Selco Genesis 200 AC-DC, WU 15, Genesis 200 TLH Repair Manual

REPAIRS MANUAL

E
N
G

L

I

S
H

Genesis

200 AC-DC

Genesis

200 TLH

WU 15

Cod. 92.08.00901
Edition: 02/02
Rev.: 1.0

SELCO s.r.l.

Via Palladio, 19
I - 35010 ONARA DI TOMBOLO (Padova) Italy
Tel. [phone]
Fax [phone]
e-mail: [e-mail]

How to contact Selco's Service Department:

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

Via Macello, 61
I - 35010 CITTADELLA (Padova) Italy
Tel. [phone]
Fax [phone]
e-mail: [e-mail]

All rights reserved. Copyright Selco s.r.l.. No part of this
manual may be translated, reproduced or adapted by any
means (including photocopying, filming and microfilming)
without the written permission of Selco s.r.l.

INDEX :

1) GUARANTEE CONDITIONS

. . . . . . . . . . . . . . . .3

2) PURPOSE OF THE MANUAL . . . . . . . . . . . . . . .3

3) WARNINGS, PRECAUTIONS, GENERAL

INFORMATION ON EXECUTING REPAIRS

. . . .4

4) DIAGNOSTICS AND REPAIR INSTRUMENTS

AND TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . .5

5) WIRING AND CONNECTION DIAGRAMS . . . .6

6) DESCRIPTION OF MACHINE'S COMPONENT

PARTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7) DESCRIPTION OF DIAGNOSTIC INDICATIONS .12

8)

SET-UP PARAMETERS . . . . . . . . . . . . . . . . . . . . .18

9) DESCRIPTION OF BOARDS . . . . . . . . . . . . . . . .19

10) (ENGLISH) FINAL INSPECTION

OF POWER SOURCE AND SETTINGS

. . . . . . . .34

(DEUTSCH) ENDPRÜFUNG DES GENERATORS
UND EICHUNGEN

. . . . . . . . . . . . . . . . . . . . . . . . . .36

(FRANÇAIS) ESSAI FINAL DU GÉNÉRATEUR
ET RÉGLAGES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

(ESPAÑOL)PRUEBA FINAL DEL GENERADOR Y
CALIBRACIONES

. . . . . . . . . . . . . . . . . . . . . . . . . . .40

11)

AVAILABLE SPARE PARTS . . . . . . . . . . . . . . . . . .42

12) TECHNICAL DATES . . . . . . . . . . . . . . . . . . . . . . .48

2

1) GUARANTEE CONDITIONS

To specify the present warranty conditions , we remind that
SELCO does not repair under warranty the damages:
a) resulting from attempts by personnel not allowed by

SELCO to install, repair or service the products;

b) resulting from improper use or connection to incompatible

equipment;

c) in products that have been modified or integrated with

other products when such modification or integration can
be the cause of the failure.

The warranties will in any case be invalidated if :

- the customer is not up-to-date with payments

- Selco has not received the warranty card properly filled-in
with required information

- removal or modifing of serial numbers of machines, boards
or parts

- damages are caused by wrong input power supply volta­ge/connections.

2) PURPOSE OF THE MANUAL

The purpose of this manual is to furnish authorized service
centres with essential information required to repair model
Genesis 200 (TLH and AC-DC).
To avoid serious personal injury or damage to property, it is
vital this manual be used by qualified technical personnel only.
Selco s.r.l. declines all responsibility for any injury or damage
to property caused whilst repairs are being carried out, inclu­ding any injury or damage to property subsequent to the rea­ding or putting into practice of the contents hereof.
For a detailed description of operation, use and routine main­tenance of the machine, refer to the "Owner's manual", which
must always be kept together with the machine.
To perform operations described herein, you will need a digi­tal multimeter and a clamp-on AC-DC ammeter together with
basic knowledge of how the machine works. A fundamental
grasp of electrical technology is also required.
Repair work consists in locating the faulty part - as this part is
included on the list of available spare parts - and in replacing
it.
If a circuit board is faulty, repairs will consist in replacing the
board and not replacing the faulty electronic component on
the actual board.
Refrain from making any changes or performing any mainte­nance work not contemplated herein.
Should the problem persist even after following the instruc­tions described herein, contact Selco's Service Department or
send the machine to Selco for relevant work.

The purchaser is obliged to comply with the directions contai­ned in the manual. Failure to do so will result in Selco decli­ning all liability.

Guarantee conditions - Purpose of the manual 3

4 Warnings, precautions, general information on executing repairs

3) WARNINGS, PRECAUTIONS, GENERAL
INFORMATION ON EXECUTING REPAIRS

lmminent danger of serious bodily harm and dange­rous behaviours that may lead to serious bodily
harm.

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

The notes preceded by this symbol are mainly tech­nical and facilitate operations.

Behaviour linked expressly to HF striking, which
might result in minor injuries or damage to property
(especially measuring instruments).

Repairs may be executed by qualified personnel only.

Before attempting any repairs, we advise you to read and
understand the information in this manual, especially in regard
to safety recommendations.

Do not carry out any repair unless another person is present
who can provide help in case of an accident.

To repair equipment, access is necessary to the internal parts
of the machine, and to obtain this, some protective panels
have to be removed. Therefore, some extra precautions are
necessary, over and above those applying to normal use of the
machine for welding, in order to prevent any damaged caused
by contact with:

- Live parts

- moving parts

- parts at high temperature

- Live parts:

WARNING!: When accessing parts inside the machi­ne, remember that turning off the switch will not
prevent the danger of electric shocks. We therefore

advise you to remove the plug and wait for about a
minute before attempting any job.
Further, as capacitors charged with high voltage may be present,
wait about a minute before working on the internal parts.

WARNING!: When taking measurements, remember

that the measuring instruments themselves can

become live and, therefore, do not touch their metal

parts.

WARNING!: When TIG mode is selected with HF

start, the machine generates a series of high-voltage

pulses (approx. 10,000 V) to strike the welding arc.
Consequently, when diagnostic phases do not expressly inclu­de an arc striking test in TIG mode with HF discharge, you are
recommended to disconnect board 15.14.286.
Once repairs are done, remember to reconnect board

15.14.286 before closing the machine case for the last time

,
and then perform a number of welding tests, including a num­ber of starts in TIG HF mode.

- Moving parts:

WARNING!: Keep your hands well away from the
fan when the machine is connected to the power
supply. Make sure that the power plug is removed
and that the fan is idle before replacing it.

- Parts at high temperature:

WARNING!: When you have to handle internal parts
of the machine, remember that some could be at
high temperature. In particular, do not touch cooling
radiators.

WARNING!: To avoid damaging the cooling unit,
always fit the bypass pipe when the torch is not con­nected to the coolant inlet/outlet.

Diagnostics and repair instruments and tools 5

4) DIAGNOSTICS AND REPAIR INSTRUMENTS
AND TOOLS

4.1)

Instruments for basic diagnostics

You will need:

- a multimeter with the following scale:
Ohms: in the range 0 to several Mohms
Diode test
Direct voltage (Vdc): from mVdc to 1000 Vdc
Alternating voltage (Vac): in the range 10 Vac to 700 Vac

NOTE: You are advised to use an instrument with an automa­tic scale as, theoretically speaking, when the machine is faulty,
it is not possible to foresee the level of the electrical value to
be measured.

- a class 2.5 or higher clamp-on AC-DC ammeter with end of

scale 300A pk

- instead of the clamp-on ammeter, you can use a shunt with

a value of 60 mV @ 200 A.

NOTE:

- Remember that other shunts may do the job just as well,

though a greater capacity means less accuracy, whilst with
lower capacities, the measurement must be taken quickly or
the shunt will overheat.

Once inserted, the shunt is at welding potential
(watch out, above all, for discharges during striking
in TIG HF mode!)

- Nonetheless, in practical terms, a clamp-on ammeter is the

best choice.

4.2)

Tools for repairs

- complete set of open-ended spanners

- complete set of 6-point socket spanners

- complete set of flat-tip screwdrivers

- complete set of Phillips screwdrivers

- complete set of Allen keys

- a Phillips torque wrench for M3 screws with torque settings

in the range 1 to 2 Nxm accurate to 0.1 Nxm.

- a crimping tool for insulated wire terminals (blue, red and

yellow)

- a pair of pliers for AMP contacts

- pliers and nippers commonly used with electronic compo-

nents

- a larger pair of nippers for cutting small thicknesses of sheet

metal

- tongs (suitable size for closing gas pipe clamps)

- a soldering iron for electronic components with min. power

50 W

- portable DIY electric drill

4.3)

Conventions

We have adopted a convention whereby, when you are asked
to take a measurement between two points, such as ab,
the tip of the arrow always indicates where to apply the mul­timeter's red probe (a), whilst the black probe is applied to the
other end (b).

When the arrow between two measuring points is double (e.g.:
c d), the voltage to be measured is alternating (usually at
50 Hz) and, consequently, it does not matter what order the mul­timeter's probes are applied in.

In drawings and tables, when a voltage measurement referring
to terminals of components such as diodes, BJTs, mosfets and
IGBTs appears, reference is made to the multimeter being used
in "diode test" mode (such measurements should always be
taken with the machine switched off, and usually give values
in the range +0.10… +0.90 Vdc). In this case, the relevant
symbol appears next to the value to be measured.

Junction measurement (multimeter in "diode test"
mode)

Similarly, the following symbols will be used:

AC or DC voltage measurement (multimeter in voltme­ter mode)

Resistance measurement (multimeter in ohmmeter
mode)

Current measurement (clamp-on ammeter or shunt +
multimeter in millivoltmeter mode)

Measuring conditions (power source on/off, MMA/TIG opera­ting mode etc.) are always clearly indicated next to the value
to be measured.

Connector pins are indicated with the name of the actual con­nector followed by a slash and by the number of the pin; for
instance, CN1/2 indicates pin 2 of connector CN1.

Unless otherwise specified, all measurements should be taken
with the boards in their slots and connected accordingly.

Remember that testing should always start with a
VISUAL INSPECTION!
Visual inspection reduces the time spent troubles­hooting and points any subsequent tests in the direc­tion of the damaged part!

6 Wiring and connection diagrams

5) WIRING AND CONNECTION DIAGRAMS

5.1) WU15 Wiring diagram (fig. 1)

Review 28-04-98

1

QUESTO DISEGNO E' DI PROPRIETA' SELCO. SONO PROIBITE LA RIPRODUZIONE E LA DIFFUSIONE NON AUTORIZZATE.

2

Wiring and connection diagrams 7

5.4) Connectors (fig. 5) Review 17-03-00

A

22

2

2



2

2

QUESTO DISEGNO E' DI PROPRIETA' SELCO. SONO PROIBITE LA RIPRODUZIONE E LA DIFFUSIONE NON AUTORIZZATE.

2



2

5.5) Connections for central adapter and remote control connector (fig. 5 )

Note:

- To connect the trigger on the torch, use the central adapter only;

- The sole purpose of the military connector is to connect the button on the remote control, where applicable
(e.g.: RC 12);

- if there is a potentiometer, it should have a value in the range [2.5 ~ 10] k .

8 Wiring and connection diagrams

FRONT VIEWS

CENTRAL TORCH ADAPTER REMOTE CONTROL

3 - 5 = Torch trigger A = EXT +V

B = EXT GND
C = EXT RIF
D = - (not connected)
E = - (not connected)
F = - (not connected)
G = EXT Torch trigger

Wiring and connection diagrams 9

5.5) RC12 - RC16 remote control wiring diagrams (fig. 6 )

RC16 Wiring diagram

RC12 Wiring diagram

10 Description of machine's component parts

6) DESCRIPTION OF MACHINE'S PARTS (fig. 7)

6.1)

In terms of electrics, power source Genesis 200 (AC-DC

and TLH) is made up of the following parts:

a) master switch
b) connector for cooling unit WU15
c) input filter board (15.14.252)
d) bus board (15.14.285/15.14.315)
e) power supply board + UPFR + power inverter ("main-

board" 15.14.250)
f) UPFR inductor
g) thermal cutout capsules
h) inverter capacitors board (15.14.288)
i) power transformer
j) secondary power rectifier [differs from AC-DC to TLH]
k) secondary clamp board (15.14.256) [G200 AC-DC only]
l) secondary IGBT module for AC [G200 AC-DC only]
m) AC module connection board (15.14.289) [G200 AC-DC

only]
n) Hall-effect current probe
o) output inductor
p) output filter board (15.14.238)
q) HF transformer
r) central adapter for TIG torch
s) outputs for earth clamp and electrode holder
t) 24Vdc motor-powered fan
u) HF generation board (15.14.286)
v) AC control and superimposition board (15.14.253) [G200

AC-DC only]
w) 48Vdc TIG gas solenoid valve

x) front panel board (15.14.236) [FP122 for G200 AC-DC,

FP106 for G200 TLH]
y) output resistor
z) remote control connector

Note:

The TLH differs from the AC/DC model as follows:

- front panel " x ",

- different configuration of secondary power rectifier " j "

- does not feature parts " k-l-m-v "
as there is no AC function (also see master wiring diagram)

1

panel boards 15.14.236 have different factory set­tings depending on the version of the panel they are
fitted on (FP106 or FP 122); this setting can be made
by the manufacturer only.

Description of machine's component parts 11

(fig. 8 )

6.2)

In terms of electrics, cooling unit WU15 is made up

of the following parts.

a) connector for connection to power source G200
b) 230Vac motor-powered fan
c) 230Vac pump

1212 Description of diagnostic indications

7) DESCRIPTION OF DIAGNOSTIC INDICATIONS

7.1) EXTERNAL DIAGNOSTIC INDICATIONS

FP 106 - GENESIS 200 TLH (fig. 10)

FP 122 - GENESIS 200 AC-DC (fig. 9)

The front panel controls the status of the actual equipment, which is reported to the operator via the LEDs and display.
See the owner's manual for meanings and use of the various controls as this section deals with diagnostic signals only.

Power LED (GREEN)

Indicates machine on/off status. Always lit if the panel, and hence the machine, is powered correctly.

Alarm LED (YELLOW)

Indicates the equipment is in alarm status. Never lit unless there is a problem.
The display indicates the type of alarm in question.

Display

When the power source is switched on, the panel runs a "self-test" during which all LEDs light and the display reads "200".
Immediately afterwards, the display indicates the control panel's software version (e.g. 1.0) for a moment.
The display indicates the welding parameters requested by the operator (with the aid of other keys) and as soon as the arc is
struck, it gives a readout, furnishing the real value of the current delivered.
When the yellow LED lights, flashing codes appear on the display to indicate an alarm status (in this status, only the two power
and alarm LEDs are lit):

Once the causes of an alarm have been removed, pressing any key (or switching the machine off and back on) will
usually exit alarm status.
The thermal cutout alarm stops automatically, allowing the power source's internal temperature to drop (it is best to
keep the power source switched on as ventilation will aid cooling). The machine will run a new self-test and then resu­me operation as normal.

Description of diagnostic indications 13

Message
E10

E11

E12

E20
E24
E25

Error type
Built-in heat sink temperature high

Supply voltage too high

Supply voltage too low

Front panel memory error

Action
Remove top cover, check internal temperature, check fan, check status of ther­mal cutout devices (NC) (see figures 11-12-13)
Remove top cover, check supply voltage is within the prescribed range.
Check voltage on 15.14.252 V

RV1 RV2 276Vac (see sect. 9.1)

Remove top cover, check supply voltage is within the prescribed range.
Check voltage on 15.14.252 V

RV1 RV2 184Vac (see sect. 9.1)

Remove top cover, check front panel power supply. Try resetting* front panel
and, where necessary, replace.
* NB: to reset the front panel (memory), see procedure in section 8 further on.

1414 Description of diagnostic indications

If error code E10 appears, also check the three thermal cutout capsules illustrated in the following figures (fig. 11-12-13).

Board 15.14.250 (fig. 11)

Description of diagnostic indications 15

Board 15.14.256 (only for G 200 AC-DC) (fig. 12)

G 200 TLH (fig. 13)

1616 Description of diagnostic indications

7.2) INTERNAL DIAGNOSTIC INDICATIONS

Board 15.14.250 (fig. 14)

Description of diagnostic indications 17

Internal diagnostic messages are supplied by the LEDs on board 15.14.250.
The LEDs indicate operating status of the relevant part, as described in the table below:

Led
L1

L2

L3

L4

L5

L6

L7

L8

L9

L10
L11

L12

L13

L14

L15

L16

Meaning

-15 Vdc supplied by 15.14.250 for 15.14.250
control section
+15 Vdc supplied by 15.14.250 for 15.14.250
control section
+5 Vdc supplied by 15.14.250 for 15.14.250
control section
+24 Vdc supplied by 15.14.250 to power front panel

+48 Vdc supplied by 15.14.250 to power front panel

-15 Vdc supplied by 15.14.250 for 15.14.250
UPFR section
+15 Vdc supplied by 15.14.250 for 15.14.250
UPFR section
Supply under voltage alarm

Supply overvoltage alarm

UPFR active
Output power enabling (also see sect. 7.1 "output power"
LED and sect. 9.2.4 "pot signal")
Thermal cutout alarm

Gate MOS 11 present
(output power enabling)
Gate MOS 12 present
(output power enabling)
Gate MOS 15 present
(output power enabling)
Gate MOS 16 present
(output power enabling)

Status (in regular operating conditions)
ON

ON

ON

ON

ON

ON

ON

OFF = everything OK
ON= unit lockup
OFF = everything OK
ON = unit lockup
ON (brightness depends on output current delivered)
MMA: ON
TIG: ON if torch trigger pulled
OFF = everything OK
ON = unit lockup
MMA: ON
TIG: ON if torch trigger pulled
MMA: ON
TIG: ON if torch trigger pulled
MMA: ON
TIG: ON if torch trigger pulled
MMA: ON
TIG: ON if torch trigger pulled

8) SET-UP PARAMETERS

Front panel settings are complemented by others that can be edited in the Setup, which is accessed as follows (also see fig. 9
and fig. 10 in sect. 7.1):

- Switch unit off; wait a while (at least 10 seconds).

- Switch unit on.

- Panel runs self-test

- As soon as all the panel's LEDs go blank and the software version is displayed, press the "PARAMETERS" key once.

- The display will read "0". By turning the current encoder (knob on panel), you can set the value in the range "0" to "99".
By pressing the "PARAMETERS" key, you can view the value of the associated parameter according to the data given in the table
below:

* note: waveform in AC

Value Half wave - Half wave +
parameter n° 5

0 Sine Sine
1 Triangle Triangle
2 Square Square
3 Sine Triangle
4 Sine Square
5 Triangle Sine
6 Triangle Square
7 Square Sine
8 Square Triangle

- The value of the parameter selected during the previous step can be changed by turning the knob on the panel.

- We can see from the table that some parameters do not really have a value associated: if we select one of these parameters
and press the "Parameters" key, the associated operation is performed (e.g. if we enter Setup, select parameter "9" and press
the "Parameters" key, factory settings are resumed for all parameters [RESET]).

- Parameters labelled "not used" cannot be accessed, i.e. nothing happens when the "Parameters" key is pressed.

- To save changes made to parameters and exit the Setup menu, return to parameter "0" and press the "Parameters" key; other­wise, switching the machine off directly will mean none of the changes will be saved, and the last confirmed parameter set­tings will remain.

- Once you have exited Setup, the machine runs a self-test and regular operation is then resumed, based on the new parame­ter settings if any have been made.

Param.

0
1
2
3
4
5

6
7
8
9

12

14

98

99

1818 Set-up parameters

Range

-

2 - 200%

0.0 - 25.0s
0 - 100%
0 - 100%

0 - 8 *(see table

below)
6 - 200 A
6 - 200 A

0 = HF 1 = LIFT

-

0 = DC-

1 = DC+

0 = Amperes

1 = % of welding

current

-

-

Default

-

50%

0.0s
80%
30%

2

(Square)

12 A

200 A

0

-

0

0

-

-

Description/meaning

Saves changes and exits Setup
Initial current as a percentage of welding current
Pregas time
Hot start as a percentage of welding current (MMA only)
Arc force as a percentage of welding current (MMA only)
Waveform in AC (G200 AC/DC only)

Remote control current minimum
Remote control current maximum
Lift or HF start in G200 AC/DC (disregarded in TIG AC and in G200 TLH)
RESET all parameters

Welding in DC+ or DC- in G200 AC/DC (disregarded in G200 TLH)

Ibase in pulsed TIG DC setup mode

Reset all parameters (only use when there are problems with the non-volatile
memory, see errors E20 - E25 on display in sect. 7.1)
Only use if solder-jumper K1 on 15.14.250 is closed (see sect. 9.2.4), otherwise
use next code "99".
Reset all parameters (only use when there are problems with the non-volatile
memory, see errors E20 - E25 on display in sect.7.1)

…………………………… parameters not used ……………………………..

…………………………… parameters not used ……………………………..

…………………………… parameters not used ……………………………..

Description of boards 19

9) DESCRIPTION OF BOARDS

The following sections illustrate regular work conditions of boards making up the power source, and furnish standard values for
the electrical measurements that can be taken at the main points of said boards.
All measurements indicated can be taken with a digital multimeter.

Remember that testing should always start with a VISUAL INSPECTION!
Visual inspection reduces the time spent troubleshooting and points any subsequent steps in the direction of the dama­ged part!

Generally speaking, the following points should be inspected visually:

- input filter zone

- DC bulk electrolytic capacitors

- check for traces of fumes on the inside of the cover

- power and signal connections

- overall status of boards.

WARNING!: Unless otherwise specified, before taking measurements described in the following sections, disconnect
HF board 15.14.286 from bus board 15.14.285/15.14.315!

IMPORTANT NOTE! When the machine is connected to the mains, the master switch is live regardless of its status
(open or closed). Consequently, you are recommended to unplug the unit before touching any of the parts inside!

9.1) INPUT FILTER BOARD 15.14.252 (fig. 15)

Filter board 15.14.252 contains a varistor1guarding against supply overvoltage, an auxiliary transformer and EMC filter circuitry.
The filter basically consists in a network of capacitors, some earthed, and a shared inductor.
This circuit has the dual purpose of limiting the machine's radiofrequency emissions to levels prescribed by regulations, and
making the power source immune from similar problems caused by any electronic devices connected to the same power supply.

1

A varistor ZN1 is inserted between the two power supply's input phases meaning that if you find an instantaneous voltage over
275Vac between terminals RV1 and RV2, the varistor instantly starts conducting so as to absorb a sufficient current spike to limit
the above-mentioned overvoltage. In this way, varistor ZN1 protects other parts of the machine from overvoltage characterized
by a limited energy content.
This process is actually non-destructive for the component if the energy delivered by the voltage spike is moderate, as is the case
with atmospheric discharges (lighting). If, on the other hand, overvoltage is considerable and prolonged, the varistor cannot dis­sipate all associated energy and blows.
This happens, for instance, if the machine is accidentally connected to supply voltages over 275Vac, or if it is subjected to over­voltage caused by inadequate or non-stabilized generating sets.

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

20 Description of boards

9.2) MAIN-BOARD 15.14.250 (fig. 16)

This board features the following circuits

- UPFR preregulator

- switching power supply

- power inverter

- welding current control

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards 21

9.2.1) BOARD 15.14.250 "UPFR SECTION" (fig. 17)

UPFR preregulator: supplies stabilized voltage (approx. 385Vdc) to electrolytic capacitors to power the power inverter. In addi­tion, this stage sees that current absorbed from the supply mains is sinusoidal (power factor = 0.99). Toroidal inductor L1 is
also included in this stage (see point "f" in fig. 7 in sect. 6.1)

WARNING: before taking measurements described, open solder-jumper K2 with the machine unplugged!

Power source / Mode Component Test point Value

OFF DD1 A K +0.34 Vdc
OFF MF7 S D +0.36 Vdc
OFF MF7 S G +0.25 Vdc
OFF MF9 S D +0.36 Vdc
OFF MF9 S G +0.25 Vdc
OFF R89 - 46 OHM*

Power source / Mode Test point LED Value

ON/TIG - L10 FAST BLINKING
ON RV1 RV2 - 230 Vac ± 20%
ON TP34 TP10 - +7.7 Vdc ± 20%
ON TP20 TP10 - +385 ± 5 Vdc
ON RL1 - CLOSED*

* Note = wait 10 minutes after switching off the power source before measuring R89

* Note: RL1 closes a few seconds after the power source is switched on

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

22 Description of boards

9.2.2) BOARD 15.14.250 "POWER SUPPLY SECTION" (fig. 18)

Switching power supply: supplies auxiliary voltage required for the whole machine to work. Generally, the various voltages
power circuits that are electrically insulated from each other (there is no ground shared by the whole machine).

WARNING: before taking measurements described, open solder-jumper K2 with the machine unplugged!

Power source / Mode Component Test point Value

OFF F1 - 0
OFF MF1 S D +0.4 Vdc

MF1 S G 10 K

Power source / Mode Test point Associated LED Value

ON RV1 RV2 - 230 Vac ± 20%
ON RV1 RV2 L8 OFF

(lit if V

RV1 RV2 184Vac)

ON RV1 RV2 L9 OFF

(lit if V

RV1 RV2 276Vac)

ON - L10 FAST BLINKING
ON TP13 TP15* L1 -15 ± 0.3 Vdc
ON TP14 TP15* L2 +15 ± 0.3 Vdc
ON TP12 TP15* L3 +5 ± 0.3 Vdc
ON TP4 TP6 L4 +24 ± 0.5 Vdc
ON TP5 TP6 L5 +48 ± 2 Vdc
ON TP19 TP22 L6 -15 ± 0.3 Vdc
ON TP23 TP22 L7 +15 ± 0.3 Vdc
ON TP2 TP22 - +14.5 ± 0.5 Vdc

* Note: for greater ease of measurement, TP15 is connected electrically to the metal TAB of IC9

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards 23

9.2.3) BOARD 15.14.250 "POWER INVERTER SECTION" (fig. 19)

Full-bridge power inverter

WARNING: before taking measurements described, open solder-jumper K2 with the machine unplugged!

Note: solder-jumper K2 causes a break in the inverter's power supply circuit and is normally closed (it may be opened to test

the power source; also see chapter 10 below)

Power source / Mode Component V S G V S D

OFF MF11 +0.25 Vdc +0.36 Vdc
OFF MF12 +0.25 Vdc +0.36 Vdc
OFF MF15 +0.25 Vdc +0.36 Vdc
OFF MF16 +0.25 Vdc +0.36 Vdc

Power source / Mode LED Status

ON / TIG 2T* L13 ON (with torch trigger pulled)
ON / TIG 2T L14 ON (with torch trigger pulled)
ON / TIG 2T L15 ON (with torch trigger pulled)
ON / TIG 2T L16 ON (with torch trigger pulled)

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

* Note: TIG 2T = 2 STROKE TIG (see owner's manual)

24 Description of boards

9.2.4) BOARD 15.14.250 "WELDING CURRENT CONTROL SECTION" (fig. 20)

Analogue adjustment circuits: control welding current (relevant logic system is located in panel board 15.14.236).

WARNING: before taking measurements described, wait 5 minutes after switching off the power source and - with the
machine unplugged - close solder-jumper K2!

Note: solder-jumper K2 enables a limitation of the power source's open circuit voltage OCV, and is normally open (can be fac­tory set only).

Power source / Mode LED / Test point Value Notes

ON L 12 OFF Thermal cutout
ON / MMA L 11 ON "Pot" signal
ON / MMA TP26 TP15 - 4.3Vdc Voltage feedback
(NO LOAD)

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards 25

9.2.5) ASSEMBLY DIAGRAM FOR KIT 15.18.017 (BOARD 15.14.250 + POWER COMPONENTS) (fig. 21)

WARNING!

1) Components sensitive to electrostatic discharges.

2) Torque wrench settings:

FASTENING ON HEAT SINK = MAX 1.5 Nx m / 13 lb x in
BOARD FASTENING = MAX 1.5 Nx m / 13 lb x in

3) Use layer of thermal grease

9.3) POWER INVERTER CAPACITORS BOARD 15.14.288 (fig. 22)

Capacitors fitted on this board are connected in series with the power transformer's primary winding (see master wiring dia­gram).

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

2626 Description of boards

9.4) SECONDARY POWER UNIT

9.4.1) SECONDARY POWER UNIT G 200 AC- DC (fig. 24)

This unit handles secondary power rectifying and AC switching.

WARNING!: Before commencing the measurements described, make sure the HF board is disconnected from the bus
board!

WARNING!: should module IGBT break and be replaced, board 15.14.253 (see sect. 9.7 below) must be tested befo

-

re reconnecting board 15.14.289 (a faulty IGBT module can break the 15.14.253 board and vice versa)!

Power source / Mode Test point Value

OFF R GA SA 10 k
OFF R GB SB 10 k
OFF V A K +0.3 Vdc
ON / MMA V GA SA -13 Vdc
ON / MMA V GB SB +13 Vdc
ON / MMA V 3 1 +0.5 Vdc
ON / MMA V 1 2 +105 Vdc
ON / MMA V out* +52 Vdc

· note: Vout = power source's open circuit voltage OCV

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

WARNING!

1) Components sensitive to electrostatic discharges.

2) Torque wrench settings:
FASTENING ON HEAT SINK = MAX 1.5 Nx m / 13 lb x in
BOARD FASTENING = MAX 1.5 Nx m / 13 lb x in

3) Use layer of thermal grease

Description of boards 27

9.4.2) SECONDARY POWER UNIT G 200 TLH (fig. 25)

This unit handles secondary power rectifying.

WARNING!: Before commencing the measurements described, make sure the HF board is disconnected from the bus
board!

Power source / Mode Test point Value

OFF V 1 2 +0.3 Vdc
OFF V 3 2 +0.3 Vdc
ON / MMA V out +52 Vdc

- V 1 2 and V 3 2 must be measured once connector CN1 is discon­nected from output filter board 15.14.238
REMEMBER TO RECONNECT CN1 ONCE YOU HAVE TAKEN THE MEASURE­MENT!

- Vout = power source's open circuit voltage OCV

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

WARNING!

1) Components sensitive to electrostatic discharges.

2) Torque wrench settings:
FASTENING ON HEAT SINK = MAX 1.5 Nx m / 13 lb x in
BOARD FASTENING = MAX 1.5 Nx m / 13 lb x in

3) Use layer of thermal grease

28 Description of boards

9.5) AC STAGE CLAMP BOARD 15.14.256 (FOR G200 AC/DC ONLY) (fig. 26)

This circuit is a filter for the AC stage.

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards 29

9.6) BOARD BUS 15.14.285/15.14.315 (fig. 27)

This is an interconnection board.

F1 = 3.15A T 250Vac cooling unit protection (pump + fan)
F2 = 3.15A T 250Vac superimposition board and HF board protection
F3 = 2.5A T 250Vac fan protection

CN1:

1 wire n° 5 +24Vdc fan power supply
2 wire n° 6 0Vdc fan power supply

CN2:

1 wire n° 21 secondary thermal cutout
2 wire n° 22 current probe output
3 wire n° 23 +15Vdc current probe power supply
4 wire n° 24 - SB driver (also see secondary power unit G 200 AC-DC sect. 9.4.1)
6 wire n° 26 - SA driver (also see secondary power unit G 200 AC-DC sect. 9.4.1)
7 wire n° 27 secondary thermal cutout
8 wire n° 28 current probe earth
9 wire n° 29 -15Vdc current probe power supply
10 wire n° 30 + GB driver (also see secondary power unit G 200 AC-DC sect. 9.4.1)
12 wire n° 32 + GA driver (also see secondary power unit G 200 AC-DC sect. 9.4.1)

CN3:

1 wire n° 61 - superimposition
2 wire n° 65 superimposition ground
3 wire n° 63 + superimposition
4 wire n° 64 - power source output voltage
6 wire n° 66 + power source output voltage

CN4:

1 wire n° 41 +24Vdc front panel power supply
2 wire n° 42 front panel power supply earth
4 wire n° 44 HF output control signal
5 wire n° 45 +48Vdc front panel power supply
8 wire n° 48 HF output control earth

CN7:

1 wire n° 11 230Vac WU15 cooling unit pump power supply
2 wire n° 12 230Vac WU15 cooling unit fan power supply
4 wire n° - protection carth connection
5 wire n° 15 230Vac WU15 cooling unit pump power supply
6 wire n° 16 230Vac WU15 cooling unit fan power supply
8 wire n° - protection carth connection

CN8 (only for 15.14.315 board):

1 & 2 = jumper (short circuit)

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

30 Description of boards

9.7) SUPERIMPOSITION AND AC CONTROL BOARD 15.14.253 (FOR G200 AC-DC ONLY) (fig. 28)

This board generates superimposing and controls AC switching of the secondary IGBT module.

WARNING: perform checks following steps 1 and 2 in the given order!

WARNING: measurements indicated in the following table should be taken with board 15.14.253 disconnec-

ted from the machine!

WARNING:

- insert board 15.14.253 in the machine and connect it to bus board 15.14.285/15.14.315

- disconnect connector CN1 from IGBT connection board 15.14.289

- switch the power source on and take measurements indicated in the table below:

- switch off the power source, reconnect connector CN1 to board 15.14.289 and repeat measurements
indicated in sect. 9.4.1

Component Test point Value

IG1 E G 10 kOHM
IG1 E C +0.4 Vdc
IG2 E G 10 kOHM
IG2 E C +0.4 Vdc
D1 A K +0.4 Vdc
D5 A K +0.4 Vdc
D20 A K +0.4 Vdc
D21 A K +0.4 Vdc

- TP15 TP14 10 kOHM

- TP17 TP16 10 kOHM

Power source / Mode Test point Value

ON / MMA TP19 TP18 +15 Vdc
ON / MMA TP13 TP18 +5 Vdc
ON / MMA TP15 TP14 -13 Vdc
ON / MMA TP17 TP16 +13 Vdc

Note (valid only for board 15.14.253 version 6 and higher):

- solder-jumpers K1, K2 are closed (can be factory set only)

- solder-jumper K3 is open (can be factory set only)

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

1

2

Description of boards 31

9.8) HIGH-FREQUENCY BOARD 15.14.286 (fig. 29)

This board generates series of very fast high-voltage pulses to facilitate TIG striking.

WARNING: perform checks following steps 1 and 2 in the given order!

WARNING: measurements indicated in the following table must be taken directly on bus board 15.14.285

/15.14.315 once HF board 15.14.286 has been removed from the machine!

* Note:

- this voltage remains for just 1.5 seconds once the torch trigger is pulled

- this voltage is equivalent to measuring +0.3 Vdc directly on the HF board's connector CN1, when connected.

WARNING:

- insert HF board 15.14.286 in the machine and connect it to bus board 15.14.285/15.14.315

- switch on the power source and take measurements indicated in the table below, without pulling the torch
trigger:

** Note: you are advised not to take measurements on D1 whilst the torch trigger is pulled as the HF dis­charge might damage your multimeter!

Power source / Mode Component Test point Value

ON CNB2 on Bus board PIN 1 5 +385 Vdc

15.14.285/15.14.315

ON / TIG HF CN4 on Bus board PIN 4 8 +6 Vdc*

15.14.285/15.14.315

Power source / Mode Component Test point Value

ON / TIG HF D1 V A K +920 Vdc

(torch trigger
not pulled)**

Power source FN1 FN2

Genesis 200 TLH WHITE RED
Genesis 200 AC-DC RED WHITE

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

1

2

32 Description of boards

9.9) OUTPUT FILTER BOARD 15.14.238 (fig. 30)

This board performs filtering on the secondary to achieve EMC (just like the input board does on the primary - see section 9.1)
and also filters out any disturbance from the torch trigger command owing to HF .

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards 33

9.10) FRONT PANEL BOARD 15.14.236 (fig. 31)

This pair of interconnected boards acts as a user interface, gives the gas solenoid valve and HF striking command, and provides
operating logic and microprocessor control of the whole machine.

Panel boards 15.14.236 have different factory settings depending on the version of the panel they are fitted on (FP106
for G200 TLH or FP 122 for G200AC/DC); this setting can be performed at the factory only.

See section 5.5 for connection of remote control.

DIP SWITCH SETTINGS 1234

Genesis 200 TLH 0111
Genesis 200 AC/DC 0110

Note: connection to the metal structure (and hence with earth potential) of the panel with the yel­low/green wire is essential to protect the board from disturbance!

CN1:
2 wire n° 52 solenoid valve control ground
3 wire n° 53 torch trigger
4 wire n° 54 torch trigger
5 wire n° 44 HF control signal
6 wire n° 48 HF control earth
8 wire n° 58 +48Vdc solenoid valve control

CN2:
1 wire n° 41 +24 Vdc panel power supply
2 wire n° 42 panel power supply ground
3 wire n° 45 +48 Vdc panel power supply

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

10) FINAL INSPECTION OF POWER SOURCE
AND SETTINGS

Precautions (also see chapter 3)

1) live parts (bare wires, HF terminals, …)

2) moving parts (fan …)

3) parts that get hot (heat sinks …)

Instruments required (also see chapter 4):

1) digital multimeter with end of scale = 1000Vdc

2)class 2.5 or higher clamp-on AC/DC ammeter with end of
scale = 300Adc

3) instead of the clamp-on ammeter, you can insert the shunt
on the earth lead and select the mVdc scale for the multi­meter, then connect the multimeter to the shunt's measuring
terminals

WARNING!: do not perform striking in TIG HF mode
with the multimeter connected to the shunt or
power source's output terminals, as if might be
damaged!

10.1)

Preliminary checks

Conditions

- Machine unplugged, ON/OFF switch set to "O".

- Top cover removed.

- Solder-jumper K2 on board 15.14.250 open.

- Board HF (15.14.286) inserted in its tracks but disconnected
from bus board (15.14.285/15.14.315)

- TIG torch not connected

- Bypass pipe connected (if cooling unit fitted) (see sect. 3).

Checks

- Make sure all boards (except the HF board) are inserted pro­perly

- Inspect boards visually (including any components sticking
out whose pins might have been bent inadvertently)

- Inspect the various wiring and relevant connections visually

- Check dip switches on board 15.14.236:
200 TLH
panel FP106 (1=0/OFF; 2=1/ON; 3=1/ON; 4=1/ON)
200 AC/DC
panel FP122 (1=0/OFF; 2=1/ON; 3=1/ON; 4=0/OFF)

10.2)

Checks on startup

Conditions

- Machine connected to 230Vac supply, set ON/OFF switch to
"I".

Checks

- Correct initialization of front panel (green LED lit), no alarm
(yellow LED unlit) and no error message on display.

- Relay RL1 on board 15.14.250 closes approx. 2 seconds
after switch is closed.

- Reset front panel with parameter 9 in Setup (see section 8):
the power source automatically switches to TIG DC 2T HF
mode with current set to 100A.

- Make sure the fan is working properly and airflow is correct
(directed towards front).

- Correct lighting of LEDs on main-board 15.14.250:

* NOTE: torch trigger not connected

10.3)

Check UPFR section on main-board 15.14.250

Conditions

- Machine connected to 230Vac power supply, ON/OFF
switch set to "I".

Checks

- Voltage between TP20 and TP10 on board 15.14.250 at
+385 ± 5 Vdc.

- Green LED L10 blinking fast.

10.4)

Checking inverter gate signals on main-board 15.14.250

Conditions

- As point above, with TIG torch connected.

Checks

- Make sure output power is enabled by pulling TIG torch's
trigger, that green LEDs of the 4 gates L13/L14/L15/L16 on
mono-board 15.14.250 light, and that the green power ena­bling LED L11 also lights.
Make sure relay RL1 on bus board 15.14.285/15.14.315 is
triggered and that the cooling unit (where connected) is
switched on simultaneously.

- Select operating mode MMA, make sure the above-mentio­ned LEDs L11/ L13/L14/L15/L16 blink.

10.5)

Checking open circuit voltage OCV

Conditions

- TIG torch not connected.

- Machine switched off for last five minutes, more or less, and
unplugged.

- Make sure K1 is open on main-board 15.14.250.

- Close K2 on main-board 15.14.250.

- Plug the machine into 230Vac power supply, set ON/OFF
switch to "I".

- MMA mode.

Checks

- open circuit voltage OCV in MMA +52 ± 2Vdc (measured
on fixed output sockets or on output filter board 15.14.238)

10.6)

Checking thermal cutout operation

Conditions

- As point above.

Checks

- Disconnect connector CN4 from board 15.14.250 (thermo­stat T2) and make sure the thermal cutout trips:

yellow "Alarm" LED on front panel lights;
"E10" alarm message on display;
no open circuit voltage.

- Reconnect CN4 and make sure all functions are operating as
before.

- Disconnect connector CN5 from board 15.14.250 (thermo­stat T1) and make sure the thermal cutout trips:

yellow "Alarm" LED on front panel lights;
"E10" alarm message on display;
no open circuit voltage.

- Reconnect CN5 and make sure all functions are operating as
before.

- Disconnect connector CN1 from board 15.14.256 (thermo­stat T3) and make sure the thermal cutout trips (in version
200TLH, T3 is connected directly to connector J6, as there is
no board 15.14.256):

yellow "Alarm" LED on front panel lights;
"E10" alarm message on display;
no open circuit voltage.

- Reconnect CN1 and make sure all functions are operating as
before.

3434 Final inspection of power source and settings

Power source / Mode LED Colour Status
ON / TIG* L1, L2, L3, L4, L5, L6, L7 Green ON
ON / TIG* L8, L9, L12 Red OFF
ON / TIG* L10 Green FAST

BLINKING

ON / TIG* L11, L13, L14, L15, L16 Green OFF

ENGLISH

Final inspection of power source and settings 35

10.7)

Functional MMA tests

Conditions

- Power source powered, MMA mode

- Electrode holder and earth lead connected

- Welding circuit not connected to protection earth potential.

Checks

- Perform various functional tests in MMA mode, making sure
the controls on the panel work, i.e.:

correct arc striking
correct maintenance of arc stability
welding even at max. power, according to data given in the
table below:

- Repeat the above tests with earth lead connected to protec­tion earth potential.

10.8)

Functional TIG tests

Conditions

- HF board inserted in connectors of board

15.14.285/15.14.315 and secured with relevant fasteners

- Power source on, TIG mode.

- Welding circuit not connected to protection earth potential.

Checks

- Perform various welding tests in TIG mode, making sure the
controls on the panel work, i.e.:

correct activation of solenoid valve and gas delivery
idle HF discharge in order to discover HF leakage within
central adapter
correct arc striking in TIG DC LIFT, TIG DC HF and TIG AC
modes
correct maintenance of arc stability
welding even at max. power
check various functions (2 stage, 4 stage, slope up and
down, BI-LEVEL, pulsation…)
perform welding tests in DC and AC with various current,
frequency and pulsation levels according to the contents
of the table below:

- Repeat the above tests with earth lead with connected to
protection earth potential.

10.9)

Checking current delivered

Conditions

- Ammeter clamped on earth lead.

- Power source on, set to TIG DC mode.

Checks

- Perform various welding tests in TIG mode, making sure the
value read off the power source's panel matches the clamp­on ammeter's reading, i.e.:

WARNING!: If you are using a shunt & multimeter
for measuring the output current, perform tests in
TIG LIFT mode so as not to risk damaging the instru­ment as a result of HF!

Electrode type Diameter Amperage

Basic 2.5 95
Basic 5 180
Rutile 2.5 95
Rutile 5 180

Set value Reading Reading

on panel on ammeter

50 A 50 ± 2 A 50 ± 5A
100 A 100 ± 2 A 100 ± 5A
200 A 200 ± 2 A 200 ± 5A

Electrode type red red green green
Diameter 1.6 2.4 1.6 2.4
Polarity DC DC AC AC
Const. current YES YES YES YES
Pulsed YES YES YES YES
Medium freq. YES YES - -
Amperage 10-100 100-200 10-100 100-200

10) ENDPRÜFUNG DES GENERATORS UND
EICHUNGEN

Vorsichtsmaßnahmen (siehe auch Kapitel 3)

1) unter Spannung stehende Teile (blanke Leiter, HF­Endverschlüsse, …)

2) Bewegungsteile (Ventilator …)

3) Temperatur ausgesetzte Teile (Wärmesenke …)

Erforderliche Instrumente (siehe auch Kapitel 4):

1) digitales Multimeter mit Skalenendwert = 1000Vdc

2) AC/DC Zangenstrommesser zumindest in Klasse 2.5 mit
Skalenendwert = 300Adc

3) als Alternative zum Zangenstrommesser, den Shunt in das
Massekabel einschalten und die Skala mVdc für das
Multimeter wählen, dann das Multimeter an den
Messklemmen des Shunt anschließen.

ACHTUNG!: keine Zündungen in WIG HF ausfüh­ren, wenn das Multimeter am Shunt oder an den
Ausgangsendverschlüssen des Generators angesch-

lossen ist, da er beschädigt werden könnte!

10.1)

Vorprüfungen

Bedingungen

- Von der Versorgung abgetrennte Maschine, Schalter auf "O".

- Obere Abdeckung entfernt.

- Überbrückung durch Löttropfen K2 auf Karte 15.14.250

geöffnet.

- HF-Karte (15.14.286) in ihren Führungen, aber nicht an der

Bus-Karte (15.14.285/15.14.315) angeschlossen

- WIG-Brenner nicht angeschlossen

- Bypass-Schlauch angeschlossen (falls das Kühlaggregat vor-

handen ist) (siehe Abschn. 3).

Überprüfungen

- Prüfen, ob alle Karten korrekt einschalten (mit Ausnahme

der HF-Karte)

- Die Karten visuell überprüfen (einschließlich eventuelle vor-

springende Teile, deren Füßchen nicht unregelmäßig gebo­gen sein dürfen)

- Die verschiedenen Verdrahtungen und die jeweiligen

Verbindungen visuell kontrollieren

- Überprüfung der Dip-Switch auf Karte 15.14.236:

200 TLH
Schaltfeld FP106 (1=0/OFF; 2=1/ON; 3=1/ON; 4=1/ON)
200 AC/DC
Schaltfeld FP122 (1=0/OFF; 2=1/ON; 3=1/ON; 4=0/OFF)

10.2)

Kontrollen bei der Zündung

Bedingungen

- An die 230Vac Versorgung angeschlossene Maschine,

Schalter auf "I".

Überprüfungen

- Korrekte Initialisierung des vorderen Schaltfeldes

(Aufleuchten der grünen LED), kein Alarm (gelbe LED aus)
und keine Fehlermeldung am Display.

- Schließen des Relais RL1 an Karte 15.14.250 ca. 2 Sekunden

nach dem Schließen des Schalters.

- Das vordere Schaltfeld über Parameter 9 in Setup rückstel-

len (siehe Kapitel 8): der Generator stellt sich auf den
Betrieb im Modus WIG DC 2T HF mit auf 100A eingestell­ten Strom ein.

- Den Betrieb des Ventilators und die Richtung des

Luftstromes überprüfen (er muss nach vorne gerichtet sein).

- Korrektes Aufleuchten der LEDs auf der Einkarte 15.14.250:

* N.B.: Brennertaste nicht angeschlossen

10.3)

Überprüfung der Sektion UPFR auf der Einkarte

15.14.250

Bedingungen

- An die 230Vac Versorgung angeschlossene Maschine,
Schalter auf "I".

Überprüfungen

- Spannung zwischen TP20 und TP10 der Karte 15.14.250 auf
+385 ± 5 Vdc.

- Grüne LED L10 blinkt schnell.

10.4)

Überprüfung der Gate-Invertersignale auf Einkarte

15.14.250

Bedingungen

- Wie oben, WIG-Brenner angeschlossen.

Überprüfungen

- Die Leistungsabgabe durch die WIG-Brennertaste überprü­fen, mit Aufleuchten auf der Einkarte 15.14.250 der grünen
LEDs der 4 Gate L13/L14/L15/L16 und mit Aufleuchten der
grünen LED L11 für Leistungsabgabe.
Die gleichzeitige Aktivierung des Relais RL1 auf der Bus­Karte 15.14.285/15.14.315 und das folgliche Einschalten
des Kühlaggregats (falls vorhanden) überprüfen.

- Die Betriebsweise MMA auswählen und prüfen, ob die oben
erwähnten LEDs L11/ L13/L14/L15/L16 blinken.

10.5)

Überprüfung der Leerlaufspannung

Bedingungen

- WIG-Brenner nicht angeschlossen.

- Maschine seit ca. fünf Minuten ausgeschaltet und
Versorgung abgetrennt.

- Prüfen, ob K1 auf der Einkarte 15.14.250 geöffnet ist.

- K2 auf der Einkarte 15.14.250 schließen.

- Die Maschine an die 230Vac Versorgung anschließen,
Schalter auf "I" stellen.

- Modus MMA.

Überprüfungen

- Leerlaufspannung in MMA +52 ± 2Vdc (an den festen
Ausgangsbuchsen oder an der Ausgangsfilterkarte

15.14.238 gemessen)

10.6)

Überprüfung des Ansprechens des Wärmeschutzes

Bedingungen

- Wie oben.

Überprüfungen

- Den Verbinder CN4 von der Karte 15.14.250 (Thermostat
T2) abtrennen und das Ansprechen des Wärmeschutzes
überprüfen:

Aufleuchten der gelben Alarm-LED am vorderen Schaltfeld;
Alarmanzeige "E10" am Display;
keine Leerlaufspannung im Ausgang.

- CN4 wieder anschließen und prüfen, ob die Funktionalitäten
wieder hergestellt sind.

36 Endprüfung des Generators und Eichungen

Generator / Modus LED Farbe Status
EIN /WIG* L1, L2, L3, L4, L5, L6, L7 Grün LEUCHTET
EIN /WIG* L8, L9, L12 Rot LEUCHTET

NICHT

EIN /WIG* L10 Grün BLINKT

SCHNELL

EIN /WIG* L11, L13, L14, L15, L16 Grün LEUCHTET

NICHT

DEUTSCH

Endprüfung des Generators und Eichungen 37

- Den Verbinder CN5 von der Karte 15.14.250 (Thermostat
T1) abtrennen und das Ansprechen des Wärmeschutzes
überprüfen:

Aufleuchten der gelben Alarm-LED am vorderen Schaltfeld;
Alarmanzeige "E10" am Display;
keine Leerlaufspannung im Ausgang.

- CN5 wieder anschließen und prüfen, ob die Funktionalitäten
wieder hergestellt sind.

- Den Verbinder CN1 von der Karte 15.14.256 (Thermostat
T3) abtrennen und das Ansprechen des Wärmeschutzes
überprüfen (in der Version 200TLH ist T3 direkt an den
Verbinder J6 angeschlossen, da die Karte 15.14.256 nicht
vorhanden ist):

Aufleuchten der gelben Alarm-LED am vorderen Schaltfeld;
Alarmanzeige "E10" am Display;
keine Leerlaufspannung im Ausgang.

- CN1 wieder anschließen und prüfen, ob die Funktionalitäten
wieder hergestellt sind.

10.7)

MMA-Funktionsprüfungen

Bedingungen

- Generator gespeist, Modus MMA

- Elektrodenzange und Massekabel angeschlossen

- Schweißkreislauf nicht geerdet.

Überprüfungen

- Verschiedene MMA-Funktionsprüfungen ausführen und die
Richtigkeit der Einstellungen über Schaltfeld prüfen, insbe­sondere:

korrekte Bogenzündung
korrekte Beibehaltung des Bogens
Schweißen auch auf Höchstleistung, nach den Angaben in
folgender Tabelle:

- Die obigen Prüfungen mit Massekabel auf Erdpotential wie­derholen.

10.8)

WIG-Funktionsprüfungen

Bedingungen

- HF-Karte in die Verbinder der Karte 15.14.285/15.14.315

eingesteckt und mit ihren Feststellvorrichtungen blockiert

- Generator eingeschaltet, Modus WIG.

- Schweißkreislauf nicht geerdet.

Überprüfungen

- Verschiedene WIG-Funktionsprüfungen ausführen und die
Richtigkeit der Einstellungen über Schaltfeld prüfen, insbe­sondere:

korrekte Aktivierung des Magnetventils und des
Gasaustritts
HF-Entladung in der Luft, um eventuelle Leckagen am
Zentralanschluss festzustellen
korrekte Bogenzündung in WIG DC LIFT, WIG DC HF und
WIG AC
korrekte Beibehaltung des Bogens
Schweißen auch auf Höchstleistung
Überprüfung der verschiedenen Funktionalitäten (2T, 4T,
An- und Abstiegsrampe, BILEVEL, Pulsationen…)
Schweißtests in DC und AC mit verschiedenen Strom-,
Frequenz- und Pulsationswerten ausführen, nach den
Angaben in folgender Tabelle:

- Die obigen Prüfungen mit Massekabel auf Erdpotential wie­derholen.

10.9)

Kontrolle des abgegebenen Stroms

Bedingungen

- Zangenstrommesser am Massekabel.

- Generator ein, Modus WIG DC.

Überprüfungen

- Verschiedene WIG-Schweißtests ausführen und prüfen, ob
der am Schaltfeld des Generators gelesene Wert mit dem
am Zangenstrommesser gelesenen übereinstimmt, insbe­sondere:

ACHTUNG!: Falls zur Messung des
Ausgangsstromes ein Shunt und ein Multimeter ver­wendet werden, die Tests im Modus WIG LIFT
ausführen, damit das Instrument aufgrund der
Hochfrequenz nicht beschädigt wird!

Elektrodentyp Durchmesser Stromstärke

Basisch 2.5 95
Basisch 5 180
Rutil 2.5 95
Rutil 5 180

Eingestellter Am Schaltfeld An der Zange
Wert gelesener Wert gelesener Wert

50 A 50 ± 2 A 50 ± 5A
100 A 100 ± 2 A 100 ± 5A
200 A 200 ± 2 A 200 ± 5A

Elektrodentyp rot rot grün grün
Durchmesser 1.6 2.4 1.6 2.4
Stromrichtung DC DC AC AC
Dauerstrom Ja Ja Ja Ja
Pulsiert Ja Ja Ja Ja
Mittelfrequenz Ja Ja - -
Stromstärke 10-100 100-200 10-100 100-200

38 Essai final du générateur et réglages

10) ESSAI FINAL DU GÉNÉRATEUR ET RÉGLAGES

Précautions à prendre (voir également au chapitre 3)

1) parties sous tension (conducteurs sans gaine, cos­ses HF, etc.)

2) parties en mouvement (ventilateur, etc.)

3) parties sujettes à une certaine température (radia­teurs, etc.)

Instruments nécessaires (voir également au chapitre 4):

1) multimètre numérique avec f.s. = 1000Vdc

2) pince ampèremétrique AC/DC au moins en classe 2.5 avec
f.s. = 300Adc

3) à la place de la pince ampèremétrique, mettre le shunt sur
le câble de masse et sélectionner l'échelle mVdc pour le
multimètre, brancher ensuite le multimètre aux bornes de
mesure du shunt.

ATTENTION!: ne pas effectuer de démarrages en
TIG HF avec le multimètre branché au shunt ou aux
cosses de sortie du générateur pour ne pas l'abîmer!

10.1)

Contrôles préliminaires

Conditions

- Machine coupée du réseau d'alimentation, interrupteur d'al-

lumage sur "O".

- Carter supérieur enlevé.

- Bulle de soudure K2 sur la carte 15.14.250 ouverte.

- Carte HF (15.14.286) placée dans son logement mais

débranchée de la carte bus (15.14.285/15.14.315)

- Torche TIG pas branchée

- Tube de by-pass relié (si le groupe de refroidissement est

prévu) (voir section 3).

Contrôles à effectuer

- Vérifier si toutes les cartes sont bien mises (sauf la carte HF)

- Contrôler visuellement les cartes (y compris les composants

en saillie éventuels dont les pieds ne doivent pas être pliés
de façon anormale)

- Contrôler visuellement les différents câbles et les conne-

xions correspondantes

- Vérifier les microcontacts sur la carte 15.14.236:

200 TLH
panneau FP106 (1=0/OFF; 2=1/ON; 3=1/ON; 4=1/ON)
200 AC/DC
panneau FP122 (1=0/OFF; 2=1/ON; 3=1/ON; 4=0/OFF)

10.2)

Contrôles à l'allumage

Conditions

- Machine reliée au réseau d'alimentation 230Vac, mettre l'in-

terrupteur d'allumage sur "I".

Contrôles à effectuer

- Initialisation correcte du panneau frontal (allumage de la

DIODE verte), aucune alarme (DIODE jaune éteinte) et
aucun message d'erreur sur l'afficheur.

- Fermeture du relais RL1 sur la carte 15.14.250 environ 2

secondes après avoir actionné l'interrupteur.

- Remettre le panneau frontal avec le paramètre 9 du Setup à

zéro (voir chapitre 8): le générateur se prépare à fonctionner
en mode TIG DC 2T HF avec le courant saisi de 100A.

- Contrôler si le ventilateur fonctionne bien et si le courant

d'air est correct (tourné vers l'avant).

- Allumage correct des DIODES sur la monocarte 15.14.250:

* REMARQUE: bouton de la torche pas branché

10.3)

Contrôle section UPFR sur monocarte 15.14.250

Conditions

- Machine reliée au réseau d'alimentation 230Vac, interrup­teur d'allumage sur "I".

Contrôles

- Tension entre TP20 et TP10 de la carte 15.14.250 en +385
± 5 Vdc.

- DIODE verte L10 qui clignote rapidement.

10.4)

Contrôle signaux grille onduleur sur monocarte

15.14.250

Conditions

- Comme au point précédent, avec la torche TIG branchée.

Contrôles à faire

- Vérifier le déblocage de la puissance à l'aide du bouton tor­che TIG, avec allumage sur monocarte 15.14.250 des diodes
vertes des 4 grilles L13/L14/L15/L16 et allumage de la diode
verte de déblocage de la puissance L11.
Vérifier si le relais RL1 s'active en même temps sur la carte
bus 15.14.285/15.14.315 et si le groupe de refroidissement
s'allume (s'il est prévu).

- Sélectionner le fonctionnement MMA, contrôler si les dio­des citées plus haut L11/ L13/L14/L15/L16 clignotent.

10.5)

Contrôle tension à vide

Conditions

- Torche TIG pas branchée.

- Machine éteinte depuis environ cinq minutes et coupée du
réseau d'alimentation.

- Vérifier si K1 est ouverte sur la monocarte 15.14.250.

- Refermer K2 sur la monocarte 15.14.250.

- Brancher la machine au réseau d'alimentation en 230Vac,
mettre l'interrupteur d'allumage sur "I".

- Mode MMA.

Contrôles à faire

- Tension à vide en MMA +52 ± 2Vdc (mesurée sur les pri­ses fixes de sortie ou sur la carte du filtre de sortie

15.14.238)

10.6)

Contrôle intervention protection thermique

Conditions

- Comme au point précédent.

Contrôles à effectuer

- Débrancher le connecteur CN4 de la carte 15.14.250 (ther­mostat T2) et contrôler s'il y a intervention de la protection
thermique:

allumage de la DIODE jaune "Alarme" sur le panneau frontal;
message d'alarme "E10" sur l'afficheur;
absence de tension à vide à la sortie.

- Brancher de nouveau le connecteur CN4 et contrôler si le
fonctionnement est rétabli.

Générateur/ Mode LED Couleur Etat
ALLUME / TIG* L1, L2, L3, L4, L5, L6, L7 Verte ALLUMEE
ALLUME / TIG* L8, L9, L12 Rouge ETEINTE
ALLUME / TIG* L10 Verte CLIGNOTE

RAPIDEMENT

ALLUME / TIG* L11, L13, L14, L15, L16 Verte ETEINTE

FRANÇAIS

Essai final du générateur et réglages 39

- Débrancher le connecteur CN5 de la carte 15.14.250 (ther­mostat T1) et vérifier s'il y a intervention de la protection
thermique:

allumage de la DIODE jaune "Alarme" sur le panneau frontal;
message d'alarme "E10" sur l'afficheur;
absence de tension à vide à la sortie.

- Brancher de nouveau le connecteur CN5 et vérifier si le
fonctionnement est rétabli.

- Débrancher le connecteur CN1 de la carte 15.14.256 (ther­mostat T3) et vérifier s'il y a intervention de la protection
thermique (dans la version 200TLH, le connecteur T3 est
branché directement au connecteur J6 si la carte 15.14.256
n'est pas prévue):

allumage de la DIODE jaune "Alarme" sur le panneau frontal;
message d'alarme "E10" sur l'afficheur;
absence de tension à vide à la sortie.

- Brancher de nouveau le connecteur CN1 et vérifier si le
fonctionnement est rétabli.

10.7)

Contrôles fonctionnels MMA

Conditions

- Générateur alimenté, mode MMA

- Pince porte-électrode et câble de masse branchés

- Circuit de soudure pas branché à la terre.

Contrôles à effectuer

- Faire différents essais fonctionnels de soudure en MMA, en
vérifiant si les réglages sont corrects sur le panneau, en par­ticulier:

amorçage correct de l'arc
maintien correct de l'arc
soudure même à la puissance max., selon ce qui est repor­té dans le tableau suivant:

- Répéter les essais précédents avec le câble de masse au
potentiel de terre.

10.8)

Contrôles fonctionnels TIG

Conditions

- Carte HF placée dans les connecteurs de la carte

15.14.285/15.14.315 et bloquée par les butées correspon­dantes

- Générateur allumé, mode TIG.

- Circuit de soudure pas branché à la terre.

Contrôles à effectuer

- Faire différents essais de soudure en TIG, en vérifiant si les
réglages sont corrects sur le panneau, en particulier:

activation correcte de l'électrovanne et sortie gaz
évacuation de HF dans l'air pour déterminer les fuites
éventuelles sur le raccord centralisé
amorçage correct de l'arc en TIG DC LIFT, TIG DC HF et TIG AC
maintien correct de l'arc
soudure même à la puissance max.
contrôle des différentes fonctions (2T, 4T, rampe de mon­tée et de descente, BILEVEL, pulsations, etc.)
faire des essais de soudure en DC et AC avec différents
niveaux de courant, fréquence et pulsation, selon ce qui
est reporté dans le tableau suivant:

- Répéter les essais précédents avec le câble de masse au
potentiel de terre.

10.9)

Contrôle du courant distribué

Conditions

- Pince ampèremétrique placée sur le câble de masse.

- Générateur allumé, réglage en TIG DC.

Contrôles à effectuer

- Faire différents essais en mode de soudure TIG en contrô­lant si la valeur lue sur le panneau du générateur correspond
à celle lue avec la pince ampèremétrique, en particulier:

ATTENTION!: En cas d'utilisation d'un shunt et d'un
multimètre pour mesurer le courant de sortie, faire
les essais en mode TIG LIFT pour ne pas risquer d'a­bîmer l'instrument à cause du HF!

Type d'électrode Diamètre Ampérage

Basique 2.5 95
Basique 5 180
Rutile 2.5 95
Rutile 5 180

Valeur Valeur lue Valeur lue
saisie sur le panneau avec la pince

50 A 50 ± 2 A 50 ± 5A
100 A 100 ± 2 A 100 ± 5A
200 A 200 ± 2 A 200 ± 5A

Type d'électrode rouge rouge verte verte
Diamètre 1.6 2.4 1.6 2.4
Polarité DC DC AC AC
Cour. Constant OUI OUI OUI OUI
Pulsé OUI OUI OUI OUI
Fréq. moyenne OUI OUI - -
Ampérage 10-100 100-200 10-100 100-200

40 Prueba final del generador y calibraciones

10) PRUEBA FINAL DEL GENERADOR Y CALIBRACIONES

Precauciones (ver también el capítulo 3)

1) partes bajo tensión (conductores pelados, termi­nales HF, etc.)

2) partes en movimiento (ventilador, etc.)

3) partes sometidas a alta temperatura (radiadores,
etc.)

Instrumentos necesarios (ver también el capítulo 4):

1)multímetro digital con f.s. = 1000Vdc

2)pinza amperométrica AC/DC por lo menos en clase 2.5 con
f.s. = 300Adc

3)como alternativa a la pinza amperométrica colocar un shunt
en el cable de masa y seleccionar la escala mVdc del multí­metro, luego conectar el multímetro a los bornes de medi­ción del shunt

¡ATENCIÓN!: ¡No cebar TIG HF con el multímetro
conectado al shunt o a los terminales de salida del
generador, podría dañarse!

10.1)

Verificaciones preliminares

Condiciones

- Máquina desconectada de la alimentación, interruptor de
encendido en "O".

- Capó superior extraído.

- Bola de soldadura K2 en la tarjeta 15.14.250 abierta.

- Tarjeta HF (15.14.286) integrada en los patines pero desco­nectada de la tarjeta bus (15.14.285/15.14.315)

- Luz TIG no conectada

- Tubo by-pass conectado (si existe el grupo de enfriamiento)
(ver secc. 3).

Verificaciones

- Averiguar la correcta inserción de todas las tarjetas (excepto
tarjeta HF)

- Controlar a vista las fichas (incluyendo eventuales compo­nentes salientes cuyos pis no deben estar doblados en
modo anómalo)

- Controlar a vista los varios cableados y las relativas cone­xiones

- Verifica el dip switch en la tarjeta 15.14.236:
200 TLH
panel FP106 (1=0/OFF; 2=1/ON; 3=1/ON; 4=1/ON)
200 AC/DC
panel FP122 (1=0/OFF; 2=1/ON; 3=1/ON; 4=0/OFF)

10.2)

Controles en el momento del encendido

Condiciones

- Máquina conectada a la alimentación de 230Vac, llevar el
interruptor de encendido a "I".

Verificaciones

- Corregida inicialización del panel frontal (encendido LED
verde), ninguna alarma (LED amarillo apagado) y ningún
mensaje de error en el display.

- Cierre del relé RL1 en la tarjeta 15.14.250 después de unos
2 segundos desde el cierre del interruptor.

- Resetear el panel frontal con parámetro 9 del Setup (ver
capítulo 8): el generador se prepara para funcionar en
modalidad TIG DC 2T HF con corriente programada de
100A.

- Verificar el funcionamiento del ventilador y la exactitud del
flujo de aire (dirigido hacia la parte delantera).

- Correcto encendido de los LED en la monotarjeta

15.14.250:

* NOTA: botón luz no conectado

10.3)

Verificación sección UPFR en monotarjeta 15.14.250

Condiciones

- Máquina conectada a la alimentación de 230Vac, interruptor
de encendido en "I".

Verificaciones

- Tensión entre TP20 y TP10 en la tarjeta 15.14.250 a +385 ±
5 Vdc.

- LED Verde L10 relampaguea velozmente.

10.4)

Verificación de las señales de gate inverter en la mono-

tarjeta 15.14.250

Condiciones

- Como en el punto precedente, con luz TIG conectada.

Verificaciones

- Verificar el desbloqueo de potencia mediante el botón luz
TIG, con encendido en la monotarjeta 15.14.250 de los Led
verdes de los 4 gate L13/L14/L15/L16 y el encendido del Led
verde de desbloqueo potencia L11.
Verificar la activación contemporánea del relé RL1 en la tar­jeta bus 15.14.285/15.14.315 y el consiguiente encendido
del grupo de enfriamiento (si existe).

- Seleccionar el funcionamiento MMA, verificar el relampa­gueo de los LED mencionados arriba L11/ L13/L14/L15/L16.

10.5)

Verificación de la tensión en vacío

Condiciones

- Luz TIG no conectada

- Máquina apagada desde aproximadamente cinco minutos y
con la alimentación desconectada.

- Verificar que K1 esté abierto en la monotarjeta 15.14.250.

- Cerrar K2 en la monotarjeta 15.14.250.

- Conectar la máquina a la alimentación de 230Vac, llevar el
interruptor de encendido a "I".

- Modalidad MMA.

Verificaciones

- Tensión en vacío en MMA +52 ± 2Vdc (medida en las
tomas fijas de salida o bien en la tarjeta filtro de salida

15.14.238)

10.6)

Verificación de la activación de la protección térmica

Condiciones

- Como en el punto precedente.

Verificaciones

- Desconectar el conector CN4 de la tarjeta 15.14.250 (ter­mostato T2) y verificar la intervención de la protección tér­mica:

encendido LED amarillo "Alarma" en el panel frontal;
visualización alarma "E10" en el display;
falta de tensión en vacío en salida.

- Volver a conectar el CN4 y verificar el restablecimiento de
las funciones.

Generador / Modo LED Color Estado
ENCENDIDO/TIG * L1, L2, L3, L4, L5, L6, L7 Verde ENCENDIDO
ENCENDIDO/TIG * L8, L9, L12 Rojo APAGADO
ENCENDIDO/TIG * L10 Verde RELAMPAGUEA

VELOZMENTE

ENCENDIDO/TIG * L11, L13, L14, L15, L16 Verde APAGADO

ESPAÑOL

Prueba final del generador y calibraciones 41

- Desconectar el conector CN5 de la tarjeta 15.14.250 (ter­mostato T1) y verificar la intervención de la protección tér­mica:

encendido LED amarillo "Alarma" en el panel frontal;
visualización alarma "E10" en el display;
falta de tensión en vacío en salida.

- Volver a conectar el CN5 y verificar el restablecimiento de
las funciones.

- Desconectar el conector CN1 de la tarjeta 15.14.256 (ter­mostato T3) y verificar la intervención de la protección tér­mica (en la versión 200TLH el T3 está conectado directa­mente al conector J6, falta la tarjeta 15.14.256):

encendido LED amarillo "Alarma" en el panel frontal;
visualización alarma "E10" en el display;
falta de tensión en vacío en salida.

- Volver a conectar el CN1 y verificar el restablecimiento de
las funciones.

10.7)

Verificaciones funcionales MMA

Condiciones

- Generador alimentado, modalidad MMA

- Pinza portaelectrodo y cable de masa conectados

- Circuido de soldadura no conectado a tierra.

Verificaciones

- Ejecutar varias pruebas funcionales de soldadura en MMA,
comprobando la función de las regulaciones desde el panel,
en particular:

correcto cebado del arco
correcto mantenimiento del arco
soldadura también a máx potencia, según cuanto indicado

en la tabla siguiente:

- Repetir las pruebas anteriores con cable de masa a potencial
de tierra.

10.8)

Verificaciones funcionales TIG

Condiciones

- Tarjeta HF insertada en los conectores de la tarjeta

15.14.285/15.14.315 y bloqueada con retenes.

- Generador encendido, modalidad TIG.

- Circuido de soldadura no conectado a tierra.

Verificaciones

- Ejecutar varias pruebas de soldadura en TIG, comprobando
la función de las regulaciones desde el panel, en particular:

correcta activación de la electroválvula y salida de gas
descarga de HF en aire para determinar eventuales pérdi­das en la conexión centralizada
correcto cebado del arco en TIG DC LIFT, TIG DC HF y TIG
AC
correcto mantenimiento del arco
soldadura también a máx potencia
verificación de las varias funciones (2T, 4T, rampa de sub­ida y bajada, BILEVEL, pulsaciones, etc.)
ejecutar pruebas de soldadura en DC y AC con varios nive­les de corriente, frecuencia y pulsación, según cuanto indi­cado en el tablero siguiente:

- Repetir las pruebas anteriores con cable de masa a potencial
de tierra.

10.9)

control de la corriente producida

Condiciones

- Pinza amperométrica puesta en el cable de masa.

- Generador encendido, programación modalidad TIG DC.

Verificaciones

- Ejecutar varias pruebas en soldadura TIG, verificando la cor­respondencia del valor leído en el panel del generador con
el leído en la pinza amperométrica, en particular:

¡ATENCIÓN!: ¡En caso de utilización de shunt y mul­tímetro por la medida de la corriente de salida, efec­tuar las pruebas en modalidad TIG LIFT para no per­judicar el instrumento a causa del HF!

Tipo electrodo Diámetro Amperaje

Básico 2.5 95
Básico 5 180
Rutilo 2.5 95
Rutilo 5 180

Valor Valor leído Valor leído
program. del panel de la pinza

50 A 50 ± 2 A 50 ± 5A
100 A 100 ± 2 A 100 ± 5A
200 A 200 ± 2 A 200 ± 5A

Tipo electrodo Rojo Rojo Verde Verde
Diámetro 1.6 2.4 1.6 2.4
Polaridad DC DC AC AC
Corr. constante SÍ SÍ SÍ SÍ
Pulsado SÍ SÍ SÍ SÍ
Media freq. SÍ SÍ - -
Amperaje 10-100 100-200 10-100 100-200

42

11) AVAILABLE SPARE PARTS

11.1 GENESIS 200 AC-DC (fig. 32)

42 Available spare parts

ITALIANO

POS. DESCRIZIONE CODICE

1 Pannello plastico frontale 01.04.262

2 Pannello plastico posteriore 01.05.220

3 Fondo plastico 01.06.100

4 Cofano serigrafato 03.07.059

5 Trasformatore 05.02.025

6 Trasformatore H.F. 05.03.018

7 Induttanza di livellamento 05.04.224

8 Induttore 05.18.003

9 Ventilatore 07.10.020

10 Serracavo 08.22.001

11 Interruttore 09.01.005

12 Elettrovalvola 09.05.003

13 Manopola 09.11.009

14 Presa fissa 10.13.020

15 Tappo 10.01.151

16 Sensore Hinode 11.19.011

17 Varistore 11.26.001

18 Diodo 14.05.083

19 Kit ricambio monoscheda 15.18.017

(contiene scheda 15.14.250 e componenti di potenza)

20 Kit ricambio modulo secondario 15.18.018

(contiene modulo IGBT secondario e scheda 15.14.289)

21 Scheda ingresso 15.14.252

22 Scheda comando

e sovrapposizione 15.14.253

23 Scheda bus 15.14.315

24 Scheda HF 15.14.286

25 Pannello comandi FP122 15.22.122

(contiene scheda 15.14.236 e targa serigrafata)

26 Adattatore 19.06.005

27 Piedino antiscivolo 21.03.003

28 Cinghia 21.06.004

29 Cavo alimentazione 49.04.055

30 Scheda clamp secondario 15.14.256

31 Scheda filtro 15.14.238

ENGLISH

POS. DESCRIPTION CODE

1 Front plastic panel 01.04.262

2 Rear plastic panel 01.05.220

3 Plastic bottom 01.06.100

4 Silk-screen panel 03.07.059

5 Transformer 05.02.025

6 H.F. transformer 05.03.018

7 Leveling inductor 05.04.224

8 Inductor 05.18.003

9 Fan 07.10.020

10 Cable clamp 08.22.001

11 Switch 09.01.005

12 Solenoid valve 09.05.003

13 Knob 09.11.009

14 Fixed socket 10.13.020

15 Plug 10.01.151

16 Hinode sensor 11.19.011

17 Varistor 11.26.001

18 Diode 14.05.083

19 PC board spare kit 15.18.017

(contains board 15.14.250 and power components)

20 Secondary spare kit 15.18.018

(contains secondary IGBT moduleand board 15.14.289)

21 Input card 15.14.252

22 Superposition and control board 15.14.253

23 Bus board 15.14.315

24 H. F. card 15.14.286

25 Control panel FP122 15.22.122

(contains board 15.14.236 and screen-printed plate)

26 Adapter 19.06.005

27 Vibration-damping foot 21.03.003

28 Belt 21.06.004

29 Supply cable 49.04.055

30 Secondary clamp board 15.14.256

31 Filter board 15.14.238

DEUTSCH

POS. BESCHREIBUNG CODE

1 Stirnplastiktafel 01.04.262

2 Hintere Plastkatel 01.05.220

3 Plastikboden 01.06.100

4 Siebdruck seitenteil 03.07.059

5 Transformator 05.02.025

6 Transformator H.F. 05.03.018

7 Glättungsdrosselspule 05.04.224

8 Drosselspule 05.18.003

9 Ventilator 07.10.020

10 Kabelschelle 08.22.001

11 Schalter 09.01.005

12 Solenoidventil 09.05.003

13 Drehknopf 09.11.009

14 Feste Steckdose 10.13.020

15 Stöpsel 10.01.151

16 Sensor Hinode 11.19.011

17 Varistor 11.26.001

18 Diode 14.05.083

19 Kartenersatzteilenset 15.18.017

(enthält die Karte 15.14.250 und die Leistungsteile)

20 Sekundärersatzteilenset 15.18.018

(enthält das Sekundärmodul IGBT und Karte 15.14.289)

21 Eingangskarte 15.14.252

22 Steuerungskarte 15.14.253

23 Buskarte 15.14.315

24 HF.-Karte 15.14.286

25 Bedienungsfeld FP122 15.22.122

(enthält die Karte 15.14.236 und siebgedrucktes Schild)

26 Adapter 19.06.005

27 Antirutschfuß 21.03.003

28 Riemen 21.06.004

29 SpeiseKabel 49.04.055

30 Sekundärkarte 15.14.256

31 Filterplatine 15.14.238

FRANÇAIS

POS. DESCRIPTION CODE

1 Panneau plastique antérieur 01.04.262

2 Panneau plastique postérieur 01.05.220

3 Fond plastique 01.06.100

4 Panneau avec serigraphie 03.07.059

5 Transformateur 05.02.025

6 Transformateur H.F. 05.03.018

7 Inductance d'écrêtage 05.04.224

8 Inducteur 05.18.003

9 Ventilateur 07.10.020

10 Serre-câble 08.22.001

11 Interrupteur 09.01.005

12 Electrovanne 09.05.003

13 Bouton 09.11.009

14 Prise fixe 10.13.020

15 Capot 10.01.151

16 Détecteur Hinode 11.19.011

17 Varistance 11.26.001

18 Diode 14.05.083

19 Kit de rechange platine 15.18.017

(il contient la carte 15.14.250

et les composants de puissance)

20 Kit de rechange secondaire 15.18.018

(il contient le module IGBT secondaire

et la carte 15.14.289)

21 Carte d'entrée 15.14.252

22 Platine de contrôle

et superposition 15.14.253

23 Platine bus 15.14.315

24 Carte H.F. 15.14.286

25 Panneau de reglage FP122 15.22.122

(il contient la carte 15.14.236 et la plaque sérigraphiée)

26 Adaptateur 19.06.005

27 Pied anti-vibrations 21.03.003

28 Courroie 21.06.004

29 Câble d’alimentation 49.04.055

30 Platine clamp secondaire 15.14.256

31 Platine filtre 15.14.238

ESPAÑOL

POS. DESCRIPCION CODIGO

1 Panel plastico anterior 01.04.262

2 Panel plástico posterior 01.05.220

3 Fondo plástico 01.06.100

4 Panel con serigrafia 03.07.059

5 Transformador 05.02.025

6 Transformador H.F. 05.03.018

7 Bobina de inductancia

stabilizadora de corriente 05.04.224

8 Inductor 05.18.003

9 Ventilador 07.10.020

10 Abrazadera 08.22.001

11 Interruptor 09.01.005

12 Electroválvula 09.05.003

13 Botón 09.11.009

14 Toma fija 10.13.020

15 Tapón 10.01.151

16 Captador Hinode 11.19.011

17 Varistor 11.26.001

18 Diodo 14.05.083

19 Juego de repuestos tarjeta 15.18.017

(contiene la tarjeta 15.14.250

y los componentes de potencia)

20 Juego de repuestos secundario 15.18.018

(contiene módulo IGBT secundario

y tarjeta 15.14.289)

21 Tarjeta entrada 15.14.252

22 Tarjeta de mando

y superposición 15.14.253

23 Tarjeta bus 15.14.315

24 Tarjeta H. F. 15.14.286

25 Panel de control FP122 15.22.122

(contiene la tarjeta 15.14.236 y placa serigrafiada)

26 Adaptador 19.06.005

27 Pie antivibrador 21.03.003

28 Correa 21.06.004

29 Cable de alimentación 49.04.055

30 Tarjeta clamp secundario 15.14.256

31 Tarjeta filtro 15.14.238

43Available spare parts 43

4444 Available spare parts

11.2 GENESIS 200 TLH (fig. 33)

ITALIANO

POS. DESCRIZIONE CODICE

1 Pannello plastico frontale 01.04.262

2 Pannello plastico posteriore 01.05.220

3 Fondo plastico 01.06.100

4 Cofano serigrafato 03.07.077

5 Trasformatore 05.02.025

6 Trasformatore H.F. 05.03.018

7 Induttanza di livellamento 05.04.224

8 Induttore 05.18.003

9 Ventilatore 07.10.020

10 Serracavo 08.22.001

11 Interruttore 09.01.005

12 Elettrovalvola 09.05.003

13 Manopola 09.11.009

14 Presa fissa 10.13.020

15 Tappo 10.01.151

16 Sensore Hinode 11.19.011

17 Varistore 11.26.001

18 Diodo 14.05.083

19 Kit ricambio monoscheda 15.18.017

(contiene la scheda 15.14.250

e i componenti di potenza)

20 Scheda ingresso 15.14.252

21 Scheda bus 15.14.315

22 Scheda HF 15.14.286

23 Pannello comandi FP106 15.22.106

(contiene la scheda 15.14.236

e la serigrafia frontale)

24 Adattatore 19.06.005

25 Piedino antiscivolo 21.03.003

26 Cinghia 21.06.004

27 Cavo alimentazione 49.04.055

28 Scheda filtro 15.14.238

ENGLISH

POS. DESCRIPTION CODE

1 Front plastic panel 01.04.262

2 Rear plastic panel 01.05.220

3 Plastic bottom 01.06.100

4 Silk-screen panel 03.07.077

5 Transformer 05.02.025

6 H.F. transformer 05.03.018

7 Leveling inductor 05.04.224

8 Inductor 05.18.003

9 Fan 07.10.020

10 Cable clamp 08.22.001

11 Switch 09.01.005

12 Solenoid valve 09.05.003

13 Knob 09.11.009

14 Fixed socket 10.13.020

15 Plug 10.01.151

16 Hinode sensor 11.19.011

17 Varistor 11.26.001

18 Diode 14.05.083

19 PC board spare kit 15.18.017

(contains board 15.14.250 and power components)

20 Input card 15.14.252

21 Bus board 15.14.315

22 H. F. card 15.14.286

23 Control panel FP106 15.22.106

(contains board 15.14.236 and screen-printed

plate)

24 Adapter 19.06.005

25 Vibration-damping foot 21.03.003

26 Belt 21.06.004

27 Supply cable 49.04.055

28 Filter board 15.14.238

DEUTSCH

POS. BESCHREIBUNG CODE

1 Stirnplastiktafel 01.04.262

2 Hintere Plastkatel 01.05.220

3 Plastikboden 01.06.100

4 Siebdruck seitenteil 03.07.077

5 Transformator 05.02.025

6 Transformator H.F. 05.03.018

7 Glättungsdrosselspule 05.04.224

8 Drosselspule 05.18.003

9 Ventilator 07.10.020

10 Kabelschelle 08.22.001

11 Schalter 09.01.005

12 Solenoidventil 09.05.003

13 Drehknopf 09.11.009

14 Feste Steckdose 10.13.020

15 Stöpsel 10.01.151

16 Sensor Hinode 11.19.011

17 Varistor 11.26.001

18 Diode 14.05.083

19 Kartenersatzteilenset 15.18.017

(enthält die Karte 15.14.250 und die Leistungsteile)

20 Eingangskarte 15.14.252

21 Buskarte 15.14.315

22 HF.-Karte 15.14.286

23 Bedienungsfeld FP106 15.22.106

(enthält die Karte 15.14.236

und siebgedrucktes Schild)

24 Adapter 19.06.005

25 Antirutschfuß 21.03.003

26 Riemen 21.06.004

27 SpeiseKabel 49.04.055

28 Filterplatine 15.14.238

FRANÇAIS

POS. DESCRIPTION CODE

1 Panneau plastique antérieur 01.04.262

2 Panneau plastique postérieur 01.05.220

3 Fond plastique 01.06.100

4 Panneau avec serigraphie 03.07.077

5 Transformateur 05.02.025

6 Transformateur H.F. 05.03.018

7 Inductance d'écrêtage 05.04.224

8 Inducteur 05.18.003

9 Ventilateur 07.10.020

10 Serre-câble 08.22.001

11 Interrupteur 09.01.005

12 Electrovanne 09.05.003

13 Bouton 09.11.009

14 Prise fixe 10.13.020

15 Capot 10.01.151

16 Détecteur Hinode 11.19.011

17 Varistance 11.26.001

18 Diode 14.05.083

19 Kit de rechange platine 15.18.017

(il contient la carte 15.14.250

et les composants de puissance)

20 Carte d'entrée 15.14.252

21 Platine bus 15.14.315

22 Carte H.F. 15.14.286

23 Panneau de reglage FP106 15.22.106

(il contient la carte 15.14.236

et la plaque sérigraphiée)

24 Adaptateur 19.06.005

25 Pied anti-vibrations 21.03.003

26 Courroie 21.06.004

27 Câble d’alimentation 49.04.055

28 Platine filtre 15.14.238

ESPAÑOL

POS. DESCRIPCION CODIGO

1 Panel plastico anterior 01.04.262

2 Panel plástico posterior 01.05.220

3 Fondo plástico 01.06.100

4 Panel con serigrafia 03.07.077

5 Transformador 05.02.025

6 Transformador H.F. 05.03.018

7 Bobina de inductancia

stabilizadora de corriente 05.04.224

8 Inductor 05.18.003

9 Ventilador 07.10.020

10 Abrazadera 08.22.001

11 Interruptor 09.01.005

12 Electroválvula 09.05.003

13 Botón 09.11.009

14 Toma fija 10.13.020

15 Tapón 10.01.151

16 Captador Hinode 11.19.011

17 Varistor 11.26.001

18 Diodo 14.05.083

19 Juego de repuestos tarjeta 15.18.017

(contiene la tarjeta 15.14.250

y los componentes de potencia)

20 Tarjeta entrada 15.14.252

21 Tarjeta bus 15.14.315

22 Tarjeta H. F. 15.14.286

23 Panel de control FP106 15.22.106

(contiene la tarjeta 15.14.236 y placa serigrafiada)

24 Adaptador 19.06.005

25 Pie antivibrador 21.03.003

26 Correa 21.06.004

27 Cable de alimentación 49.04.055

28 Tarjeta filtro 15.14.238

45Available spare parts 45

4646 Available spare parts

ITALIANO

POS.DESCRIZIONE CODICE

1 Pannello laterale destro 01.03.027
2 Pannello laterale sinistro 01.03.026
3 Innesto rapido H2O 19.50.043
4 FP 115 03.05.305
5 Pannello posteriore plastico 01.05.218
6 Serbatoio 20.04.505
7 Pannello frontale plastico 01.04.261
8 Radiatore 18.81.003
9 Ventilatore 07.10.016
10 Polmone antivibrazioni 07.21.100
11 Pompa 07.21.002

Anticongelante CU10
(latta da 10Kg.) 18.91.001

FRANÇAIS

POS.DESCRIPTION CODE

1 Panneau lateral droit 01.03.027
2 Panneau lateral gauche 01.03.026
3 Embrayage rapide H2O 19.50.043
4 FP 115 03.05.305
5 Panneau arrière plastique 01.05.218
6 Reservoir 20.04.505
7 Panneau avant plastique 01.04.261
8 Radiateur 18.81.003
9 Ventilateur 07.10.016
10 Dispositif antivibratoire 07.21.100
11 Pompe 07.21.002

Antigel CU10
(bidon de 10Kg) 18.91.001

ENGLISH

POS.DESCRIPTION CODE

1 Right side panel 01.03.027
2 Left side panel 01.03.026
3 Quick coupling H2O 19.50.043
4 FP 115 03.05.305
5 Plastic back panel 01.05.218
6 Tank 20.04.505
7 Plastic front panel 01.04.261
8 Heat sink 18.81.003
9 Fan 07.10.016
10 Vibration damping device 07.21.100
11 Pump 07.21.002

Antifreeze CU10
(10kg tin) 18.91.001

ESPAÑOL

POS.DESCRIPCION CODIGO

1 Panel lateral derecho 01.03.027
2 Panel lateral izquierdo 01.03.026
3 Embraque rapido H2O 19.50.043
4 FP 115 03.05.305
5 Panel posterior plástico 01.05.218
6 Tanque 20.04.505
7 Panel frontal plástico 01.04.261
8 Radiador 18.81.003
9 Ventilador 07.10.016
10 Dispositivo antivibrador 07.21.100
11 Bomba 07.21.002

Anticongelante CU10
(lata de 10Kg.) 18.91.001

DEUTSCH

POS.BESCHREIBUNG CODE

1 Seitenteil re 01.03.027
2 Seitenteil l' 01.03.026
3 Schnellkupplung H2O 19.50.043
4 FP 115 03.05.305
5 Hinteres Plastikpaneel 01.05.218
6 Behälter 20.04.505
7 Stirnseitiges Plastikpaneel 01.04.261
8 Wärmesenke 18.81.003
9 Ventilator 07.10.016
10 Schwingungsdämpfende

vorrichtung 07.21.100

11 Pumpe 07.21.002

Frostschutzmittel CU10
(10Kg Kanister) 18.91.001

WU 15 (fig. 34)

47Available spare parts 47

ITALIANO

POS.DESCRIZIONE CODICE

1 Carrello portageneratore GT 18 71.03.019
2 Fondo completo carrello GT 18 02.07.040
3 Ruota fissa PBF 180 04.04.003
4 Porta bombola carrello 02.07.041
5 Manico a tubo carrello GT 18 01.15.032
6 Supporto bombola carrello 02.07.042
7 Tubo porta elettrodi GT 18 02.07.044

FASI DI MONTAGGIO

1) Unire le ruote (3) alla base del carrello (2) con viti e
dadi M8

2) Assemblare il supporto bombola inferiore (4) alla base
del carrello (2) con viti e dadi M8

3) Inserire il manico (5) negli appositi fori ed avvitare sul
fondo (2) con viti M8

4) Unire il supporto bombola superiore (6) al manico con
viti M6 ed inserire il porta elettrodi (7) ed unirlo al
fondo con viti M8

5) Completare aggiungendo la catena e gli occhioli al
supporto superiore della bombola

FRANÇAIS

POS.DESCRIPTION CODE

1 Chariot générateur GT 18 71.03.019
2 Parti inférieure GT 18 02.07.040
3 Roue PBF 180 04.04.003
4 Support bouteille 02.07.041
5 Manche GT 18 01.15.032
6 Unité ablocage bouteille 02.07.042
7 Etui électrodes GT 18 02.07.044

ASSEMBLAGE

1) Fixer les roues (3) sous la partie inférieure (2) par vis
et écrous M8

2) Fixer le support bouteille (4) sur la partie inférieure (2)
par vis et écrous M8

3) Insérer le manche dans les trous correspondants et
fixer le par vis M8

4) Fixer l'unité ablocage bouteille sur le manche par vis
M6 et insérer l'étui électrodes (vis m8)

5) Fixer la chaîne sur l'unité ablocage bouteille

ENGLISH

POS.DESCRIPTION CODE

1 Generator trolley GT 18 71.03.019
2 Bottom GT 18 02.07.040
3 Wheel PBF 180 04.04.003
4 Cylinder holder 02.07.041
5 Handle GT 18 01.15.032
6 Cylinder locking unit 02.07.042
7 Electrode holder GT 18 02.07.044

ASSEMBLY

1) Fix the wheels (3) under the bottom (2) with M8
screws and nuts

2) Fix the cylinder holder (4) to the bottom (2) with M8
and nuts

3) Put the handle (5) in the specific holes and fix to the
bottom (2) with M8 screws

4) Fix the locking unit (6) to the handle (5) with M6
screws and put the electrode holder in with M8 screws

5) Fix the metal chain on the cylinder locking unit

ESPAÑOL

POS.DESCRIPCION CODIGO

1 Carro generador GT 18 71.03.019
2 Fondo GT 18 02.07.040
3 Rueda PBF 180 04.04.003
4 Soporte bombona 02.07.041
5 Mango GT 18 01.15.032
6 Bloqueo bombona 02.07.042
7 Portaelectrodos GT 18 02.07.044

MONTAJE

1) Fijar las ruedas (3) debajo del fondo (2) con tornillos y
tuercas M8

2) Fijar el soporte bombona (4) al fondo (2) con tornillos
y tuercas M8

3) Poner el mango (5) en los agujeros apropiados y fijar
en el fondo con tornillos M8

4) Fijar el bloqueo bombona (6) al mango (5) con tornil­los M6 y colocar el portaelectrodos (M8)

5) Colocar la cadenilla en el bloqueo bombona

DEUTSCH

POS.BESCHREIBUNG CODE

1 Gerätewagen GT 18 71.03.019
2 Unterteil GT 18 02.07.040
3 Rad PBF 180 04.04.003
4 Flaschenhalter 02.07.041
5 Stiel GT 18 01.15.032
6 Flaschenverriegelungseinricht. 02.07.042
7 Elektrodenhalter GT 18 02.07.044

AUFBAU

1) Räder (3) unter den Unterteil (2) durch Schrauben und
Mutter M8 befestigen

2) Flaschenhalter (4) auf den Unterteil durch Schrauben
und Mutter M8 befestigen

3) Stiel (5) in die entsprechenden Löcher einfügen und
mit Schrauben M8 festmachen

4) Flaschenverriegelungseinrichtung (6) auf den Stiel (5)
anschrauben (M6) und Elektrodenhalter einfügen (M8)

5) Kettchen auf die Verriegelungseinrichtung anbringen

GENERATOR TROLLEY 1 CYLINDER (fig. 35)

12) TECHNICAL DATES

* Note:

- when topping up, use only coolant mod. CU-10 cod. 18.91.001 (10kg tin)

- the coolant is a ready product and should not be diluted!

48

TECHNICAL CHARACTERISTICS

Supply voltage (50/60 Hz)
Max. absorbed power in TIG (x=40%)
Max. absorbed current in TIG (x=40%)
Absorbed current in TIG (x=100%)
Max. absorbed power in MMA (x=40%)
Max. absorbed current in MMA (x=40%)
Absorbed current in MMA (x=100%)
Power factor
Cosϕ
Welding current in TIG (x=40%)

(x=60%)
(x=100%)

Welding current in MMA (x=35%)

(x=60%)

(x=100%)
Adjustment range in TIG (MMA)
Open-circuit voltage
Protection rating
Insulation class
Construction standards
Dimensions (lxdxh)
Weight

TECHNICAL CHARACTERISTICS

Supply voltage (50/60 Hz)
Nominal input current
Capacity of reservoir *
Cooling power
Protection rating
Dimensions (lxdxh)
Weight with liquid

WU15

1x230 V ± 15%

0.8 A

1.7 l

900 W

IP23C

179x430x160 mm

9.5 Kg

48 Technical dates

G 200 TLH

1x230V ± 15%

4.9 kW

21.8 A

12.9 A

6.0 kW

26.7 A

17.9 A

0.99

0.99
200 A
170 A
140 A
180 A
150 A
130 A

6-200 (180 A)

53.7 V
IP23C

H

EN60974-1/EN50199

179x430x293 mm

16 Kg

G 200 AC/DC

1x230 V ± 15%

5.3 kW

23.4 A

14.2 A

6.6 kW

28.8 A

18.7 A

0.99

0.99
200 A
170 A
140 A
180 A
150 A
130 A

6-200 (180A)

53.7 V
IP23C

H

EN60974-1/EN50199

179x430x293 mm

16 Kg