Selco Genesis 240 TLH Repair Manual Download Page 37

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Available spare parts

119

Pos.

Code

01.04.262

03.07.043

01.05.220

49.04.057

01.06.100

10.13.020

15.22.104

08.22.001

11.26.006

14.10.161

15.14.233

05.11.259

14.05.076

15.14.240

09.11.009

09.01.008

14.60.060

07.10.014

21.06.004

12.03.020

Description

Plastic front panel

Upper cover

Plastic back panel

Supply cable

Plastic bottom

Fixed socket

Front panel FP104

Cable clamp

Varistor

Diode bridge

Input board

Auxiliary transformer

Diode

Secondary rectifier board

Switch knob

Switch

Logic+power board kit

Fan

Belt

Capacitor

TAB. 01

GENESIS 240 SPARE PARTS

Note: With power electronic components order code

16.03.102 ( thermal paste) too

7) AVAILABLE SPARE PARTS

G 240 :

(see TAB. 01)

NOTES :

Code 15.14.233 (no.11) comprises:

- board 15.14.233 and the diode bridge 14.10.161 (no.10)

supplied loose.

The diode bridges can also be supplied separately.

Code 14.60.060 (no.17) comprises:

- board 15.14.254 complete with power IGBT and radiator.

Neither board 15.14.254 nor the power IGBTs can be supplied

separately.

Summary of Contents for Genesis 240 TLH

Page 1: ...REPAIRS MANUAL E N G L I S H Genesis 240 Genesis 240 TLH...

Page 2: ...AND REPAIR INSTRUMENTS AND TOOLS 121 10 DIAGNOSIS PROCEDURE 122 LEVEL 1 LEVEL 2 11 PARTS DISMANTLING AND RE INSTALLATION PROCEDURE 152 12 OPERATING TESTS AND SETTINGS 159 13 TELEPHONE ASSISTANCE REQUE...

Page 3: ...more sophisticated instruments tools are used By taking into account the training level of its technicians and its available instruments each service centre can decide whether to use the first or sec...

Page 4: ...g rectifier circuit with overtemperature detection device e snubber circuit h output filter i levelling inductance with overtemperature detection device j current transducer Hall effect probe k fan l...

Page 5: ...ormer q H F discharge generation r gas solenoid valve s cooling unit power supply circuits Some of these parts are independent while others are housed inside the following electronic cards G 240 TLH F...

Page 6: ...e input voltage is applied to the board 15 14 233 containing the line overvoltage suppressor cir cuit b consisting of three varistor see note and the radio interference suppressor circuit b see note c...

Page 7: ...ency emissions within limits specified by standards and to ensure G 240 s immunity against the same type of problems caused by any electronic devices connected to the same power supply source The filt...

Page 8: ...um radiator by means of a profiled plastic bar but electrically insulated from the radiator by a strip of insulating tape with low thermal resistance The IGBT switch on control circuit is located on b...

Page 9: ...Description of machine operation 91 n m k a o q r l c b i p j d s e f g h e FIG 6...

Page 10: ...on air flow by a radiator temperatu re detection device this device sends a signal to the control logic which then locks the inverter and signals the fault to the front panel The diodes are connected...

Page 11: ...Description of machine operation 93 n m k a o q r l c b i p j d s e f g h e FIG 8...

Page 12: ...es the machine s output current to provide the following functions G 240 in MMA increase of current when welding is started hotstart the following relation applies supplied current requested current 8...

Page 13: ...ns within the permitted limits re set occurs automatically after a few seconds in the case of the G 240 to re set the G 240 TLH press any button on the front panel All the machine electronic circuits...

Page 14: ...ow position open circuit voltage is available on the machine terminals when it is powe red and further the hot start arc force and overheating protection functions are all enabled When the selector sw...

Page 15: ...tart Arc Force I max external I min external I2 in Bilevel mu sec sec A A sec Hz sec sec A sec A A A min 0 0 2 0 0 6 6 0 02 20 0 02 0 0 6 0 0 0 0 6 6 6 max 25 0 200 10 0 240 240 2 00 500 2 00 10 0 240...

Page 16: ...slope down At the end of slope down the current is maintained equal to the final current If 4th stroke Torch button released the inverter switches off and the solenoid valve is kept open for a variab...

Page 17: ...H F discharge generation q see fig 13 The H F discharge generation circuit board 15 14 192 and the H F transformer create a series of high voltage pulses a few thousand volts to spark the TIG H F wel...

Page 18: ...hes relay and triac via which the 230 Vac power supply voltages from the auxiliary transformer l are supplied to the pump and fan of the cooling unit WU15 during TIG operation The power supplies are r...

Page 19: ...IG 15 5 8 auxiliary transformer l see fig 15 16 17 Provides the power supplies at the electronic board inputs It also provides the 230 Vac power supply voltages for the fans power source and cooling u...

Page 20: ...102 Description of machine operation n m k a o q r l c b i p j d s e f g h e FIG 16 F1 F2 FIG 17...

Page 21: ...k a o q r l c b i p j d s e f g h e FIG 18 NOTE connection of the three thermal protection probes already mentioned and the protection from the cooling unit pressure switch to the current locking circ...

Page 22: ...LAY OUTS OF CARDS...

Page 23: ...Lay outs of cards 105 Card 15 14 233 Fig 20...

Page 24: ...106 Lay outs of cards Card 15 14 236 side A Fig 21...

Page 25: ...Lay outs of cards 107 Card 15 14 236 side B Fig 22...

Page 26: ...108 Lay outs of cards Card 15 14 236 side C Fig 23...

Page 27: ...Lay outs of cards 109 Card 15 14 254 side A Fig 24...

Page 28: ...110 Lay outs of cards Card 15 14 254 side B Fig 25...

Page 29: ...Lay outs of cards 111 Card 15 14 254 side C Fig 26...

Page 30: ...112 Lay outs of cards Card 15 14 254 side D Fig 27...

Page 31: ...Lay outs of cards 113 Card 15 14 192 Fig 28...

Page 32: ...114 Lay outs of cards Card 15 14 239 Fig 29...

Page 33: ...Lay outs of cards 115 Card 15 14 240 Fig 30...

Page 34: ...see fig n 31 The G 240 has two leds on the front panel with diagnostic functions FIG 31 Position L1 L2 Colour GREEN YELLOW Status under normal conditions ON OFF Meaning Machine powe red and master sw...

Page 35: ...ations 117 G 240 TLH FP106 see fig 32 In addition to the two leds previously described there is also a third led with the following meaning FIG 32 Position L3 Colour RED Status under normal conditions...

Page 36: ...led on the front panel is also off then see previous section L2 if it is off and the green led on the front panel is on then there is a fault in the adjustment circuits power supply circuits board 15...

Page 37: ...clamp Varistor Diode bridge Input board Auxiliary transformer Diode Secondary rectifier board Switch knob Switch Logic power board kit Fan Belt Capacitor TAB 01 GENESIS 240 SPARE PARTS Note With power...

Page 38: ...e too Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Description Plastic front panel Upper cover Plastic back panel Plastic bottom Fixed socket Centralised TIG socket FP106 Plug...

Page 39: ...board 15 14 192 Moving parts IMPORTANT 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 befor...

Page 40: ...station off the shelf unwelding tracce may be used instead 10 DIAGNOSIS PROCEDURE 10 1 General information The diagnosis procedure is according to this logic starting off from a known situation you a...

Page 41: ...his batch the procedure does not apply they must be sent to SELCO for repair The board code is given on the board itself in the area indi cated in figure 34 IMPORTANT The electronic boards can undergo...

Page 42: ...124 Diagnosis procedure Card 15 14 254 soldering side FIG 35A Card 15 14 254 soldering side FIG 35B...

Page 43: ...h the master switch closed taking the measurement between the machine input phases and cables no 22 and no 23 In this case however if a negative result is obtained it can depend not only on the diode...

Page 44: ...ary With the master switch open reconnect CN1 of board 15 14 233 Close the master switch and check operation of the fan presence of air flow from back to front of machine yes go on no check connection...

Page 45: ...ate of the tracks of the 15 14 233 After removing board 15 14 192 take the following measurements values 400 V line voltage Board Connector Cables Value 15 14 233 CN3 52 50 400 Vac yes go on no after...

Page 46: ...15 14 236 CN4 4 CN4 3 34 Vdc with torch button released CN4 4 CN4 3 0 with torch button pressed yes go on no check the torch button check continuity between CN4 4 and pin 3 Mechafin and CN4 3 and pin...

Page 47: ...Select MMA operating mode from the front panel and apply the load 3 8 or weld selecting TIG DC LIFT 2 strokes operating mode Set 120 A via the potentiometer on the front panel Checks With the shunt on...

Page 48: ...54 D S from IG1 to IG6 OPEN S D from IG1 to IG6 approx 0 4V With a multimeter set to Ohm check between the points of figure G S from IG3 to IG6 10 kOhm G S of IG1 and IG2 22 Ohm yes go on no replace p...

Page 49: ...nsformer cable from each of the two output rectifier diodes Checks With a multimeter set to diode testing check between the diode terminals d e circuit open 2V e d 0 2 V yes go on no replace the diode...

Page 50: ...TP10 TP3 5 Vdc TP13 TP3 10 Vdc yes replace board 15 14 239 or check flat cable connected to it no after disconnecting the machine from the mains power supply replace fuse F1 in 15 14 254 or in part 1...

Page 51: ...use F1 in 15 14 254 or in part 14 60 060 Perform the same check after reconnecting connector CN3 of board 15 14 254 yes go on no after disconnecting the machine from the mains replace the front panel...

Page 52: ...sure between the terminals CN2 2 CN2 3 0V yes go on no check continuity of connection between T1 T3 and pressure switch if WU15 present according to attached diagram on board 15 14 254 using a tester...

Page 53: ...nd perform lift start by placing the electrode in contact with the piece and lifting the torch Checks With oscilloscope set to TRIGGER ROLL Time scale 100 ms Amplitude scale 2 V Measure on board 15 14...

Page 54: ...ecks With oscilloscope set to TRIGGER ROLL Time scale 200 ms Amplitude scale 2 V Measure on board 15 14 254 TP14 TP3 oscillogram no 10 shows the moments before and after sparking of the arc With oscil...

Page 55: ...on no check correct insertion of connector CN4 on board 15 14 254 with a tester set to Vdc measure between the points indicated on board 15 14 254 CN3 2 TP3 5V approx yes replace front panel FP 106 n...

Page 56: ...yes go on no replace the front panel FP106 level 1 and 2 Stage 5 6 and 7 Do not perform these tests they apply only to G 240 Stage 8 Select the external reference from the front panel Insert the remot...

Page 57: ...0 Vac of line yes go on no check correct insertion of the connector With multimeter set to Vdc check between the points of board 15 14 192 i ii 900 100 Vdc yes go on no replace board 15 14 192 Stage 2...

Page 58: ...140 Diagnosis procedure J9 connector frontal side FIG 36 Card 15 14 192 FIG 37...

Page 59: ...Diagnosis procedure 141 FIG 38 Card 15 14 233 FIG 39...

Page 60: ...142 Diagnosis procedure Card 15 14 254 version 1 soldering side FIG 40A...

Page 61: ...Diagnosis procedure 143 Card 15 14 254 version 2 soldering side FIG 40B soldering side view...

Page 62: ...144 Diagnosis procedure Card 15 14 236 FP106 FIG 41...

Page 63: ...Diagnosis procedure 145 FIG 43 H F 15 14 192 wring diagrama FIG 42...

Page 64: ...146 Oscillograms Oscillogram 1 Oscillogram 2...

Page 65: ...Oscillograms 147 Oscillogram 3 Oscillogram 4...

Page 66: ...148 Oscillograms Oscillogram 5 Oscillogram 6...

Page 67: ...Oscillograms 149 Oscillogram 7 Oscillogram 8...

Page 68: ...150 Oscillograms Oscillogram 9 Oscillogram 10...

Page 69: ...Oscillograms 151 Oscillogram 11...

Page 70: ...he earth terminal on the intermediate support Unscrew the two cable grip fixing screws to release the power supply cable To refit carry out these jobs in reverse order 11 6 Cable grip Remove the power...

Page 71: ...o not require any particular precautions 11 14 Diode bridges on board 15 14 233 The bridges can be disassembled with part 15 14 233 already removed Shear one terminal at a time inserting a pair of cut...

Page 72: ...e solenoid valve suppor ting bracket Disconnect cables no 26 no 27 and the yellow green cable Disconnect the gas pipe To refit carry out these jobs in reverse order IMPORTANT When mounting the front n...

Page 73: ...Parts dismantling and re installation procedure 155 FIG 44...

Page 74: ...156 Parts dismantling and re installation procedure FIG 45...

Page 75: ...Parts dismantling and re installation procedure 157 FIG 46 FIG 47...

Page 76: ...158 Parts dismantling and re installation procedure FIG 48...

Page 77: ...tments of the value can be effected with potentiometer P1 on Card 15 14 239 on the front panel 12 2 Measurement and setting of maximum current Set to 240A with the potentiometer on the front panel and...

Page 78: ...240A via the potentiometer on the front panel and check that this is the value read by the multimeter Any value adjustments can be made via the potentiometer P2 on board 15 14 254 12 3 Measuring and c...

Page 79: ...Operating tests and settings 161 Card 15 14 239 FIG 49...

Page 80: ...162 Operating tests and settings Card 15 14 254 FIG 50...

Page 81: ...Operating tests and settings 163 FP106 FIG 51...

Page 82: ...Tecnica A T SELCO Selco technical service department Information may be given by telephone or fax calling the following numbers Tel 39 0 499413111 Fax 39 0 499413311 of via the E mail to service dept...

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