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5) MACHINE DESCRIPTION

These constant current inverter power sources are able to perform 

the following types of welding with excellent results:

- MMA,

- TIG (with reduction in the current on short-circuiting).

In inverter welders, the output current is unaffected by variations in 

the supply voltage and the length of the arc, and is perfectly levelled, 

giving the best welding quality.

The generator is equipped with:

- positive (+) and negative (-) socket,

- front panel,

- rear control panel.

5.1) FRONT CONTROL PANEL (FIG.1)

* L1 : Voltage warning light green led.

Comes on with the start switch (Fig.) “I1” in position “I” and indica-

tes that the plant is on and there is voltage.

* L2 : Safety device warning light yellow led.

lndicates that the safety devices like thermal cutout. With “L” on, 

the power source remains connected to the supply mains, but does 

not supply output power. “L” remains on until the fault has been 

removed and in any case until the inner temperatures are not within 

the  normal  values;  in  this  case  it  is  necessary  to  leave  the  power 

source on to exploit the operating ventilator and reduce the time 

when it is not active.

* P1: Potentiometer for setting the welding current

Allows  you  to  continuously  adjust  the  current  both  in  TIG  and  in 

MMA welding. This current stays unchanged when the supply and 

welding conditions vary within the allowed ranges.

In  MMA  welding,  the  presence  of  HOT-START  and  ARC-FORCE 

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-STICKING  are  auto-

matically activated.

With  the  lever  up:  it  is  in  the  mode  for  welding  with  non-consu-

mable tungsten electrode in an inert atmosphere (TIG). The MMA 

functions are removed, and the LIFT start is activated.

         

Fig. 1

5.2) REAR CONTROL PANEL (FIG. 2)

* I1: Off/On switch

Turns on the electric power to the welder.

It has two positions, “O” off, and “I” on.

 

* 1 : Supply cable

*  : Ventilation slots. Never allow them to be obstructed.

         

5.3) TECHNICAL CHARACTERISTICS

Power supply voltage 50/60Hz

1 15% 

Max. absorbed power (x=35%)

4.65kW

Max. absorbed current (x=35%)

31.1A

Absorbed current (x=100%)

18.6A

Absorbed current .50 (80A@40%)

9.A

Absorbed current with

3.5 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

10A

100A

Adjustment range

5-145A

Open-circuit voltage (limited)

6V

Protection rating

IP3C

lnsulation class

H

Construction standards

EN60974-1/EN50199

Dimensions (lxdxh)

111x80x0 mm

Weight

4.1kg

Above data are referred to environment al 40°C

               

CAUTION     

*   With the I1 switch in the “I” on position, the welder is ope-

rational, and gives a voltage between the positive (+) and 

negative (-) clamps.

*   The welder is connected to the mains supply even if the I1 

switch is in the “O” position, and therefore there are electri-

cally live parts inside it. Carefully follow the instructions gi-

ven in this manual..    

                                       

Содержание GENESIS 145

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 18: ...18...

Страница 19: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 44: ...43...

Страница 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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