Sel Genesis 260AC-DC User manual

USE AND MAINTENANCE MANUAL
E
N
G
L
I
S
H
SQUARE WAVE INVERTER GENERATORS
FOR TIG DC AND TIG AC WELDING
Genesis
260AC-DC
Genesis
350AC-DC

SELCO s.r.l.
Via Palladio, 19
35010 ONARA DI TOMBOLO (Padova) Italy
Tel. [phone]
Fax [phone]
This manual is an integral part of the unit or machine and
must accompany it when it changes location or is resold.
The user must assume responsibility for maintaining this
manual intact and legible at all times.
SELCO s.r.l. reserves the right to modify this manual at
any time without notice.
All rights of translation and total or partial reproduction by
any means whatsoever (including photocopy, film, and
microfilm) are reserved and reproduction is prohibited
without the express written consent of SELCO s.r.l.
Edition 07/99
CONTENTS Pag.
1.0 WARNINGS - PRECAUTIONS -
GENERAL ADVICE . . . . . . . . . . . . . . . . . . . . . .17
1.1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.1.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.1.2 Operator and other persons' protection . . . . . .17
1.1.3 Fire/explosion prevention . . . . . . . . . . . . . . . .17
1.1.4 Protection against fumes and gases . . . . . . . . .17
1.1.5 Positioning the power source . . . . . . . . . . . . .17
1.1.6 lnstalling the apparatus . . . . . . . . . . . . . . . . . .18
1.2 ELECTROMAGNETIC COMPATIBILITY
(EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
1.2.1 General information . . . . . . . . . . . . . . . . . . . .18
1.2.2 Installation, use and area examination . . . . . . .18
1.2.3 Emission reduction methods . . . . . . . . . . . . . .18
1.3 RISK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . .19
2.0 MACHINE DESCRIPTION . . . . . . . . . . . . . .19
2.1 CONTROLS, ADDITIONAL ACCESSORIES
AND OPTIONALS . . . . . . . . . . . . . . . . . . . . . . .19
2.1.1 Generator trolleys . . . . . . . . . . . . . . . . . . . . .19
2.1.2 Front control panel FP62 . . . . . . . . . . . . . . . .19
2.1.3 Front control panel FP110 . . . . . . . . . . . . . . .19
2.1.4 Front control panel FP73 . . . . . . . . . . . . . . . .22
2.1.5 Rear control panel . . . . . . . . . . . . . . . . . . . . .22
2.1.6 Remote control RC08 . . . . . . . . . . . . . . . . . .23
2.1.7 Remote control RC10 . . . . . . . . . . . . . . . . . .23
2.1.8 Control software . . . . . . . . . . . . . . . . . . . . . .23
2.1.9 Potentiometer remote control RC16
for MMA and TIG welding . . . . . . . . . . . . . . . . . . .23
2.1.10 Pedal remote control RC12
for MMA and TIG welding . . . . . . . . . . . . . . . . . . .23
2.2 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . .24
2.2.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . .24
2.2.2 Dimensions and mass . . . . . . . . . . . . . . . . . . .24
2.2.3 Technical characteristics . . . . . . . . . . . . . . . . .24
3.0 TRANSPORT - UNLOADING . . . . . . . . . . . .25
4.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .25
4.1 GENERAL RULES . . . . . . . . . . . . . . . . . . .25
4.2 ASSEMBLING THE EQUIPMENT . . . . . . . .25
4.2.1 Assembling the movable trolley . . . . . . . . . . .25
4.2.2 Installing the WU14 and the generator . . . . .25
4.3 CONNECTING THE UNIT . . . . . . . . . . . . .25
4.3.1 Electric/electronic connection
between the generator and the WU14 . . . . . . . . . .25
4.3.2 Filling the coolant tank . . . . . . . . . . . . . . . . .26
4.3.3 Hydraulic connection to the WU14 . . . . . . .26
4.4 ELECTRIC CONNECTION
TO THE SUPPLY MAINS . . . . . . . . . . . . . . . . . . .26
4.5 CONNECTING THE EQUIPMENT
COMPONENTS (EARTH CLAMP, ELECTRODE
HOLDER, TORCH, GAS PIPE,
HYDRAULIC PIPES) . . . . . . . . . . . . . . . . . . . . .27
4.5.1 Connection for MMA welding . . . . . . . . . . .27
4.5.2 Connection for TIG welding . . . . . . . . . . . . .27
5.0 PROBLEMS - CAUSES . . . . . . . . . . . . . . . . . .27
5.1 POSSIBLE FAULTS
IN THE MMA AND TIG WELDING . . . . . . . . . .27
5.2 POSSIBLE ELECTRICAL FAILURES . . . . . . .27
6.0 ROUTINE MAINTENANCE . . . . . . . . . . . . . .28
7.0 NOMINAL DATA . . . . . . . . . . . . . . . . . . . . .28
8.0 ELECTRICAL DIAGRAMS
WU14 Power supply wiring diagram (Fig. 23) . . . . . . . .72
WU14 Electrical diagram (Fig. 24) . . . . . . . . . . . . . . . .72
Genesis 260 AC-DC electrical diagram (Fig. 25) . . . . . . .73
Genesis 350 AC-DC electrical diagram (Fig. 26) . . . . . . .74
SPARE PARTS TABLES
TAV.01 SPARE PARTS GENESIS 260 AC-DC . . . . . .76
TAV.02 SPARE PARTS GENESIS 350 AC-DC . . . . . .78
TAV.03 COOLING UNIT WU14 . . . . . . . . . . . . . . . .80
TAV.04 GENERATOR TROLLEY GT15/GT17 . . . . .82
TAV.05 TIG TORCH SR 26 . . . . . . . . . . . . . . . . . . . .84
TAV.06 TIG TORCH SR 18 . . . . . . . . . . . . . . . . . . . .86
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
TIG SPARE ELECTRODES . . . . . . . . . . . . . . . . . . . .88
16

17
1.0 WARNINGS - PRECAUTIONS -
GENERAL ADVICE
1.1 SAFETY
Prior to performing any operation on the machine, make
sure that you have thoroughly read and understood the
contents of this manual.
Do not perform modifications or maintenance operations
which are not prescribed. For any doubt or problem
regarding the use of the machine, even if not described
herein, consult qualified personnel or SELCO s.r.l., which
is always at your disposal.
SELCO s.r.l. cannot be held responsible for damage to
persons or property caused by the operator's failure to
read or apply the contents of this manual.
1.1.1 Symbols
Imminent danger of serious bodily harm
and dangerous behaviours that may lead to
serious bodily harm.
Important 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.
1.1.2 Operator and other persons' protection
The welding process is a noxious source of radiations,
noise, heat and gas emissions. The persons fitted with
vital electronic devices (pacemakers) should consult a
doctor before attending any arc welding or plasma arc
cutting operation.
Personal protection:
- Do not wear contact lenses!!!
- Keep a first aid kit ready for use.
Do not underestimate any burning or injury.
- Wear protective clothing to protect your skin from the
arc rays, sparks or incandescent metal, and a helmet or
a welding cap.
- Wear masks with side face guards and suitable protec-
tion filter (at least NR10 or above) for the eyes.
- Use headphones if dangerous noise levels are reached
during the welding.
- Always wear safety goggles with side guards, especially
during the manual or mechanical removal of welding
slags.
lf you feel an electric shock, interrupt the welding ope-
rations immediately.
Other persons' protection:
- Put up a fire-retardant partition to protect the sur- roun
ding area from rays, sparks and incandescent slags.
- Advise any person in the vicinity not to stare at the arc
or at the incandescent metal and to get an adequate
protection.
- lf the noise level exceeds the limits prescribed by the
law, delimit the work area and make sure that anyone
getting near it is protected with headphones or ear-
phones.
1.1.3 Fire/explosion prevention
The welding process may cause fires and/or explosions.
- Compressed gas cylinders are dangerous; consult the
supplier before handling them.
Protect them from:
- direct exposure to sun rays;
- flames;
- sudden changes in temperature;
- very low temperatures.
Compressed gas cylinders must be fixed to the walls or
to other supports, in order to prevent them from falling.
- Clear the work area and the surrounding area from any
inflammable or combustible materials or objects.
- Position a fire-fighting device or material near the work
area.
- Do not perform welding or cutting operations on clo-
sed containers or pipes.
- lf said containers or pipes have been opened, emptied
and carefully cleaned, the welding operation must in
any case be performed with great care.
- Do not weld in places where explosive powders, gases
or vapours are present.
- Do not perform welding operations on or near contai-
ners under pressure.
1.1.4 Protection against fumes and gases
Fumes, gases and powders produced during the welding
process can be noxious for your health.
Important: do not use oxygen for the ven-
tilation
- Provide for proper ventilation, either natural or forced,
in the work area.
- In case of welding in extremely small places the work
of the operator carrying out the welding should be
supervised by a colleague standing outside.
- Position gas cylinders outdoors or in places with good
ventilation.
- Do not perform welding operations near degreasing or
painting stations.
1.1.5 Positioning the power source
Keep to the following rules:
- Easy access to the equipment controls and connections
must be provided.
- Do not position the equipment in reduced spaces.
- Do not place the generator on surfaces with inclination
exceeding 10° with respect to the horizontal plane.

18
1.1.6 lnstalling the apparatus
- Comply with the local safety regulations for the instal-
lation and carry out the maintenance service of the
machine according to the constructor’s directions.
- Any maintenance operation must be performed by
qualified personnel only.
- The connection (series or parallel) of the SELCO gene-
rators is prohibited.
- Before operating inside the generator, disconnect the
power supply.
- Carry out the routine maintenance on the equipment.
- Make sure that the supply mains and the earthing are
sufficient and adequate.
- The earth cable must be connected as near as possible
to the area to be welded .
- Take the precautions relevant to the protection degree
of the power source.
- Before welding, check the condition of the electric
cables and of the torch, and if they are damaged repair
or change them.
- Neither get on the material to be welded, nor lean
against it.
The operator must not touch two torches
or two electrode holders at the same time.
1.2 ELECTROMAGNETIC COMPATIBILITY (EMC)
1.2.1 General information
This device is built in compliance with the indications
contained in the harmonized standard EN50199, which
the operator must refer to for the use of this apparatus.
Install and use the apparatus keeping to
the instructions given in this manual.
This device must be used for professional
application only, in industrial environ-
ments. It is important to remember that it
may be difficult to ensure the electromag-
netic compatibility in other environments.
1.2.2 Installation, use and area examination
- The user is responsible for the installation and use of the
equipment according to the manufacturer's instructions.
lf any electromagnetic disturbance is noticed, the user
must solve the problem, if necessary with the manu-
facturer's technical assistance.
- In any case electromagnetic disturbances must be
reduced until they are not a nuisance any longer.
- Before installing this apparatus, the user must evaluate
the potential electromagnetic problems that may arise
in the surrounding area, considering in particular the
health conditions of the persons in the vicinity, for
example of persons with pacemakers or hearing aids.
1.2.3 Emission reduction methods
MAINS POWER SUPPLY
The welding power source must be con-
nected to the supply mains according to
the manufacture’s instructions.
In case of interference, it may be necessary to take further
precautions like the filtering of the mains power supply.
lt is also necessary to consider the possibility to shield the
power supply cable.
WELDING POWER SOURCE MAINTENANCE
The welding power source needs routine maintenance
according to the manufacturer's instructions.
When the equipment is working, all the access and opera-
ting 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 cables must be kept as short as possible,
positioned near one another and laid at or approximately
at ground level.
EQUIPOTENTIAL CONNECTION
The earth connection of all the metal components in the
welding installation and near it must be taken in conside-
ration.
However, the metal components connected to the work-
piece will increase the risk of electric shock for the ope-
rator, if he touches said metal components and the elec-
trode at the same time.
Therefore, the operator must be insulated from all the
earthed metal components.
The equipotential connection must be made according
to the national regulations.
EARTHING THE WORKPIECE
When the workpiece is not earthed for electrical safety
reasons or due to its size and position, the earthing of the
workpiece may reduce the emissions. It is important to
remember that the earthing of the workpiece should nei-
ther increase the risk of accidents for the operators, nor
damage other electric equipment.
The earthing must be made according to the national
regulations.
SHIELDING
The selective shielding of other cables and equipment
present in the surrounding area may reduce the problems
due to interference. The shielding of the entire welding
installation can be taken in consideration for special
applications.

ratures are not within the normal values; in this case it is
necessary to leave the generator on to exploit the ventila-
tor in operation.
* L3 : Voltage output warning light (work) ( )red led.
Indicates the presence of output voltage.
* J1 : Serial connector.
To be used for the synergic remote control SW updating.
* J2 : Control device connector ( ).
To be used for the RC08-RC10 connection.
* J3 : Remote control connector ( ).
For the connection of all the remote controls for the
MMA and TIG welding.
It is operated through selection on the keyboard. If it is
operated with disconnected remote controls, the cur-
rent will remain at the minimum values available (6A).
Fig. 1
2.1.3 Front control panel FP110 (Fig. 2)
For the description of the particulars I1, L1, L2, L3, J3,
see 2.1.2 (Front control panel FP62).
* L2: Safety device warning light ( ) yellow led.
Its coming on signals a fault and the power flow is inter-
rupted.
The alarm identification number blinks on the display
(D1):
Alarm type:
14 - Overvoltage.
15 - Undervoltage.
11 - No coolant.
12 - Power module overtemperature.
22 - Wrong configuration of the card 15.14.149 or
unstable communication.
2.1.1 Generator trolleys
* The following generator trolleys with cylinder carrier
are available:
- GT 15 for the GENESIS 260 AC-DC;
- GT 17 (slightly different from the GT 15) for the
GENESIS 350 AC-DC.
2.1.2 Front control panel FP62 (Fig. 1)
* I1 : Start switch.
It is provided with two positions: "O" off; 'I' on.
* L1 : Voltage warning light ( ) green led.
Indicates that the plant is on and there is voltage.
* L2: Safety device warning light ( ) yellow led.
Indicates that the safety devices like thermal cutout,
mains overvoltage and undervoltage are in operation.
With “L2“ on, the generator remains connected to the
mains but does not provide power at the output. The con-
trol RC08, RC10 or the PC display information on the type
of protection in operation. “L2” remains on until the fault
has been removed and in any case until the inner tempe-
2.0 MACHINE DESCRIPTION
The GENESIS AC-DC are generators that can perform the
following types of welding with excellent results:
- MMA;
- TIG DC;
- TIG AC.
The generator is equipped with:
- TIG ( ) torch socket;
- an electrode holder socket ( ) and an earth cable
socket ( );
- front panel;
- rear control panel.
2.1 CONTROLS, ADDITIONAL ACCESSORIES
AND OPTIONALS
The accessories FP73, RC08, RC10, control
software, are provided with specific USE and
MAINTENANCE manuals.
19
Risks posed
by the machine
Mechanical risks caused by the
machine's mass and stability.
Risk of wrong installation.
Electrical risks.
Risks connected with electromagne-
tic disturbances produced by the
welding power source and induced
on the welding power source.
Solutions adopted
to prevent them
Positioning of the machine, by
means of screws, on a plane and
stable support (movable trolley)
with 4 wheels for its horizontal
shifting.The vertical shifting of the
whole plant cannot be carried out.
A manual with the instructions for
use has been produced for this
purpose.
Application of the EN 60974-1
Standard.
Application of the EN 50199
Standard.
1.3 RISK ANALYSIS

0 Exit from setup
1 Setting the initial "I" percentage on the welding "I"
(2÷200% predef. 50)
2 Pre-gas time (0-25s, predef. 0 secs)
3 Arc-Force percentage
(MMA, 0÷100% predef. 30%)
4 Hot-Start percentage
(MMA, 0÷100% predef. 80%)
5 Setting the wave form with AC.
The following table indicates the possible combi-
nations of the two half-waves.
6 Min. current value with remote control
(6÷max, predef. 6)
7 Max. current value with remote control
(6÷max, predef. max)
8 LIFT or HF start in DC, ignored in AC
(predef. 0)
9 Reset of all parameters
10 Remote control selection
0= RC12 1=RC16 (predef. 1)
11 2T or 4T bilevel selection
0= B. 2T 1=B. 4T (predef. 1)
The combination DC+ SQUARE WAVE and DC-
SQUARE WAVE is the recommended one.
BILEVEL 2T
When the torch button is pressed, the gas begins to flow
and the electrode is powered. The arc is sparked at the
initial current, performs the ascent ramp (if present) and
settles at current I1.
When the torch button is released and then immediately
pressed again, the current will switch from I1 to I2.
If the torch button is released for a relatively long time,
the current will drop to the final value following the set
descent ramp and the arc will then be cut off.
The gas will flow for the whole of the set post gas time.
BILEVEL 4T
When the torch button is pressed, the gas begins to flow,
the electrode is powered and the arc is sparked at the ini-
tial current. When the torch button is released, the cur-
rent increases to I1, performing the pre-set ascent ramp.
When the button is pressed again and then immediately
released, the current switches from I1 to I2.
If the torch button is pressed for a relatively long time, the
welding current will drop to the final value following the
set descent ramp.
Release of the button will cut the arc off.
The gas will flow for the whole of the set post gas time.
* 1: Push button for the selection of the desired pola-
rity in the torch or on the electrode holder.
It is possible to choose among:
- DC + Positive polarity;
- DC - Negative polarity;
- AC Alternating current.
The coming on of the led beside the symbol confirms
the selection.
* 2 : current adjusting system push button.
Selects the welding current adjusting system:
- from front panel "inside" ( );
- from remote control "outside" ( )
The coming on of the led beside the symbol confirms
the selection.
* 3: welding selection push button.
Selects the process and the relative welding mode.
The coming on of the led beside the symbol confirms
the selection.
Processes:
- electrode ( )
- TIG with HIGH FREQUENCY start - 2-STEP MODE
( )
- TIG with HIGH FREQUENCY start - 4-STEP MODE
( )
- TIG HF BILEVEL
* 4 : TIG welding current selection push button.
The coming on of the led beside the symbol confirms
the selection.
- CONSTANT current with or without SLOPES with
DC +, DC - and AC ( );
- PULSED current with or without SLOPES with DC +,
DC - and AC ( );
- MEDIUM-FREQUENCY current with or without
SLOPES with DC +, DC - ( ).
The MEDIUM FREQUENCY function is not enabled
with AC. To avoid any conflict between the AC fre-
quency and the AC pulsed overlapped frequency, the
minimum pulse time is 0.2 seconds both for the peak
and for the base current.
* 5 : AC BALANCE potentiometer
It adjusts the positive current percentage in the alterna-
ting current period.
With the potentiometer positioned on the centre notch,
the positive current is equal to 35% and the negative cur-
rent is equal to 65%.
With index on ( ) the positive current is equal to
54% (maximum cleanliness).
With index on ( ) the positive current is equal to
14% (maximum penetration).
* D1 : Display
Displays figures, data.
* 6 : SETUP/parameter push button.
Ensures access to the SETUP and to the welding parame-
ter values. If pressed within 3 seconds from the going out
of the leds (see "Operation"), ensures access to the follo-
wing parameters:
20
N°
0
1
2
3
4
5
6
7
8
Half wave DC +
SINE
TRIANGLE
SQUARE
SINE
TRIANGLE
SQUARE
SQUARE
TRIANGLE
SINE
Half wave DC-
SINE
TRIANGLE
SQUARE
SQUARE
SQUARE
SINE
TRIANGLE
SINE
TRIANGLE

* E1 : Potentiometer
Used in combination with the SETUP/parameter push
button (6), it selects the welding parameters and makes
it possible to modify the values given in the diagram (7):
Tu Increase time
I1 Welding current
I2 According to the current value
(Bilevel welding mode)
lb Base current
(Pulsed and medium-frequency welding)
Tp Peak time
(Pulsed and medium-frequency welding)
Tb Base time
(Pulsed and medium-frequency welding)
Td Decrease time
lf Final current
When operating with MEDIUM FREQUENCY
with or without SLOPES " " and the Tp and
Tb are selected by pressing the SETUP/parameter push
button (6) (see Operation), these two times are equal,
the two relevant leds are on at the same time and the
pulsed frequency value is shown on the display (D1).
By keeping the SETUP/parameter push button (6) pressed
for 2 seconds, it is possible to adjust the following values
by means of the potentiometer (E1), from any position of
the led on the diagram (7):
- AC frequency ( L4 " " warning light on);
- electrode diameter setting with AC ( L5 " " war-
ning light on);
if this value is supplied to the generator, the GENESIS
260/350 AC-DC can optimize the start parameters of
AC welding (also by means of the FUZZY LOGIC).
- post-gas time ( L6 " " warning light on).
The coming on of the led beside the symbol confirms
the selection.
Fig. 2
Operation:
The machine stores the last welding step and
presents it again when restarted.
* Position the start switch (I1) on " I"; the coming on of
the voltage warning light (L1) ( ) (green led) confirms
that the plant is under voltage.
* The display (D1) shows the control panel management
software version (for example 1.3) for three seconds.
* After three seconds, all the leds on the panel come on
(for a control) and the display shows the numbers 0, 1,
2, 3 with an interval of 650 milliseconds.
* When "3", has appeared, the panel leds go out and
from this moment, for three seconds, it is possible to:
- enter the SETUP mode by pressing the SETUP/para-
meter push button (6);
- or go on starting the machine
* If selected, the SETUP mode is confirmed by a central
"0" on the display (D1).
- Rotate the potentiometer (E1), the display (D1) shows
the numbers corresponding to the parameters (0÷11)
in sequence, see SETUP/parameter push button; stop
at the desired parameter and push the SETUP/para-
meter push button (6). With parameter (9) all the
modifications made in the SETUP mode are cancelled
and the standard values set by SELCO are restored.
- The number on the display (D1) is replaced by the
value of the parameter that can be modified through
the potentiometer (E1).
* If it is necessary to modify the values of the welding
parameters of the diagram (7), proceed as follows:
- Wait three seconds after the leds on the panel have
gone out, the led "I"(welding current) will remain on in
the diagram.
- Press the SETUP/parameter push button (6); every
time the push button is pressed, one of the leds in the
diagram (7) comes on (in clockwise sequence) and the
value of the relevant parameter appears on the display
(D1) stop at the desired parameter.
21

22
Access to the three following parameters is ensured by
pressing the SETUP/parameter push button (6) for 2
seconds: AC frequency (L4) “ ”; electrode dia-
meter with AC (L5) “ ”; post-gas time (L6) “ ”;
which must be selected in sequence by pressing the
SETUP/parameter push button (6) again.
- Rotate the potentiometer (E1) and modify the parame-
ter value.
- Press the SETUP/parameter push button (6) again to
pass to another parameter, or wait five seconds (the led
" I" in the diagram (7) comes on again automatically).
The machine is always ready to weld and its
state is defined by all the leds that are on the
panel.
2.1.4 Front control panel FP73 (Fig. 3)
The GENESIS 260 AC-DC and 350 AC-DC generators can
be provided with a "robot interface" that makes it possible
to connect them to welding robots.
The installation of the "robot interface" requires the repla-
cement of the front panel FP62 with the panel FP73.
The front panel FP73 is provided with a 19-pin special
connector (J4) that presents the interfacing signals, kee-
ping the functionality unchanged.
It is not possible, instead, to use the common MMA and
TIG remote controls.
The control RC08 or RC10 is necessary to guarantee the
operation of the generator.
For the description of the particulars I1, L1, L2, L3, J1,
J2, see 2.1.2 (Front control panel FP62).
J4 : 19-pin special connector for "robot interface".
For the connection to welding robots.
Fig. 3
2.1.5 Rear control panel (Fig. 4).
The generator GENESIS 260 AC-DC is provi-
ded with a rear control panel having the
same functions, but a different arrangement.
* J5 : Cooling unit WU14 connector.
For the connection of the control cable bundle for the
cooling unit WU14.
* D1 : Cooling unit WU14 power supply socket.
Socket for the power supply of the WU14, see 8.0
WIRING DIAGRAMS (WU14 power supply wiring
diagram (WU14 inside the generator).
This socket delivers power only when the generator is
set for the TIG welding and is automatically disconnec-
ted when no welding is carried out for more than four
minutes.
The socket used is in compliance with the EN 60309-1
Standard.
For technical information, see 2.2.3 (Technical charac-
teristics).
Parameter
Pre-gas time
Initial current
Increase time tu
Welding current I
Back current Ib
Frequency AC
Balance
Pulse time tp
Frequency tp & tb
Back time tb
Decrease time td
Final current If
Post-Gas time
Hot-Start
Arc-Force
Electrode diameter
predef.
0.0
50
0.0
100
20
50
34
0.24
100
0.24
0.0
8
1.0
80
30
2.4
mu
s
%
s
A
A
Hz
%
s
Hz
s
s
A
s
%
%
mm
min
0.0
2
0.0
6 DC
8 AC
6 DC
8 AC
20
14
0.02 DC
0.2 AC
20
0.02 DC
0.2 AC
0.0
6
0.0
0
0
1
max
25.0
200
10.0
max
max
100
54
2.00
500
2.00
10.0
max
25.0
100
100
5
Note
It can be set from setup only
Percentage on the welding current, setup only
Pulsed only
Combined with the panel potentiometer
Slow pulsed only
In fastpulse only, repr. by leds Tpulds and Tback
Slow pulsed only
MMA, it can be set from setup only
MMA, it can be set from setup only
Only for TIG AC (AC optimization)

23
The socket is always under voltage, until the
generator main switch is disconnected or the
plug is disconnected from the power supply.
Incorrect use of the socket or non-compliance with the
indications given above may be dangerous for the ope-
rator and seriously damage the generator.
* F1: fuse carrier.
F1 = 500 V 4 A delayed fuse (size 6,3 x 30).
* 1: Gas coupling ( ), see 4.5 (CONNECTING THE
EQUIPMENT COMPONENTS (EARTH CLAMP, ELEC-
TRODE HOLDER, TORCH, GAS PIPE, HYDRAULIC
PIPES)).
Fig. 4
2.1.6 Remote control RC08 (Fig. 5)
This remote control makes it possible
to set the welding parameters and
modes in the MMA and TIG processes.
It is equipped with 6 m fiber-optic
connection cable. The parameters and
measures are displayed on a graphic
display.
A MEMORY CARD reader and a wide
memory ensure personalized pro-
gramming.
2.1.7 Remote control RC10 (Fig. 6)
This remote control ma-
kes it possible to set the
welding parameters and
modes in the MMA and
TIG processes.
It is equipped with a 6 m
fiber-optic cable.
The RC10 is characterized by:
- a user-friendly keyboard;
- a large graphic display;
- a sophisticated and complete user interface software.
Personalized welding programmes can be stored on the
MEMORY CARD and on the internal memory.
2.1.8 Control software (Fig. 7)
The control software ma-
kes it possible to control
the generator with a
Personal Computer.
The connection kit com-
prises a 10 m fiber-optic
connection cable and an
interface for the connec-
tion to the serial port
RS232 of any IBM-com-
patible PC available on the market. The software includes
all the functions of the remote controls RC08 and RC10.
The possibility to measure, store and print the actual wel-
ding data makes it a very important instrument for the
processing quality control.
2.1.9 Potentiometer remote control RC16 for MMA and TIG
welding (Fig. 8)
It can be installed on generators
provided with front panel
FP110 or FP62.
This device makes it possible to
remotely vary the necessary
quantity of current, with no need
to interrupt the welding process
or to leave the work position.
5, 10 and 20 m connection cables are available.
2.1.10 Pedal remote control RC12 for MMA and TIG wel-
ding (Fig. 9)
It can be installed on generators
provided with front panel FP110
or FP62.
Once the generator has been swit-
ched to the "EXTERNAL CON-
TROL" mode, the output current
is varied from a minimum to a
maximum value (which can be set
through SETUP with FP110 and
through remote control with FP62) by varying the inclination
of the foot resting surface with respect to the pedal base.
Fig. 7
Fig. 6
Fig. 5
Fig. 8
Fig. 9

24
2.2 TECHNICAL DATA
2.2.1 Identification
The data plate stamped on the metal structure, see 7.0
(DATA PLATES), complies with the IEC 974-1 and EN
60974-1 international standards and contains the following
information:
* Manufacturer's name and address
* SELCO trademark
* (Type ) Model
* (N°) Serial number
*( ) The welding power source comprises a
frequency converter followed by an insulation transfor-
mer and rectifier that transforms the three-phase input
voltage into direct current (a second stage provides for
supplying the square wave for the TIG AC process).
* (IEC 974-1) Safety standard applied.
* ( ) Drooping static characteristic.
* ( ---- ) Direct current.
*(Box on the right of ( ---- )) Output current and voltage
ranges available.
*(x) Duty factor, that is, 10 minute time percentage during
which the welding can be carried out at a given current
without any overheating.
* (I2) Rated weld current.
* (U2) Conventional load voltage.
* (Uo) Rated no-load voltage.
* ( ) TIG welding.
* ( ) MMA welding.
* ( ) 3 input phases.
* (I.CL.H ) Insulation class H.
* (COOLING A.F. ) Forced ventilation cooling.
* (IP 23) Casing protection degree in compliance with the
EN 60529 Standard:
IP2X Casing protected against access to dangerous com-
ponents with fingers and against the introduction
of foreign matters with diameter 12.5 mm.
IPX3 Casing protected against rain failing at 60°on the
vertical line.
* (U1) Rated power supply voltage.
* (50/60 Hz) Power supply rated frequency.
* (I1) Rated power supply current.
*( ) Generator suitable for installation in places where
major risks of electric shocks are present.
* ( ) In compliance with the European regulations in force.
2.2.2 Dimensions and mass (Fig. 10)
2.2.3 Technical characteristics
Technical characteristics of the generators.
Model
Genesis 260
AC-DC
Genesis 350
AC-DC
Trolley
(GT 15) 36.5
(GT 17) 38
Generator
37
46
WU14
19.5
19.5
Tot.
93
103.5
Fig. 10
Trolley
type Mass
Kg
ABC
Dimensions in mm
GT 15
GT 17 900 980 960 960 445 445 36.5 38
TECHNICAL
CHARACTERISTICS
Power supply voltage
(50/60Hz)
Max. absorbed power
Max. absorbed
current
Delayed fuses 500V
Efficiency
Power factor
Welding current
(x=40%)
(x= 60%)
(x=100%)
Adjustment range
TIG DC
TIG AC
MMA DC
MMA AC
No-load voltage
Protection degree
Insulation class
Construction
standards
GENESIS 260 AC-DC
3x400V
+10% -15%
9.9kW
14.7A
20A
0.80
0.72
260A
200A
165A
6A/10V-260A/20.4V
10A/10V-260A/20.4V
6A/20V-260A/30.4V
10A/20V-260A/30.4V
80V
IP23
H
EN60974-1/EN50199
GENESIS 350 AC-DC
3x400V
+10% -15%
14.9kW
22A
30A
0.80
0.75
-
350A
270A
6A/10V-350A/24V
10A/10V-350A/24V
6A/20V-350A/34V
10A/20V-350A/34V
80V
IP23
H
EN60974-1/EN50199

25
WU14 socket electrical characteristics
Power supply voltage 230 V a.c.
Frequency 50/60Hz
Current 1A
Power 230VA
WU14 technical characteristics
Power supply voltage 230 V a.c.
Frequency 50/60Hz
Max. instantaneous power absorbed 300VA
Protection degree IP23
Tank capacity 4.2l
For the wiring diagrams, see 8.0 (WIRING DIAGRAMS).
3.0 TRANSPORT - UNLOADING
IMPORTANT! Never underestimate the weight
of the equipment, see 2.2 (TECHNICAL DATA).
For correct lifting of the unit provided with eye-
bolts, see figure 11.
During transport and storage operations,
NEVER place the equipment or the single unit
over materials and vice versa.
Never make the cargo pass or leave it suspen-
ded over people or things.
Neither let the equipment or the single unit fall,
nor put it down with force.
4.0 INSTALLATION
4.1 GENERAL RULES
Choose an adequate installation area by following the cri-
teria provided in Section "1.0 WARNINGS - PRECAU-
TIONS - GENERAL ADVICE".
Do not position the generator and the equipment on sur-
faces with inclination exceeding 15° with respect to the
horizontal plane.
Protect the installation from heavy rain and sun.
The machine protection degree (IP23) is effective against
water that falls down in a direction forming an angle up
to 60° with the vertical line.
4.2 ASSEMBLING THE EQUIPMENT
4.2.1 Assembling the movable trolley
For the assembly of the generator trolley GT15,
see 9.0 (SPARE PARTS) Table 04.
For the assembly of the generator trolleys GT17, follow the
same procedures indicated for the GT15.
4.2.2 Installing the WU14 and the generator (Fig. 12)
* Lift the WU14 without resting the feet (1) and make it
slide on the front part of the movable trolley.
* Center the WU14 between the supports (3).
* Insert the four fastening elements (2) in corresponden-
ce with the holes on the supports (3) and fix them.
* Lift the generator (4) and introduce it between the sup-
ports (3) in the upper part.
* Place the generator on the two crosspieces of the sup-
ports.
* Insert the four fastening elements (5) in corresponden-
ce with the holes on the supports (3) and fix them.
4.3 CONNECTING THE UNIT
4.3.1 Electric/electronic connection between the generator
and the WU14 (Fig. 13)
Make the con-
nection with the
generator plug
disconnected from the
mains socket.
* Insert the plug S1 (1) in
the socket D1(2) of the
generator.
* Insert the connector J4
(3) in the generator
connector J5 (4).
Tighten the locking
ring of the connec-
tor J4 completely.
Fig. 11
Fig. 12
Fig. 13

4.3.2 Filling the coolant tank (Fig. 14)
Fill the coolant
tank with the
generator plug discon-
nected from the mains
socket.
*Press the slide shutter (1)
downwards, pull and
extract the coolant tank.
* Unscrew the plug T1
(2) and remove it.
* Prepare the coolant
solution as follows:
1/3 antifreeze + 2/3 water and pour it into the neck.
* Tighten the plug T1 (2) completely.
* Push the front panel together with the tank trolley until
the shutter snaps.
Periodically check the coolant level in the tank.
If the tank is completely empty andlor there is
air in the pump, this may fail to start.
In this case, proceed as follows:
* Open the screw valve (3) connected with the vent
pipe, by unscrewing it moderately.
* Wait for the pump start and the normal recirculation
of the coolant, then tighten the screw valve (3).
To empty the coolant tank:
* Extract the tank.
* Position a container with at least 5l capacity on the right
of the tank.
* Release the flexible pipe (4) from its seat (groove) and
position the cock (5) in the container at a lower level
with respect to the tank base.
* Open the cock and drain the coolant.
After the draining operation, close the cock (5)
and put back the flexible pipe (4) in its seat.
4.3.3 Hydraulic connection to the WU14
Failure to carry out
the operations in-
dicated below may
cause irreparable
damage to the tor-
ches.
Check the tighte-
ning of the con-
nections.
For MMA welding or TIG welding in which the torch is
NOT liquid-cooled, it is advisable to close the cooling
circuit and make the connections illustrated in Fig.15
and 16:
For TIG welding opera-
tions in which the torch
is liquid-cooled, carry
out the following con-
nections:
Ref. Fig. 16
* Make the connection
illustrated in Fig. 16.
Ref. Fig. 17
* Connect the coolant
delivery pipe (1) of
the TIG torch to the
coupling A1 (2) ( )
on the front panel.
* Connect the return
pipe (3) of the TIG
torch to the coupling
A2 (4) ( ) on the
front panel.
4.4 ELECTRIC CONNECTION TO THE SUPPLY MAINS
The equipment is provided with a single electric connec-
tion with a 5 m cable positioned in the rear part of the
generator and supplied without plug.
Size table of the generator input cables and fuses:
Generator GENESIS 260 AC-DC GENESIS 350 AC-DC
Rated voltage 400 V3~
Voltage range 340V ÷440V (400V +10% -15%)
Delayed fuses 20A 30A
Power supply cable 4x4mm2 4x6mm2
The electrical system must be made by skilled
technicians with the specific professional and
technical qualifications and in compliance with
the regulations in force in the country where
the equipment is installed.
The welding power source supply cable is pro-
vided with a yellow/green wire that must
ALWAYS be earthed.
This yellow/green wire must NEVER be used
with other voltage conductors.
26
Fig. 14
Fig. 15
Fig. 16
Fig. 17

27
* Verity the existence of the earthing in the used plant
and the good condition of the socket/s.
* Install only plugs that are homologated according to
the safety regulations.
4.5 CONNECTING THE EQUIPMENT COMPONENTS
(EARTH CLAMP, ELECTRODE HOLDER, TORCH, GAS
PIPE, HYDRAULIC PIPES)
Keep to the safety regulations contained in sec-
tion 1.0 WARNINGS - PRECAUTIONS - GENE-
RAL ADVICE.
Disconnect the generator plug from the mains
socket before making the connections.
Connect the components carefully, in order to
avoid power losses.
4.5.1 Connection for MMA welding (Fig. 18)
Carefully read 4.5 (CON-
NECTING THE EQUIP-
MENT COMPONENTS
(EARTH CLAMP, ELEC-
TRODE HOLDER, TOR-
CH, GAS PIPE, HYDRAU-
LIC PIPES)).
* Connect the earth
clamp (2) negative
cable (-) connector (1) to the earth socket ( ) (6) of
the generator.
* Connect the electrode holder (5) positive cable (+) con-
nector (4) to the electrode holder socket ( ) (3) of the
generator.
The connection described above ensures wel-
ding with straight polarity. To weld with reverse
polarity, reverse the connection.
4.5.2 Connection for TIG welding (Fig. 19)
Carefully read 4.5 (CON-
NECTING THE EQUIP-
MENT COMPONENTS
(EARTH CLAMP, ELEC-
TRODE HOLDER, TOR-
CH, GAS PIPE, HY-
DRAULIC PIPES)).
* Connect the earth
clamp negative connec-
tor (-) (1 - Fig. 19) to the earth socket ( ) (2 - Fig. 19) of
the generator.
* Connect the TIG torch coupling (3 - Fig. 19) to the torch
socket ( ) (4 - Fig. 19) of the generator.
* Connect the gas pipe coupling (1 - Fig.20) to the gas
coupling ( ) (2 - Fig.20) on the generator rear panel.
If the TIG torch is cooled with liquid:
* Connect the hydraulic
pipes of the torch to
the cooling unit, see
4.3.3 (Hydraulic con-
nection to the WU14).
* Connect the gas pipe
coupling (1 - Fig.20) to
the gas coupling ( )
(2 - Fig. 20) on the ge-
nerator rear panel.
5.0 PROBLEMS - CAUSES
5.1 POSSIBLE FAULTS IN THE MMA AND TIG WELDING
Fault Cause
Oxidations 1) Insufficient gas.
2) No protection on the reverse.
Tungsten inclusions 1) Incorrect electrode sharpening.
2) Electrode too small.
3) Operating failure (contact of the
tip with the workpiece).
Porosity 1) Dirt on the edges.
2) Dirt on the filler material.
3) High advancement speed.
4) Current intensity too low.
Hot cracks 1) Unsuitable filler material.
2) High heat supply.
3) Dirty materials.
5.2 POSSIBLE ELECTRICAL FAILURES
Fig. 19
Fig. 18
Failure
Machine does not start.
Generator does not give correct
welding parameters.
Cancellation of the output power
indicated by the coming on of the
safety device warning light L2 ( )
(yellow led) on the front panels
FP110, FP62, FP73 and by an
error message on FP110, RC8,
RC10 or on the PC display, if con-
nected.
Cause
1) Check the fuse F1.
2) Make sure that there is voltage in
the supply mains.
1 ) Check the state of the machine
and the welding parameters on
the control device.
2) Faulty torch push button.
3) Incorrect earth connection.
1) WU14 inconveniences.
2) Generator overheating.
3) Input voltage beyond limits.
4) Excessive output current required.
5) Software communication pro-
blems among the equipment
components.
Fig. 20

6.0 ROUTINE MAINTENANCE
Prevent metal powder from accumulating near the aera-
tion fins and over them.
Disconnect the power supply before every ope-
ration!
Carry out the following periodic controls on the genera-
tor:
* Clean the generator inside by means of low-pressure
compressed air and soft bristel brushes.
* Check the electric connections and all the connection
cables.
For the WU14 maintenance, periodically check:
* the coolant quantity in the tank;
* the electropump conditions;
* the pipe connections;
* the electric connections.
NEVER use the WU14 without coolant.
Periodically check the fastening of the equipment com-
ponents to the generator trolley and in particular the fa-
stening of the cylinders.
For the use and maintenance of the pressure reducers,
consult the specific manuals.
For the maintenance or replacement of torch
components, electrode holder and/or earth
cables:
*Disconnect the power supply before every operation.
*Check the temperature of the components and make
sure that they are not overheated.
*Always use gloves in compliance with the safety stan-
dards.
*Use suitable spanners and tools.
TIG torches
Tighten the components with care, in order to avoid:
- heating;
- false contacts;
- gas leaks;
- mechanical damage.
Make sure that there is no dirt or metallic powder in the
cooling pipes, in the contact joints and near the electrode.
Wrong connections, as well as throttling of the
cooling pipes or malfuntions of the cooling unit
may result in overheating and irreparable da-
mage to the torch.
7.0 NOMINAL DATA
Fig. 21
Fig. 22
Type
Available
lengths
Current 100%
d.c.
a.c.
Electrode
diameter
Type of
cooling
Type of
connector
SR26
4m
8m
240A
200A
0.5-4.0mm
Air
Centralized
SR18
4m
8m
320A
240A
0.5-4.0mm
Liquid
Centralized
28

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8.0 SCHEMI ELETTRICI
8.0 ELECTRICAL DIAGRAMS
8.0 SCHALTPLAN
8.0 SCHEMA ELECTRIQUE
8.0 DIAGRAMA ELÉCTRICO
Genesis
260AC-DC
Genesis
350AC-DC

SCHEMA ELETTRICO ALIMENTAZIONE WU14 (interno generatore) - WU14 POWER SUPPLY WIRING DIAGRAM (inside the generator) -
SCHALTPLAN FÜR WU14 SPEISUNG (im Generator) - SCHÉMA ÉLECTRIQUE ALIMENTATION WU14 (intérieur générateur) - FIG. 23
DIAGRAMA ELÉCTRICO DE ALIMENTACIÓN WU14 (interior del generador)
72
SCHEMA ELETTRICO WU14 - WU14 ELECTRICAL DIAGRAM - SCHALTPLAN WU14 -
SCHEMA ELECTRIQUE WU14 - DIAGRAMA ELÉCTRICO WU14 FIG. 24
A= 15.14.219 260/350 AC-DC
B= 15.14.219 260/350 AC-DC
- Presa conforme alle norme EN 60309-1
- Socket in compliance with the
EN 60309-1 Standards.
- Steckdose in Konformität mit den Normen
EN60309-1
- Prise conforme aux normes EN60309-1
- Tomacorriente conforme a las normas
EN60309-1

73
SCHEMA ELETTRICO GENESIS 260 AC-DC - ELECTRICAL DIAGRAM - SCHALTPLAN -
SCHEMA ELECTRIQUE - DIAGRAMA ELÉCTRICO FIG. 25

74
SCHEMA ELETTRICO GENESIS 350 AC-DC - ELECTRICAL DIAGRAM - SCHALTPLAN -
SCHEMA ELECTRIQUE - DIAGRAMA ELÉCTRICO FIG. 26

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TAVOLE RICAMBI
SPARE PARTS TABLES
ERSATZTEILTAFELN
VUES DES PIECES DETACHEES
TABLAS DES REPUESTOS
Genesis
260AC-DC
Genesis
350AC-DC

76
RICAMBI - SPARE PARTS - ERSATZTEILZ -
PIECES DETACHEES - REPUESTOS GENESIS 260 AC-DC TAV.01