Selco GENESIS 145 Repair Manual Download | Manualshive

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REPAIRS MANUAL

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Genesis 145

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Summary of Contents for GENESIS 145

Page 1: ...REPAIRS MANUAL E N G L I S H Genesis 145...

Page 2: ...icrofil ms are reserved and forbidden without the written authorisation of Selco S r l INDEX 1 PURSPOSE OF THE MANUAL PAG 3 2 WARNINGS PRECAUTIONS AND GENERAL NOTICES FOR PERFORMING REPAIRS PAG 4 3 IN...

Page 3: ...any 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...

Page 4: ...at high temperature CAUTION LIVE PARTS When handling internal parts of the machine remember that ope ning of the switch does not prevent the risk of electric shocks the machine must be unplugged from...

Page 5: ...tween 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 meas...

Page 6: ...12Vdc 50A 14Vdc 100A 18Vdc 200A etc 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 performe...

Page 7: ...near it is pro tected with headphones or earphones 4 1 2 Fire explosion prevention The welding process may cause fires and or explosions Compressed gas cylinders are dangerous consult the supplier be...

Page 8: ...rer s instructions When the equipment is working all the access and operating doors and covers must be closed and fixed The welding power source must not be modified in any way WELDING AND CUTTING CAB...

Page 9: ...CE means that the average output current may be higher than that set S1 MMA TIG selection switch With the lever down it is in electrode welding MMA mode and thus the HOT START ARC FORCE and ANTI STICK...

Page 10: ...uses with a 20A rating are required to be able to carry out 100 A electrode welding continuously and to make maximum use of the potential of the power source 16 A fuses are sufficient for welding with...

Page 11: ...3 Hydrogen in weld present on electrode coating 5 6 2 Possible faults in the TIG welding Fault Cause Oxidations 1 lnsufficient gas 2 No protection on the rever se Tungsten inclusion 1 lncorrect elect...

Page 12: ...ster switch b Varistor c EMI input filter board d Input rectifier e DC LINK capacitor f Power stage Forward converter g Power transformer h Output rectifier i Doubler j Output inductor k Primiry senso...

Page 13: ...the persistence time exceeds certain limits the varistor is not capable of supporting this energy and burns out This happens for example as a result of overvoltages on the electric line or overvoltage...

Page 14: ...of smoothing capacitors Thus the capacitor bank forms a DC LINK or a connection between the rectifier stage and the inverter stage on which a constant voltage difference is present The value of the D...

Page 15: ...at the output current has the required dynamic range and the transformer does not become saturated The Forward converter made by Selco provides a suitable transfor mer resetting circuit in order to im...

Page 16: ...uired to supply the various boards The electronic switch of the feeder is a MOSFET The functional wiring diagram of a multi output DC DC Flyback converter is illu strated in the figure below The weldi...

Page 17: ...17 7 WIRING AND CONNECTION DIAGRAM...

Page 18: ...18...

Page 19: ......

Page 20: ...U 2 Fase U dopo l interruttore Phase U after switch 4 Neutro N Neutral N 5 Neutro N dopo l interruttore Neutral N after switch 7 VBUS VBUS 8 GND_BUS GND_BUS 9 18Vdc 18Vdc 10 25Vdc 25Vdc 11 VSH VSH 12...

Page 21: ...as a temperature alarm even if it is correctly supplied it does not release the power output For fast cooling leave the welding machine on in order to make use of the internal fan and thus reduce the...

Page 22: ...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 smo...

Page 23: ...ntains the overcurrent protection devices varistor EMC filter circuitry the electronic welding logic and the switching power supply INSTRUMENTS REQUIRED Multimeter Set of screwdrivers BOARD CN1 L2 L1...

Page 24: ...c 25Vdc LEDs ON L1 ON L2 ON 12Vdc power supply 12Vdc power supply Output voltage ON CN1 4 CN1 1 50Vdc 5Vdc Open Circuit Voltage MOSFET MF6 OFF S G S D 10kohm 0 5V Diode of the switching feeder OFF D23...

Page 25: ...mer and to better the performance of the power stage INSTRUMENTS REQUIRED Multimeter Set of pipe spanners for exagonal nuts Set of screwdrivers BOARD L1 L2 MF1 MF2 MF5 K1 R11 1 R11 2 MF3 MF6 MF8 MF9 M...

Page 26: ...c 10kohm Pre load relay ON RL1 D30 K A 24Vdc Listen to the preloading relay tripping with a time delay after switching on Relay supply voltage Power supply ON L1 ON L2 ON L3 ON when the welding machin...

Page 27: ...upports 7 Fit the new diode bridge 8 Smear high temperature grease underneath the rectifier bridge and underneath the power devices MF1 MF2 MF3 MF4 MF6 MF7 MF8 MF9 9 Position the new sheet of SILPAD i...

Page 28: ...the plastic support 5 Remove the sheet of SILPAD insulation which insulates the MOSFET MF5 WARNING The sheet of SILPAD insulation can NOT be re used 6 Clean any high temperature grease off the heat s...

Page 29: ...r instruments required Multimeter Set of pipe spanners for exagonal nuts Set of screwdrivers BOARd NOTE Resistance R is not supplied with the 15 14 245 board If board 15 14 243 is replaced unsolder re...

Page 30: ...0 4Vdc 0 4Vdc 0 4Vdc 0 4Vdc 0 4Vdc 0 4Vdc With board removed With board removed With board removed With board removed Diode OFF D5 A K 0 4Vdc Resistence R OFF R R 1 R 2 470ohm Notes Unless specified o...

Page 31: ...e excellent arc striking in all welding conditions INSTRUMENTS REQUIRED Multimeter Set of pipe spanners for exagonal nuts Set of screwdrivers BOARD D1 Functional part Generator Mode Component Test Poi...

Page 32: ...spanners for exagonal nuts Set of screwdrivers BOARD P2 P1 sw1 sw2 sw3 pt1 pt2 pt3 Functional part Generator mode Component Test Point Value Type of measure Note Switch OFF SW SW1 SW2 SW2 SW3 0ohm 0oh...

Page 33: ...urrent value to 145 3A 9 7 SHUNT CHECK The current sensing is done by a shunt i e a bar of very low resistance made of constantan alloy through which the output current flows and a voltage drop propor...

Page 34: ...ntify the description which is closest to the problem you have The problems are grouped into five sections 10 1 Power supply failed 10 2 Fan 10 3 Thermal alarm 10 4 Open circuit volatage 10 5 Power pa...

Page 35: ...connected between phase and neutral i e a device protecting the downstream electronics against overvoltages In case of an overvoltage which is too high or lasts for too long the varistor explodes The...

Page 36: ...pre sent Check the welder power supply and the sin gle phase rectifier bridge according to the procedure illustrated on page 25 The green and yellow LEDs lighten 1 Switching feeder in overload If the...

Page 37: ...ssible problem Suggestions The fan will not start 1 Fan broken 2 15Vdc supply failure If the fan is correctly supplied by a voltage of 15Vdc but does not work replace the fan The 15Vdc supply voltage...

Page 38: ...ggestions Machine in temperature alarm No problem Temperature device fault Logic fault The machine was working correctly and en tered into temperature alarm because the limit temperature was reached W...

Page 39: ...e Zero no load voltage If the control system does not read the ou tput voltage the no load voltage rises consi derably about 100V In this case check that the red wire which reads the positive output v...

Page 40: ...broken The forward converter can have some pro blems Check the rectifier bridge according to the procedure on page 25 If you must replace the rectifier bridge following the procedure on page 26 Chek t...

Page 41: ...40 11 spare part list...

Page 42: ...001 10 karte 15 14 243 11 Bus 49 02 79601 12 Elektrolytischer Kondensator 12 06 101 13 Diodenbr cke 14 10 150 14 Relais 09 09 026 15 Kit Leistungskarte 15 18 012 16 Ventilator 14 70 014 17 Kit Sekund...

Page 43: ...3 25 electrode 110 A 40 13A Absorbed current with 4 00 electrode 140 A 40 17 8A Efficiency x 100 0 87 Power factor 0 7 Cos 0 99 Welding current x 35 x 60 x 100 145A 120A 100A Adjustment range 5 145A O...

Page 44: ...43...

Page 45: ...44 Selco s r l Via Palladio 19 35010 Onara di Tombolo Padova Italy Tel 39 049 9413111 Fax 39 049 9413311 e mail info selcoweld com...

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