Selco Genesis 90 Repair Manual Download Page 18 | Manualshive

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Wiring and connection diagrams

17

6.2) Connections for torch

FRONT VIEW

1

=

torch cap protection

2

=

common (protection and torch button)

3

=

trigger

7, 8

=

pilot arc

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Summary of Contents for Genesis 90

Page 1: ...REPAIRS MANUAL Genesis 90 E N G L I S H...

Page 2: ...INSTRUMENTS AND CONVENTIONS FOR PERFORMING DIAGNOSIS AND REPAIR 5 4 DESCRIPTION OF OPERATION OF THE POWER SOURCES 7 5 OPERATING PRINCIPLE BLOCK DIAGRAM 15 6 WIRING AND CONNECTION DIAGRAM 16 7 PC BOARD...

Page 3: ...purchaser must follow the directions contai ned in the above manual Failure to do so will exempt Selco from all liability The operations described in this manual require the use of a digital multimet...

Page 4: ...ne must be unplugged from the power supply Wait approx one minute before carrying out work on the internal parts as the capacitors may be loaded at high voltage CAUTION When taking measurements remem...

Page 5: ...gonal nuts complete set of blade screwdrivers complete set of Phillips screwdrivers complete set of Allen keys Phillips torque screwdriver for M3 screws with tigh tening torque adjustable range from 1...

Page 6: ...ymbols will be used in the same way AC or DC voltage measurement multimeter in voltmeter mode Resistance measurement multimeter in ohmmeter mode Current measurement ammeter clamp or shunt multi meter...

Page 7: ...plosive powders gases or vapours are present Do not perform welding cutting operations on or near contai ners under pressure Don t use this machine to defrost pipes 4 1 3 Protection against fumes and...

Page 8: ...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 CABLES The welding cutting cables must be ke...

Page 9: ...arm green led Means that the torch cap has not been properly tightened The generator has no power output L4 compressed air alarm green led Means that the pressure of compressed air is below 3 bar too...

Page 10: ...s been removed from the packing the power source is supplied with an extendible belt which can be used to move it in the hand or on the shoulder 4 6 INSTALLATION Choose an adequate installation area b...

Page 11: ...rking cor rectly and some display If operating faults occur in the generator it will be inhibited until normal operating conditions are restored Press the gas test pushbutton T2 in Fig 1 in order to r...

Page 12: ...the plasma arc made very hot and highly concentrated by the design of the torch transfers onto the conductive piece to be cut closing the electrical circuit with the generator The material is first me...

Page 13: ...00 500 14000 3200 1200 900 400 21000 7200 3200 1400 900 400 250 200 Thickness mm 1 3 1 3 6 5 10 15 1 3 6 5 10 15 20 25 30 Current A 30 30 60 60 60 60 60 90 90 90 90 90 90 90 90 Speed mm min 5700 1000...

Page 14: ...e speed must be adjusted so that the outflow of the arc below the workpiece is perpendicular 5 10 degrees of slope are acceptable A slow speed start is advisable to prevent spray of material which cou...

Page 15: ...r 5 Snubbing inductor 6 Primary current transformer 7 Resonant inductor 8 Power transformer 9 Secondary power rectifier 10 Pilot arc IGBT 11 Hall effect probe cutting current 12 Output filter 13 Auxil...

Page 16: ...ent fast protection circuit Auixiliary power supplies switching frequency derived from inverter logic System synchronization for noiseless welding arc audible subarmonic frequency generation avoided i...

Page 17: ...6 WIRING AND CONNECTION DIAGRAM 6 1 Genesis 90...

Page 18: ...Wiring and connection diagrams 17 6 2 Connections for torch FRONT VIEW 1 torch cap protection 2 common protection and torch button 3 trigger 7 8 pilot arc...

Page 19: ...18 PC boards location 7 PC BOARDS LOCATION...

Page 20: ...PC boards location 19...

Page 21: ...therefore the machine is correctly powered Torch cap missing LED GREEN It indicates that the torch end tip is missing Always off when the torch is working and connected to the generator correctly When...

Page 22: ...the ventilation effect Indicat 01 02 03 11 13 Description of diagnostic indications 21 Type of error Front panel memory error Torch not correctly assembled connected Low air pressure Overtemperature...

Page 23: ...circuit supply 24Vdc Power supply not used 24Vdc Power supply not used 26Vdc Main positive auxiliary power supply 10Vdc P logic power supply 20Vdc Main negative auxiliary power supply 12Vdc Primary L...

Page 24: ...8 3 Thermal devices connectors locations Description of diagnostic indications 23...

Page 25: ...24 Description of diagnostic indications...

Page 26: ...nfirms the new value The table shows that some parameters have no values associated to them by selecting one of these parameters and pressing the Parameters button the associated operation is performe...

Page 27: ...switched off instrumental check on power parts and any boards that may be faulty if faults are found repla ce the parts with equivalent spares be careful of any configurations calibrations to be perfo...

Page 28: ...e power supply the main switch is live regardless of its status open or closed It is therefore important to unplug the machine before touching any internal part of the power source Wait approx one min...

Page 29: ...r sources for the various machine circuits see table on following page fan and gas solenoid valve power supply the signals for the Hall probe and torch button pass through this board The weld switchin...

Page 30: ...P7 CNB 9 TP8 CNB 9 CN7 2 CN7 1 CN1 4 CN1 5 CN1 1 CN1 5 CN1 2 CN1 5 CN5 7 CN5 9 CN5 8 CN5 9 TP26 TP21 CN8 2 CN8 1 TP22 TP21 CN8 6 CN8 5 400Vac 15 400Vac 15 400Vac 15 560Vdc 15 12Vdc 30Vdc 24Vdc 24Vdc 2...

Page 31: ...ms over under voltage phase lack not used power supply output Negative auxiliary power supply inverter control logic welding logic panel logic Hall probe Microprocessor logic power supply front panel...

Page 32: ...e electronic boards current calibration 31 Functional part Input fuse Output fuses Driver Power switches Power diodes Generator Mode OFF OFF OFF OFF OFF Component F1 F2 F3 F4 F5 F6 F7 F8 F9 MF3 MF1 MF...

Page 33: ...on above NOTE Values below are referred to each sigle component tested alone without any connection any other other value in this page is referred to normal conditions with all connections correctly m...

Page 34: ...Thermal switches Inverter input high voltage Output voltage Generator Mode OFF OFF OFF ON STICK ON STICK Component IG1 IG2 D1 D2 D3 D4 D5 D6 MF1 G E MF2 G E IG1 or IG2 Test point C2 E1 C1 E2 C2 E1 B1...

Page 35: ...y source at low voltage and limited current protected against short circuits switching the generator everything works normally but the output voltage reading must be appropriately scaled e g by connec...

Page 36: ...Inverter Enabled power out L3 POT signal that is Inverter Disabled due to microprocessor logic command coming from Front Panel PC Board Note fuses are located on Aux Power Supply PC board 15 14 271 se...

Page 37: ...rd performs the following functions driving of resonant inverter power components Soldered jumpers factory setted all located on solder side of PC Board K1 CLOSED K2 CLOSED K3 CLOSED K4 CLOSED K5 CLOS...

Page 38: ...terface relays for the RL1 torch button and RL2 torch protection WARNING PZ_PE must always be earthed Note before carrying out this operation disconnect CN2 from the HF 15 14 192 board so as to avoid...

Page 39: ...ions with all connections correctly made Unless specified otherwise all the measurements must be taken with the boards fitted together with their connections 38 Description testing and replacement of...

Page 40: ...off This test must therefore be performed with FN1 and FN2 disconnected Unless specified otherwise all the measurements must be taken with the boards fitted together with their connections Descriptio...

Page 41: ...FF 3 OFF 4 ON NOTE dip switch 3 being ON allows bypassing the alarm generated by the pressure switch in the event of air pressure being non existent or lower than 3 bar this operating mode can make te...

Page 42: ...arc solenoid valve HF control Pilot arc control Cutting current sensor Inverter power breakover Reference for inverter control Output voltage Generator Mode ON ON ON ON ON ON ON ON ON ON ON ON NO LOA...

Page 43: ...ccurate measurement of actual output current is required You are advised to use an ammeter clamp with class 2 minimum rating accurately calibrated calibration certificate issued no more than 12 months...

Page 44: ...anges by adju sting P3 trimmer adjust P3 trimmer on resonant inverter control PCB 15 14 152 until value showed by external clamp amme ter matches the value showed on control panel this value is the re...

Page 45: ...11 AVAILABLE SPARE PARTS 44 Available spare parts 56 01 090 GENESIS 90...

Page 46: ...lterkarte 15 14 276 20 Resonanzdrosselswule 05 04 208 21 Drosselspule Snubber 15 14 241 22 Einheit Prim rinverter 14 60 069 23 Hintere Plastkatel 01 05 222 24 Resonanzlogikkarte 15 14 298 25 Halterung...

Page 47: ...SELCO s r l Via Palladio 19 35010 ONARA DI TOMBOLO PADOVA ITALY Tel 39 049 9413111 Fax 39 049 9413311 http www selcoweld com E mail info selco it SELCO 2 Via Macello 61 35013 CITTADELLA PADOVA ITALY...

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