Sel Genesis 240 TLH Operating instructions

REPAIRS MANUAL
E
N
G
L
I
S
H
Genesis
240
Genesis
240 TLH

Cod. 92.08.011
Edition: 11/99
SELCO s.r.l.
Via Palladio, 19
35010 ONARA DI TOMBOLO (Padova) Italy
Tel. [phone]
Fax [phone]
INDEX :
1) GUARANTEE CONDITIONS . . . . . . . . . . . . . . . . . . .84
2) PURPOSE OF THE MANUAL . . . . . . . . . . . . . . . . . .85
3) MACHINE TECHNICAL SPECIFICATIONS . . . . . . . .85
4) DESCRIPTION OF MACHINE PARTS . . . . . . . . . . . .86
5) DESCRIPTION OF MACHINE OPERATION . . . . . . .88
LAY-OUTS OF CARDS . . . . . . . . . . . . . . . . . . . . . . .104
6) DESCRIPTION OF DIAGNOSTIC INDICATIONS : . .116
- EXTERNAL
- INTERNAL
7) AVAILABLE SPARE PARTS
. . . . . . . . . . . . . . . . . . . .119
8) WARNINGS, PRECAUTIONS, GENERAL
INFORMATION ON EXECUTING REPAIRS . . . . . . .121
9) DIAGNOSTIC 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
REQUEST PROCEDURE . . . . . . . . . . . . . . . . . . . . .164
1) GUARANTEE CONDITIONS.
To specify the present warranty conditions , we remind that
SELCO does not repair under warranty the damages
a) resulting from attempts by personnel not allowed by SELCO
to install, repair or service the products
b) resulting from improper use or connection to incompatible
equipment
c) in products that have been modified or integrated with other
products when such modification or integration can be the
cause of the failure.
84 Guarantee conditions

Power supply voltage
(50/60Hz)
Max. absorbed power (x=40%)
Max. absorbed current (x=40%)
Absorbed current (x=100%)
Efficiency (x=40%)
Power factor (x=40%)
Cosj(x=40%)
Welding current (x=40%)
(x=60%)
(x=100%)
Adjustment range
Open-cicuit voltage (limited)
Protection rating
Insulation class
Construction standards
Dimensions (lxpxh)
Weight
3x400V
+10% -10%
8.4 KW
12.9 A
7.9 A
0.84
0.94
0.99
240 A
185 A
160 A
6-240 A
59 V
IP23
H
EN60974-1/EN50199
179x430x290 mm
15.4 Kg
2) PURPOSE OF THE MANUAL
The purpose of this manual is to provide authorised technical ser-
vicing centres the information required for repairing Genesis 240
and Genesis 240 TLH (see NOTE *).
To avoid serious damage to people and things, this manual must
be used strictly by qualified technicians.
What is involved in a repair job?: identifying the faulty part - as
this part is included in the list of available spare parts - and
replacing it according to the procedures described below.
If an electronic card is faulty, repair entails replacing the card
and not replacing the faulty electronic component on the card
itself.
If trouble cannot be solved by observing the procedures in the
manual, the machine must be sent back to SELCO.
We suggest two diagnosis procedures on two levels: at the first
level, simple initial action instruments/tools are used, at the
second level, 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 second procedure.
The order of the subjects in this manual is based on a logic that
gradually provides the repair technician with knowledge of the
machine. We therefore advise you to follow the suggested
order, by starting at the beginning.
* NOTE : the information contained in this manual does not
apply to the first versions of the machine as specified
in point 10.2.
Purpose of the manual - Machine technical specifications 85
WU15
3) MACHINE TECHNICAL SPECIFICATIONS .
GENESIS 240
GENESIS 240 TLH
Power supply voltage
(50/60Hz)
Max. absorbed power in TIG
(x=40%)
Max. absorbed current in TIG
(x=40%)
Absorbed current in TIG
(x=100%)
Max. absorbed power in MMA
(x=40%)
Max. absorbed current in MMA
(x=40%)
Absorbed current in MMA
(x=100%)
Efficiency (x=40%)
Power factor
Cosj
Welding current (x=40%)
(x=60%)
(x=100%)
Adjustment range
Open-cicuit voltage (limited)
Protection rating
Insulation class
Construction standards
Dimensions (lxpxh)
Weight
3x400V
+10% -10%
6.1 KW
9.3 A
5.4 A
8.5 KW
12.9 A
7.9 A
0.84
0.94
0.99
240 A
185 A
160 A
6-240 A
81 V
IP23
H
EN60974-1/EN50199
179x430x293 mm
17.4 Kg
Power supply voltage
(50/60Hz)
Nominal input current
Capacity of reservoir
Cooling power
Protection rating
Dimensions (lxpxh)
Weight with liquid
1x230V
+ 10% -10%
0.8 A
1.7 l
900 W
IP23
179x430x160 mm
9.5 Kg
Above data are referred to environment al 40°C.

86 Description of machine parts
4) DESCRIPTION OF MACHINE PARTS.
G 240 consists of the following circuit parts:
(see fig. 1)
a) Master switch
b) input filter for suppressing radio noise and protecting against
mains over-voltage.
c) rectifier bridge
d) power inverter with overtemperature detection device
e) resonant circuit (inductive-capacitive circuit)
f) power transformer
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) auxiliary transformer
m) power circuits feeding control/adjustment circuits
n) current control circuits
o) control circuits (front panel)
Some of these parts are independent, while others are housed
inside the following electronic cards:
G 240 :
A) Card 15.14.254
B) Card 15.14.239
C) Card 15.14.233
D) Card 15.14.240
E) Card 15.14.238
k)
a)
o) l)
i)
j)
d) e) f) g) h) e)
c)
n)
m)
b)
FIG. 1

Description of machine parts 87
In the TLH version, the following elements are also present in
addition to the above circuits:
(see fig. 2)
p) H.F. transformer
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) Card 15.14.254
G) Card 15.14.236
H) Card 15.14.233
I) Card 15.14.240
J) Card 15.14.238
K) Card 15.14.192
n)
m)
k)
a)
o)
q)
r)
l)
c)
b)
i) p)
j)
d)s) e) f) g) h)e)
FIG. 2

88 Description of machine operation
5) DESCRIPTION OF MACHINE OPERATION.
The power undergoes initial AC/DC conversion by the input
rectifier bridge (c) , subsequent AC/DC conversion at high fre-
quency by the inverter (d) , transfer via the insulation transfor-
mer (f) to the output circuits and final AC/DC conversion by the
output rectifier (g) .
More details:
5.1) Master switch (a) - input filter for suppressing radio noise
and protecting against power line over-voltage (b) .
(see fig. 3-4)
The three power supply cables are cut off by means of the
switch a). The yellow-green cable is fixed to the terminal mar-
ked by the earth symbol and located on the intermediate metal
support.
IMPORTANT !: When accessing parts inside the
machine, remember that turning off the switch will
not prevent the danger of electric shocks. We the-
refore advise you to remove the power plug.
When the switch is closed, the 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) connected to earth
via a screw and metal column.
n)
m)
k)
a)
o)
q)
r)
l)
c)
b)
i) p)
j)
d)s) e) f) g) h)e)
NOTE : If the electrical component know as a varistor is placed
between the two power supply phases, when an instantaneous
voltage in excess of 460 V appears on its terminals, the varistor
very rapidly becomes conductive, absorbing a current peak
which is sufficient to limit the said over-voltage and it thus pro-
tects the other parts of the machine.
This process has no destructive effect on the component if the
energy generated by the voltage peak is low, as in the case of
atmospheric lightning strikes. If, however, over-voltage is high
and prolonged, the varistor cannot dissipate this high energy
and blows.
This happens if, for example, the machine is wrongly connected
to 460 Vac mains voltage, or following over-voltage caused by
non stabilised power units of inadequate capacity.
FIG. 3

Description of machine operation 89
NOTE : The radio noise suppression circuit has two purposes:
to keep the machine's radio frequency 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 filter consists of a network of capacitors, some of which are
grounded, and a toroidal inductor.
k)
a)
o) l)
i)
j)
d) e) f) g) h) e)
c)
n)
m)
b)
FIG. 4

90 Description of machine operation
5.2) rectifier bridge (c) - power inverter with overtemperature
detection device (d) - resonant circuit (inductive-capacitive
circuit) (e) - power transformer (f)
(see fig. 5-6)
The three-phase power supply voltage is applied to the rectifier
bridge (c), the output of which is connected to the power inverter
(d) via cables no.22(+) and no.23(-).
The inverter has a bridge type structure with four power IGBTs
(one on each branch) welded directly to board 15.14.254 and
fixed to the aluminium radiator by means of screws.
The resonant circuit (inductive-capacitive circuit) at the inverter
output terminals and the presence of an auxiliary circuit on
board 15.14.254 permit operation at high (variable) frequency.
The auxiliary circuit consists of two IGBTs and two power
diodes fixed on the aluminium 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 board
15.14.254.
The radiator is cooled by the air flow generated by the fan (k)
powered at 230Vac. This voltage is insulated from the mains by
means of the auxiliary transformer (l) and protected by a fuse on
board 15.14.233. The air flows from the rear grille (air inlet) of the
machine towards the front grille (air outlet). The inverter is
protected against overloads or blocking of the ventilation air flow
by a radiator temperature 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 power transformer (f), positioned in series with the inducti-
ve-capacitive load, transfers the power to the output circuits
which are therefore electrically insulated from the power supply
network.
k)
a)
o) l)
i)
j)
d) e) f) g) h) e)
c)
n)
m)
b)
FIG. 5

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

92 Description of machine operation
5.3) rectifier circuit with overtemperature detection device and
snubber circuit (g) - output filter (h) - levelling inductance with
overtemperature detection device (i).
(see fig. 7-8)
The power transformer output is connected to the two current
rectifier diodes fixed on the aluminium radiator by means of
screws.
Like the inverter, the radiator is cooled by the air flow genera-
ted by the fan. The rectifier circuit is protected against overloads
or blocking of the ventilation 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 to board 15.14.240 by means of cop-
per bus-bars containing the snubber circuit (g) , the function of
which is to suppress the overvoltages produced at the ends of
the diodes during normal operation.
The output board 15.14.238 contains the output filter (h) .
The levelling inductance (i) at the output guarantees a constant
welding current. The inductance is also thermally protected by
means of a winding temperature detection device which opera-
tes as described above.
k)
a)
o) l)
i)
j)
d) e) f) g) h) e)
c)
n)
m)
b)
FIG. 7