: remove the cables on M1 M2 M3 M4,CN1 CN2 and screws on metal spacer . Reference mark on connection are suggested.

NOTE: The pc board included input varistor to protect against the risk of extra input voltage :his failure is consequent of high input voltage, failure not warranty covered.

M2 R1/1 R2/2

CN1

CN2

Page 47

157

Connectors Pcb

Logic flow-chart for pre-loading relay

Measurement

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Power supply ON --- M1

M2 230Vac+15%

Filtered power supply

ON --- M3 M4 230Vac+15%

Input phases detection

ON CN2 CN2/1 CN2/3 230Vac+15%

Pre-loading relay comand

ON CN1 CN1/1 CN1/2 +24Vdc

Pre-charge resistances

OFF R1 e R2 R1/1 R2/2 30ohm

Bus-resistances OFF R3, R4 , R5 M3 M4 15.6 kohm + 20%

Page 48

158

SWITCH TEST

S R U V

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Power supply ON --- R S 230Vac+15%

Power supply after switch

ON --- U V 230Vac+15% Measurement sugge-

sted on input filter card.

Page 49

159

ATTENTION

Switch replacement must be done with unplugged machine.

Risk of electric shock due to voltage presence also with main switch in OFF position.

1) Unscrew knob

Screw

2) Unscrew two switch screw

Switch screws

3) Replace switch dismantling input and output wires (ref. to electric diagram)

Page 50

160

BOARD FUNCTION: this card contains all the power components necessary for complete inverter and PFC group. All the components, three Isotop for PFC stage and one module IMS(Insulated Metal Substrate) for inverter stage ensure total ground isolation with coolers and reduced EMI disturbances. The PFC stage control the Vbus status at 375vdc. The inverter is Zero Voltage Switching type with current regulation made by Phase Shifting. Vbus reference and the main transformer current are controlled from analog card 15.14.419 that isolated and derate the signal in order to transmit relative value to digital card 15.14.415 and this one back to inverter and pfc group. A DC capacitors link is present.

LOCATION: central left side. Electrically speaking it is connect between the main power transformer and receive the power from input inductance.

DISMANTLING NOTE: remove screws on power components and cables from input stage and transformer, ref. to following photos sequence. Pay attention on dismounting and assembling to the right connection of winding from input stage and to pass trough the TA one of the two transformer leads. It’s recommended lead mark for properly assembling. The flat cables need to be removed since rack pcb 15.14.419-415,remain otherwise fixed on inverter groupt. Remove also CN6. The dismantling could be easier removing the bottom aluminium part.

NOTE: it is supply as kit togheter with power module just soldered on it and separately additional Isotop. Pay attention on dismounting and assembling to the right connection of leads from input stage and to pass trough the TA one of the two transformer leads. The power components are assembled on heat skin with use of thermic grease(thermic composed). Pcb. or power components not available separately.

12.2) Power inverter-pfc pcb ref. 15.18.035 (schede 15.14.422 e 15.14.423)

Page 51

161

PFC'S POWER COMPONENTS

D11 IG1 IG2 D1 D7

CN3

CN4

CN5

CN8

CN7

CN6

Page 52

162

PFC STAGE

LEDS INDICATIONS PFC's POWER COMPONENTS

L2 L1 IG1 IG2 D1

CN6

D11

Page 53

163

Functional Part Generator/Mode Component Point Value Type of

Measure

Notes

PFC rectifier (Power Factor Corrector)

OFF IG1 E

+0.36Vdc

+1.8kohm

IG2 E C

+0.36Vdc

+1.8kohm

D1 A K

+0.4Vdc

Open circuit

PFC snubber diodes and IGBT

OFF D7 A K

94ohm 94ohm

D11 A K

94ohm 94ohm

PFC comands ON L1=ON*

L2=ON*

* L1 and L2 are fast blinking.

BUS voltage (DC LINK)

ON CN6 CN6/1

CN6/3

+375Vdc

Note:

* If not otherwise specified all measurement have an accurancy ± 10%. ** PFC's power components.

IG1 e IG2 D1

*** CN6 **** PFC snubber diodes

Page 54

164

INVERTER STAGE

CN3

CN4

CN5

CN8

CN7

Inverter IMS power module

Page 55

165

Inverter power module

G1 = 1

C1 = 2

E1 = 3

G3 = 7

C3 = 8

E3 = 9

21= E2

20= C2

19= G2

15 = E4

14 = C4

13 = G4

Power module equivalent drawing:

Page 56

166

E3 C3 G3 E4 C4 G4

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

IGBT Inverter OFF IG1 E1

+0.38Vdc +885ohm

* Measure should be easier if done on card

15.14.423.

IG2 E2

+0.36Vdc +885ohm

IG3 E3 C3

+0.38Vdc +885ohm

IG4 E4 C4

+0.36Vdc +885ohm

Page 57

167

DRIVER Pcb 15.14.423

L4 E4

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

IGBT Inverter OFF IG1 E1

+0.38Vdc

885ohm

IG2 E2 C2

+0.38Vdc

885ohm

IG3 E3 C3

+0.38Vdc

885ohm

IG4 E4 C4

+0.38Vdc

885ohm

Inverter port ON/MMA L1=ON*

L2=ON* L3=ON* L4=ON*

* When inverter is active.

Page 58

168

PHOTOS SEQUENCES FOR INVERTER KIT DISMANTLING

1) Remove right/left side panels

Remove screws Remove screws

2) Dismantling handle

Screws

3) Remove plastic frame, then unscrew two screws

Screws

Page 59

169

4) Remove frontal mask and screws Screws frontal mask

screws

5) Will be easier and faster remove the front panel

CAN BUS cable Ground to bus card connection

15.14.431

6) Remove bottom panel

7) Disconnect flat cables from 15.14.415-15.14.419 to

15.14.422-15.14.423

Flat

8) Disconnect CN6

CN6

Page 60

170

9) Disconnect primary inverter cable to M1

10) Disconnect primary inverter cable to M2

11) Disconnect PFC inductance from RV1 and RV2

PFC inductance

12) Unscrew two fixing with heatsink

Screws for pcb fixing

Page 61

171

13) Remove 12 screws from isotop components

12 fixing screws

14) Remove 4 screws that fix inverter module

4 screws for inverter module

Page 62

172

15) Remove pcb

PFC's POWER COMPONENTS IG1 IG2 D1

NTC1

Unscrew, torque screw at 2,2N/mt

Page 63

173

16) New power group replacement

- Clean heatsink from thermic grease using alcool.

- Spread on module surface thermic component (Selco code 16.03.102).

- Positioning new pcb.

- Pass input inductance cable through SHL1 and fix to RV1.

- Connect the other from inductance to RV2.

- Pass input inverter cable through TA1 and connect to M1.

- Connect the other to M2.

- Tighten all the screws.

- Power module torque at 3,5Nxm.

- Connect all connector and flat cable.

SHL1 TA1 M1 M2 RV2 RV1

Page 64

174

DIODES AND PFC IGBT ORIENTATION

Landmark for assembling

Page 65

175

12.3) Genesis 1700-2200 AC/DC secondary power module and diodes

(Output module AC-DC ref. 15.18.036 (pcb ref. 15.14.461), diodes ref. 14.05.104)

BOARD FUNCTION: the module is available for versions 1700-2200 (15.18.036) and realizes the power current switch on second-

ary stage. Card 15.14.461 welded on gates leads allows to easy and safe winding on machine. Module’s function is to switch on command the output current into three demanded modalities DC+ DC- AC.

LOCATION: component is located in the secondary stage, side centers right side, easy identifiable as is not overlapped from cards. The electrical connection is through copper bars fixed on output terminals.

DISMANTLING NOTE: remove connector CN1 from card 15.14.461, not unsolder it from module as is just provide on spare kit. Then unscrews the module from heatsink as well the copper bars from output terminals. Suggested mounting torque is at 3N/mt. Particular attention to the thermal compound which must be removed with simple paper or cloth material (also with alcohol addiction) for later spread uniformly on both surface with use of paint-brush . The thermal compound amount must be such to allow a light spillage of the same on component’s boarder line with the radiator. It is important however not to exceed as well not lack in the amount to use. Not use mechanical abrasives tools for the removal and cleaning of the heatsink.

NOTE: two different model (Genesis 1700-2200 AC/DC) use same power module AC. Otherwise the secondary rectifier use in case of Genesis 1700 AC/DC two diodes and four diodes for Genesis 2200 AC/DC.

G1 E1 E2 G2 C1 E2 E1=C2

CN1 PCB 15.14.461

Voltage feedback winding

K1 (D1 E D2) A1(D1,D2) K2(D3,D4) A2 (D3 E D4)

Page 66

176

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

IGBT module AC OFF IG1 E1

+0.38Vdc

8.2kohm*

*CN1 connected on board 15.14.461

G1 47kohm** **CN1 connected

on board 15.14.461

IG2 E2

+0.38Vdc

8.2kohm*

*CN1 connected on board 15.14.461

G2 47kohm** **CN1 connected

on board 15.14.461

Secondary diode OFF D1 e D2 A1

K1 +0.2Vdc

D3 e D4 A2 K2 +0.2Vdc

E1=C2

Genesis 1700 AC/DC Genesis 2200 AC/DC

Landmark for assembling

Page 67

177

12.4) Thermic caps inverter side

NTC1

CN11

Page 68

178

Bus 15.14.431 back side

J13/2

J13/8

J13/7

J13/1

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Thermic T3 OFF T3 J3/2

J3/8 0ohm J13 connector remo-

ved from 15.14.431 bus board.

NTC OFF NTC1 J3/1

J3/7 10kohm@25°C J13 connector remo-

ved from 15.14.431 bus board.

Page 69

179

12.5) Thermic caps secondary side

15.14.434 CN3 CN2

Page 70

180

Thermics T1 and T2 are series connected:

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

T1 and T2 OFF --- CN3/1

CN2/4 0Vdc

0ohm

Page 71

181

BOARD FUNCTION: from power PFC regulator stage keeps the V/Bus and generate all the necessary auxiliary power supply. Controlled from digital card 15.14.415 ,permit to activate with relative electronic switch the input relè, the fan the gas valve . Powering also R.F. ignition card 15.14.430. Direct and not modulate powering also to two small fan placed on bottom close to the inverter power switch and on top of rack pcb.

LOCATION: 5th position on rack system from left, between the analogic card and water unit control card.

DISMANTLING NOTE: remove the screw at base of plastic support, then extract the pcb and when accessible disconnect CN2.

NOTE: the pc board is composed by a sandwich of two card fixed one to the other through pin strip. Pcb 15.14.42901 and

15.14.439 are not available separately, the code 15.18.034 include both pcb. A small fan is integrated in order to keep cooled

this pc board.

MF5 MF2 MF1 D2 D5 CN2

L2 L5 L3 L1 D15 D16 D17 D18 L4

12.6) Switching power supply pcb ref. 15.18.034 (15.14.42901+15.14.439)

Page 72

182

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Mosfet OFF MF1 G

S 10kohm

D2 A K +0.45Vdc

MF2 G S 10kohm

D5 A K +0.45Vdc

MF5 S D +0.45Vdc

Diode OFF D15 A K +0.25Vdc

D16 A K +0.25Vdc

D17 A K +0.25Vdc

D18 A K +0.25Vdc

DC LINK ON CN2/5 CN2/1 +375Vdc

Fan command ON L3=ON --- --- --- When fan is active

ELV1 command ON L2=ON --- --- --- ON when gas valve is

active

+15Vdc power supply M3ON L4=ON M3 fan power supply

Pre-loading relay command

ON L5=ON

ELV 2 ON L1=OFF Genesis 1700AC/DC

and Genesis 2200AC/ DC use only one gas valve

Page 73

183

POWER SUPPLY CARD 15.14.439

L1 L2

L3 L4

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

+15Vdc secondary side ON L1 = ON --- --- ---

-15Vdc secondary side ON L2 = ON --- --- ---

-15Vdc primary side ON L3 = ON --- --- ---

+15Vdc primary side ON L4 = ON --- --- ---

Page 74

184

15.14.439 15.14.42901

L3 L4

Page 75

185

Gas valve flow chart signal

Pipe 38 39

Page 76

186

1) Dismontling knob

Screw

2) Unscrew gas valve

Screws

3) Unscrew gas valve nipple use fix key 14

4) Dismontling gas valve holder, then pipe and winding

Pipe Holder Valve screws ELV

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

ELV command ON/

TIG DC

ELV 39

+2Vdc*

+24Vdc**

*Torch button switch OFF

**Torch switch pressed. Active for few second if machine is not loaded.

Note:

** Torch button pressed. Active for few second if machine is not loaded.

GAS VALVE DISMONTLING & REPLACEMENT

Page 77

187

BOARD FUNCTION: is the main control board. Manage different signal and have inside microprocessors for main program that permit to control all the internal function, welding menu, parameter and DSP (digital signal processor) for control the input stage PFC and the inverter stage. The board control:

1) Pre-loaded relais

2) gas valve

3) main fan in on-off system

4) can bus communication with all units connected on internal can bus net (front panel, remote control card, internal connector)

5) HF trigger signal

6) AC-DC plus Superposition effect

Moreover receive the signal for logic and DSP control as:

1) Vline from card 15.14.419

2) Vbus/ Vbus/2 from card 15.14.419

3) Welding current and voltage from card 15.14.419

4) NTC and thermic caps from card 15.14.419

5) Switch start buttom from output filter card 15.14.516>bus card 15.14.431>15.14.415

LOCATION: 3rd position in rack system from front panel, between hf card and analog card. Connected on bus board 15.14.431 and via ribbon cable to the main inverter. Each pc b on rack have his right position, not possible wrong placing.

DISMANTLING NOTE: remove the screw at base of plastic support ,then extract the pcb and when accessible disconnect CN4 and CN5. Pay attention during dismantling and reassembling of two ribbon cable to the hot glue present. First remove with properly tool the glue then lift up flat cable without tearing.

NOTE: pay attention before replacing card to the software release installed: is recommended to consult menu set-up SERV pwd 358 parameter 501 for information before dismantling. If generator is at first edition (FP 15.22.216) please consult Selco service (service@selcoweld.com).

L8 L9

L4 L1

L6 L7 SW1 SW2 L5

L10 L11 L12

12.7) Digital card pcb ref. 15.14.415

Page 78

188

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Machine identification DSP

ON L6 = ON*

L7 = ON**

--- --- --- *This diodes is blinking. Correct comunication DSP-uC

** This diodes is blinking slowly.

Machine identification uC

L8 = ON*

L9 = ON**

*This diodes is blinking. Correct comunication DSP-uC.

** This diodes is blinking slowly.

+5Vdc voltage supply ON L10 = ON --- --- ---

+3.3Vdc voltage supply ON L11 = ON --- --- ---

+1.9Vdc voltage supply ON L12 = ON --- --- ---

+5Vdc isolated voltage supply

ON L5 = ON --- --- ---

Firmware updated ON L1=OFF

L2=OFF

L3=OFF

L4=OFF

These diodes are blinking when firware is updating

Hardware reset uC*** ON SW1=Pressed

Hardware reset DSP*** ON SW2=Pressed

*** When SW1(or SW2) is pressed uC (or DSP) is reset.

Page 79

189

CN6 15.14.415 CN3 15.14.431 FLAT A FLAT B Inverter commands Boost commands

Page 80

190

By pass relais flow chart

Gas valve ELVI

Fan M1 and M2 command signal

Page 81

191

HF command signal

AC command signal

Torch switch buttons signals

Page 82

192

12.8) Analog signal pcb ref. 15.14.419

BOARD FUNCTION: analog card, the main purpose is to manage all the input and output reading (volt and ampere) in order to isolate and derate the different signal, permitting the management of these signals for the other control unit. Receive Vbus, input voltage, thermic and ntc sensor, output current, output voltage. The pcb works in relation with digital card.

LOCATION: 4th position in rack system from left, between the digital card and the auxiliary switching card. The pcb has got fix position, not possible slot wrong placing. Via ribbon cable it’s connect with pfc power stage switch.

DISMANTLING NOTE: remove the screw at base of plastic support ,then extract the pcb and when accessible disconnect CN1 and CN2. Pay attention during dismantling and reassembling of CN3 ribbon cable to the hot glue present. First remove with properly tool the glue then lift up flat cable without tearing.

NOTE: the pc board has got few pre-adjusted trimmers: don’t move from factory position as they manage important power threshold.

CN1 L2 L1 CN2

L4 L5 L3 L6

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

+15Vdc voltage supply ON L6 = ON --- --- ---

-15Vdc voltage supply ON L3 = ON --- --- ---

+15Vdc voltage supply primary side ON L2 = ON --- --- ---

-15Vdc voltage supply primary side ON L1 = ON --- --- ---

+15Vdc voltage supply secondary side ON L4 = ON --- --- ---

-15Vdc voltage supply secondary side ON L5 = ON --- --- ---

Page 83

193

Input voltage after EMC filter ON CN1/1 CN1/3 230Vac

DC LINK ON CN2/1 CN2/3 +375Vdc

Ref. power supply DC Bus voltage Flat with +15Vdc power supply from input filter card

Page 84

194

12.9) Superimposition pcb ref. 15.14.435

BOARD FUNCTION: receive from digital card the information relative to superimposition driver. The superimposition effect permit to manage the AC switching around the 0 crossing point, against the stopping effect. Trough short volt impulse permit the helping ignition in the sense the arc is moving. In case of DC unit the use of above card permit an double effect on output voltage, useful for strong and sure ARC ignition.

LOCATION: at 1st position in rack system from left , the first one after the front panel ,before the h.f. card. The pcb on rack have fix position, not possible wrong slot placing.

DISMANTLING NOTE: remove the screw at base of plastic support ,then extract the pcb and when accessible disconnect CN2, CN3, CN4. The connector pinning has been designed for right positioning. In case of use in DC unit disconnect also winding on MS. Also if not needful a cables mark is recommended.

NOTE: NP.

D7 D9 D12 D14 D3 IG2 IG1 D8 D10 D13 D15

MF1

D17

Page 85

195

Functional Part Generator/Mode Component Point Value Type of

Measure

Notes

Diode OFF D7 A

K +0.45Vdc

D8 A K +0.45Vdc

D9 A K +0.45Vdc

D10 A K +0.45Vdc

D12 A K +0.45Vdc

D13 A K +0.45Vdc

D14 A K +0.45Vdc

D15 A K +0.45Vdc

IGBT OFF IG1 E C

+0.5Vdc

2.2kohm

IG2 E C

+0.5Vdc

2.2kohm

Diode IGBT OFF D3

D17

A K A

+0.5Vdc +0.5Vdc

Mosfet OFF MF1 S D

+0.55Vdc

100kohm

Note:

* MF1

Page 86

196

12.10) H.F. Generator pcb ref. 15.14.430

BOARD FUNCTION: supply of H.F. for TIG arc ignition. The H.F. is capacitive discharging type. The pc board is powered with 24vdc from auxiliary supply card 15.18.033.

LOCATION: 2nd rack system position, between the ac-dc & superimposition card and digital card. The pcb on rack have fix position, not possible wrong slot placing.

DISMANTLING NOTE: remove the screw at base of plastic support ,then extract the pcb and when accessible disconnect FN1-FN2. Pay attention to correct winding H.F. sense, mark on cables is recommended.

NOTE: a relay reverse the polarity sense in order to improve the striking in DC as well AC. Three leds shown: L1=VCC, L2=RF TURN ON, L3=POLARITY RELAY COMMAND

D1 D3 D4

FN1

FN2

L3 D12

FN1= white faston

FN2= red faston

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Diodes OFF D1

A K

+0.9Vdc

+0.45Vdc

Relay coil OFF D12 K A 870ohm The relay switches

over when change from HF+ to HFmode.

+20Vdc voltage supply ON L1=ON

HF command* ON L2=ON Only with HF com-

mand.

HF- ON L3=ON Only with HF-TIG DC

L3=OFF in TIG AC. Generate from

15.14.415

Page 87

197

Notes:

* HF command signal

HF WAVEFORM

WARNING

Use a probe with a minimum attenuation of x100

Red faston

White faston

Page 88

198

HF pulse in TIG AC HF pulse in TIG DC

Page 89

199

12.11) Output module AC-DC driver pcb ref. 15.14.434

BOARD FUNCTION: this card realize the final gate’s signal for both power switch of ac-dc module. This card is informed about which bridge switch-on from digital card. Internal circuit in order to clamp overvoltage during ac-dc switching. Receive also the secondary thermostat and NTC ,and transmit the thermal status via bus board to the analogic card then to the digital control card.

LOCATION: right upper section, the pc board has got a trapezoidal shaping.

DISMANTLING NOTE: remove connectors CN1 to CN4 and wire on C1. Four screws fix the pcb on aluminium frame. Different

lay out connectors avoid wrong replacement .

NOTE: two led shown which diagonal is switched, if DC+/DC- or blinking in case of AC welding.

MF1

TR2

TR1

Z10

Z5 Z7 Z6 D9

TR3

TR4

Z11

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Diodes OFF Z4

Z10

Z11

+0.7Vdc

+0.6Vdc

+0.5Vdc

Page 90

200

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Secondary side thermal protection

OFF T2

NTC2

T2/1

T2/2

NTC2/1

NTC2/2

0Vdc

12kohm* *@T=25°C

Mosfet MF1 OFF MF1 S

D +0.7Vdc

Transistor OFF TR1 e TR4

TR1 e TR4

B C

+0.6Vdc

Led ON L2=ON

L3=OFF

L2=OFF

L3=ON

L2=ON

L3=ON

This LED is ON in:

- Sitck DC+

- TIG DC

- TIG AC part +

This LED is ON in:

- Sitck DC-

- TIG AC part -

This Leds blinking in:

Stick AC

TIG AC

Before welding, in Stick AC is only L2=ON whereas in TIG AC is only L3=ON.

CN1/1 -> Not use CN2/1 e CN2/4 -> Input NTC CN1/2 -> COM AC CN1/3 -> GND_S CN3/1 e CN3/2 -> Thermostat input CN1/4 ->+15Vdc CN1/5 -> Output Ther 2 (15.14.419 not use) CN4/1-> COM_AC_GA CN1/6 -> Output Ther 1 (15.14.419) CN4/3-> COM_AC_GB CN1/7 -> GND_S CN4/4-> RIF_COM_AC_SA CN1/8 -> Not use CN4/6-> RIF_COM_AC_SB CN1/9 -> Configuration signal CN1/10 -> Configuration signal

Page 91

201

12.12) Control panel pcb ref. 15.14.343 & 15.14.342

BOARD FUNCTION: passive remote control, could be consider as the extension of digital card microprocessor. Show the different parameter and internal set-up menu. The front panel include: Dynamic LCD display, Status Led, Seven segments display, Push button and rotary encoder , four push button used for different enable/disabled function based on display’s contest.

LOCATION: at top front side.

DISMANTLING NOTE: unscrews the two screws present on front side, then pivot and extract. Remove CN3 and earth wire.

NOTE: a piezo buzzer present for button pressing. The panel is given assembled complete with pc board 15.14.343 and 15.14.342,

display 2.5" and metal aluminium serigraphy. Display not available separately. Front panel present on first product edition (G 17002200 AC/DC FP 15.22.216).

MEASURE Perform only visual inspection, particulary connection flat cable and general components status.

CN1 CN4 CN5

CN2

CN3

Components side Weldings side

Page 92

202

LOCATION: at top front side.

DISMANTLING NOTE: unscrews the two screws present on front side, then pivot and extract. Remove CN1 and earth wire.

NOTE: a piezo buzzer present for button pressing. The panel is given assembled complete with pc board 15.14.517, display 3.5"

and metal aluminium serigraphy. Display not available separately.

L4 L5 L6 L7 L11 L12

L1 L2 CN1 L3

12.13) Control panel LCD 3.5” pcb ref. 15.14.517 (spare order ref. 15.22.279)

Page 93

203

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Power supply ON L1=ON Green

Alarms ON L2=OFF Yellow L2=ON in alarm

state

Output power enable with open circuit voltage limitation

ON L3=ON Red MMA or TIG

with trigger press

+5Vdc voltage supply ON L4=ON

+3.3Vdc voltage supply ON L5=ON

CAN BUS comunications ON L6=ON*

L7=ON*

* Blinking when there is a CAN BUS comunications

Serial Comunications ON L11=ON*

L12=ON*

* Blinking when there is a serial comunication.

Page 94

204

12.14) Bus pcb ref. 15.14.431

BOARD FUNCTION: the board contains the bus connectors for the rack’s pcb, realizing intercommunication between them and bringing the various signals through dedicated connectors to external /internal device. Contains a memory circuit for diagnostics and system configuration.

LOCATION: located at the base of the rack cards. Connected in a central position at the top, has several connections with various generator’s units.

DISMANTLING NOTE: will be useful to remove all connections from CN7 to CN17. Remove rack cards as well. Remove the screws on pcb’s board.

NOTE: the memory circuit includes a single generator’s information : is therefore necessary, before changing the card ,to contact the service at service@selcoweld.com for testing and management of board to be replaced. Connectors pinning available at par. “Connectors”.

CN7

CN8

CN9

CN10

CN11

CN12

CN13

CN14 CN15

CN16

CN17

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

+15Vdc CAN bus voltage supply

ON CN8 CN8/1

CN8/2 +15Vdc

Supply voltage ON CN9 CN9/3 CN9/4

CN9/6

CN9/4

+15Vdc

+5Vdc

Hall sensor ON CN10 CN10/7 CN10/2 0.68@50A

1.37@100A

2.02@150A

2.71@200A

3.38@250A

Stick mode

NTC1 ON CN11 CN11/1

CN11/7 12kohm @T=25°C

T1 ON CN11 CN11/2

CN11/8 0ohm

+48Vdc CAN bus voltage supply

ON CN12 CN12/1 CN12/5 +48Vdc

+24Vdc CAN bus voltage supply

ON CN13 CN13/5 CN13/8 +24Vdc

Inverter Fan supply M2 ON CN13 CN13/4 CN13/8 +24Vdc

+15Vdc CAN bus voltage supply

ON CN16 CN16/1 CN16/3 +15Vdc

Page 95

205

HALL PROBE

Allows to supply a current signal proportional to the output current. This signal arrive to card 15.14.419 the derate and convert in voltage signal thanks to I/V converter.

HALL probe Twisted winding for power supply and Iout signal

Output current value could be measured between CN10/7 CN10/3 (CN10 Pcb 15.14.431) using below conversion formule:

Vmeasured = Iout/74 [Vdc]

Iout Vmeasured Measured value example

50A 0.675Vdc 0.675Vdc 100A 1.351Vdc 1.320Vdc 150A 2.027Vdc 1.953Vdc 180A 2.432Vdc 2.365Vdc

Page 96

206

For easy measurement is suggest to adapt thin wires placed on connector side and connected to DC digital multimeter. Pay particular attention in order to avoid accidentaly short-circuit between therminals leads.

ATTENTION: AVOID TO SHORT CIRCUIT DURING MEASUREMENT.

PAY ATTENTION TO NOT DAMAGE CONNECTORS CN10.

Pin 10

Pin 5

Pin 10 Pin 9 Pin 8 Pin 7 Pin 6

Pin 5 Pin 4 Pin 3 Pin 2 Pin 1

Page 97

207

SWITCH TORCH AND OUTPUT CONNECTOR CHECK

Output connector and switch torch button could be placed on CN7 bus card side.

CN7

CN7/1

CN7/5

CN7/4

CN7/8

ATTENTION: AVOID TO SHORT CIRCUIT DURING MEASUREMENT.

PAY ATTENTION TO NOT DAMAGE CONNECTORS CN7.

Page 98

208

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

+15Vdc CAN BUS power supply

ON CN7 CN7/1

CN7/5 +15Vdc

Torch switch ON/TIG CN7 CN7/6 CN7/5 +5Vdc*

+0Vdc**

*Torch switch released.

**Torch switch pressed.

UP torch switch ON/TIG CN7 CN7/2 CN7/5 +5Vdc*

+0Vdc**

* UP torch switch released.

**UP torch switch pressed. During this operation the display shows increasing current value.

DOWN torch switch ON/TIG CN7 CN7/3

CN7/5 +5Vdc*

+0Vdc**

*DOWN torch switch released.

**DOWN torch switch pressed. During this operation the display shows decrease current value.

Note: * Measure done mit plugged torch.

PT/SWITCH

DOWN/SWITCH

UP/SWITCH

Page 99

209

BOARD FUNCTION: filtering and bypassing for: output studs,input remote amphenol. Source for the voltage feedback via analogic board. Source for dummy load resistor and remote control.

LOCATION: assembled on front plastic profile.

DISMANTLING NOTE: the pcb is fixed on plastic profile with two screws; connector CN1-2-3 and winding to be removed. The

replacement will be easier if front command display and plastic frontal mask will be removed. Then unscrews the plastic profile from aluminium frame and copper bar connection with H.F. transformer. The pcb will placed as required for inspection or replacment.

NOTE: this pcb need to be evaluate mainly for visual inspection, measure should be placed on bus card 15.14.444 connector’s side.

CN1

CN4

12.15) Output filter pcb ref. 15.14.444

Page 100

210

Functional Part Generator/

Mode

Component Point Value Type of

Measure

Notes

Output voltage (measured in open circuit voltage MMA)

ON/MMA CN10 CN1/10

CN1/3 +80Vdc

+15Vdc CAN BUS power supply

ON CN4 CN4/1 CN4/5 +15Vdc

Torch switch ON/TIG CN7 CN4/6 CN4/5 +5Vdc*

+0Vdc**

*Torch switch released.

**Torch switch pressed.

UP torch switch ON/TIG CN7 CN4/2

CN4/5 +5Vdc*

+0Vdc**

* UP torch switch released.

**UP torch switch pressed. During this operation the display shows increasing current value.

DOWN torch switch ON/TIG CN7 CN4/3

CN4/5 +5Vdc*

+0Vdc**

*DOWN torch switch released.

**DOWN torch switch pressed. During this operation the display shows decrease current value.

* Note:

It is recommend to take measurement directly on CN7 Pcb bus 15.14.431. In case of missing measurement proceed with winding inspection as well output filter card.

ATTENTION: AVOID TO SHORT CIRCUIT DURING MEASUREMENT.

PAY ATTENTION TO NOT DAMAGE CONNECTORS CN1 AND CN4.

Selco Genesis 1700 AC/DC, Genesis 2200 AC/DC Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual