Sel Genesis 60 User manual

USE AND MAINTENANCE MANUAL
E
N
G
L
I
S
H
Genesis 60
POWER SOURCES FOR PLASMA CUTTING

14
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. reser-
ves 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 4/99
CONTENTS
GENESIS 60
1.0 WARNINGS-PRECAUTIONS-GENERAL ADVICE 15
1.1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.1.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . .15
1.1.2 Operator and other persons protection .15
1.1.3 Fire/explosion prevention . . . . . . . . . . . .15
1.1.4 Protection against fumes and gases . . . . .15
1.1.5 Positioning the power source . . . . . . . . .15
1.1.6 Installing the apparatus . . . . . . . . . . . . .15
1.1.7 Precautions against risks connected
with the use of compressed air . . . . . . . . . . .16
1.2 ELECTROMAGNETIC
COMPATIBILITY (EMC) . . . . . . . . . . . . . . . . .16
1.2.1 General information . . . . . . . . . . . . . . .16
1.2.2 Installation, use and area examination . .16
1.2.3 Emission reduction methods . . . . . . . . . .16
1.3 RISK ANALYSIS . . . . . . . . . . . . . . . . . . . .17
2.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . .17
2.1 CONTROLS . . . . . . . . . . . . . . . . . . . . . . .17
2.1.1 Front control panel FP121 . . . . . . . . . . .17
2.1.2 Rear control panel . . . . . . . . . . . . . . . . .18
3.0 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . .18
3.1 ldentification . . . . . . . . . . . . . . . . . . . . .18
3.2 Technical characteristics . . . . . . . . . . . . .18
4.0 TRANSPORT - UNLOADING . . . . . . . . . . . .19
5.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .19
5.1 GENERAL RULES . . . . . . . . . . . . . . . . . . .19
5.2 ELECTRIC CONNECTION
TO THE SUPPLY MAINS . . . . . . . . . . . . . . . .19
5.3 CONNECTING THE EQUIPMENT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .19
5.4 SETTING UP . . . . . . . . . . . . . . . . . . . . . .19
6.0 PROBLEMS - CAUSES . . . . . . . . . . . . . . . . . .20
6.1 Possible cutting defects . . . . . . . . . . . . . .20
6.2 Possible electrical faults . . . . . . . . . . . . .20
7.0 ROUTINE MAINTENANCE . . . . . . . . . . . . . .20
8.0 THEORETICAL OUTLINE
OF PLASMA CUTTING . . . . . . . . . . . . . . . . .21
8.1 Plasma cutting torch . . . . . . . . . . . . . . . .21
8.1.1 Plasma cutting process . . . . . . . . . . . . . .21
8.1.2 Caracteristics of a generator
for plasma cutting . . . . . . . . . . . . . . . . . . . . .21
9.0 CUTTING SPECIFICATIONS . . . . . . . . . . . . .21
10.0 NOMINAL DATA . . . . . . . . . . . . . . . . . . . .23
A-90 TORCH
1.0 TECHNICAL DETAILS . . . . . . . . . . . . . . . . . .23
2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .23
3.0 SETTING UP FOR USE . . . . . . . . . . . . . . . . .23
4.0 USING THE TORCH . . . . . . . . . . . . . . . . . . .24
4.1 INCLINATION AND SPEED OF THE
TORCH DURING CUTTING . . . . . . . . . . . . .24
4.1.1 Puncturing . . . . . . . . . . . . . . . . . . . . . .24
4.1.2 Circular cutting . . . . . . . . . . . . . . . . . . .24
4.1.3 Practical advice . . . . . . . . . . . . . . . . . . .24
5.0 MAINTENANCE AND INSPECTION . . . . . . .24

15
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 (cutting) process is a noxious source of radia-
tions, 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
(cutting) slags.
lf you feel an electric shock, interrupt the welding (cut-
ting) operations immediately.
Other persons' protection:
- Put up a fire-retardant partition to protect the surroun-
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 (cutting) 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
closed containers or pipes.
- lf said containers or pipes have been opened, emptied
and carefully cleaned, the welding (cutting) operation
must in any case be performed with great care.
- Do not weld (cut) in places where explosive powders,
gases or vapours are present.
- Do not perform welding (cutting) operations on or near
containers under pressure.
1.1.4 Protection against fumes and gases
Fumes, gases and powders produced during the welding
(cutting) process can be noxious for your health.
Important: do not use oxygen for the ventila-
tion
- Provide for proper ventilation, either natural or forced,
in the work area.
- In case of welding (cutting) 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 (cutting) operations near
degreasing or painting stations.
Do not perform welding (cutting) operations
on painted plates
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 15° with respect to the horizontal plane.
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.

16
- 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 of welding (cutting).
- Take the precautions relevant to the protection degree
of the power source.
- Before welding (cutting), check the condition of the
electric cables and of the torch, and if they are dama-
ged repair or change them.
- Neither get on the material to be welded (cut), nor
lean against it.
The operator must not touch two torches or
two electrode holders at the same time.
1.1.7 Precautions against risks connected with the
use of compressed air
Connect the air supply to the coupling provided, making
sure pressure is at least 6 bars (0.6 MPa) with a minimum
flow rate of 200 l/min. If the air supply comes from pres-
sure reducer of a compressor or a central system, the
reducer must be set to the maximum outlet pressure that
must not, however, exceed 8 bars (0.8 MPa). If the air
supply comes from a compressed air canister it must be
equipped with a pressure regulator.
A compressed air canister must never be
directly coupled to the machine pressure redu-
cer. Pressure might exceed the capacity of the
reducer which might consequently explode.
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 environments. It
is important to remember that it may be diffi-
cult to ensure the electromagnetic 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 instruc-
tions.
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
This device must be connected to the supply
mains according to the manufactures instruc-
tions.
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.
MAINTENANCE
This device needs routine maintenance according to the
manufacturer's instructions.
When the equipment is working, all the access and ope-
rating doors and covers must be closed and fixed.
This device must not be modified in any way.
WELDING AND CUTTING CABLES
The welding (cutting) cables must be kept as short as pos-
sible, positioned near one another and laid at or approxi-
mately at ground level.
EQUIPOTENTIAL CONNECTION
The earth connection of all the metal components in the
welding (cutting) installation and near it must be taken in
consideration.
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
(cutting) installation can be taken in consideration for spe-
cial applications.

17
1.3 RISK ANALYSIS
2.0 INTRODUCTION
Genesis 60 is a user-friendly, compact generator for pla-
sma cutting.
Genesis 60 uses compressed air as its only gas source,
which can be supplied from a normal compressor or from
a suitably sized centralized plant. It is able to carry out,
cheaply, cuts of a high quality up to a thickness of 20 mm
in carbon steel, while still keeping its weight and size very
limited.
This optimum performance-to-weight ratio is made pos-
sible thanks to the use, in common with all the Genesis
range, of inverter technology.
The current is thus stable, and unaffected by variations in
the supply voltage, in the height of the cutting arc, in the
progression speed and in the thickness of the metal to be
cut. The Genesis 60 is equipped with an automatic circuit
for the reignition of the pilot arc, that allows metal grill
structures to be cut in the best way.
There are safety systems that cut off the power circuit
when the operator comes into contact with live parts of
the machine, as well as controls to reduce the wear on
the electrode and nozzle at the moment of striking the
cutting arc.
The ignition of the pilot arc takes place without the use of
high frequency, with an increase in the working life of the
parts of the torch subject to wear, and reduction in the
mains interference.
The generator is equipped with:
- one torch fitting,
- an earth socket,
- front panel,
- rear panel.
2.1 CONTROLS
2.1.1 Front control panel FP121 (Fig.1)
* L1 : Voltage warning light green led.
Comes on with the start switch (Fig.2) "I1" in position "I"
and indicates that the plant is on and there is voltage.
* Power output light red led.
Comes on as soon as the cutting process starts, and goes
off as soon as it is finished.
* L3: torch cap alarm green led.
Means that the torch cap has not been properly tighte-
ned. The generator has no power output.
* L4: compressed air alarm green led.
Means that the pressure of compressed air is below 3
bar, too low for proper functioning.
The generator has no power output.
* L5: Thermal safety device warning light yel-
low led.
lndicates that the safety devices like thermal cutout.
With "L5" on, the power source remains connected to
the supply mains, but does not supply output power.
"L5" 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.
* E1: Encoder for setting the cutting current
Allows you to continuously adjust the cutting current.
This current stays unchanged during cutting when the
supply and cutting conditions vary within the allowed
ranges.
The T1 VOLT-AMP reading selection key
permits display of either the welding voltage
or current on DISPLAY D1.
If LED V is on, the last voltage reading taken during the
last cutting operation is displayed. If you do not begin cut-
ting within 5 sec. the system automatically switches to A,
displaying the set current. Vice versa if you begin cutting
within 5 sec., the voltage is displayed during the entire
cutting operation after which the reading remains displa-
yed for a further 5 seconds.
If LED A is lit up on display D1, the set or cutting cur-
rent is displayed if the operation is in progress. The dis-
play is maintained for 5 seconds after the end of the ope-
ration.
T2: gas test pushbutton.
Allows impurities to be removed from the
compressed air circuit and preliminary
capacity and pressure settings to be made with no power
output.
* D1 displays the set current, cutting current and cutting
voltage or the letters GEN (at switch-on) and ERR
(blinking in the event of an alarm).
* D2 displays the air pressure value for the cutting pro-
cess. At switch-on it displays the software version.
In the event of an alarm, it displays the alarm code
in blinking mode:
01 IIC error
02 torch cap open
03 air pressure too low
I1 overtemperature
I2 power supply voltage too low
I3 power supply voltage too high
Risks posed by the machine
Risk of wrong installation.
Electrical risks.
Risks connected with electro-
magnetic disturbances produ-
ced by the welding power
source and induced on the
welding power source.
Solutions adopted
to pervent them
A manual with the instructions
for use has been produced for
this purpose.
Application of the EN 60974-1,
EN 50192, EN 50078
Standards.
Application of the EN 50199
Standard.

18
In the event of an alarm, the operating condi-
tions are restored only if the cause is removed
and for alarms I1, I2 and I3 button T1 must also be pres-
sed to activate initial reset of the generator.
Fig. 1
2.1.2 Rear control panel (Fig. 2)
* I1: Off/On switch
Turns on the electric power to the machine.
It has two positions, "O" off, and "I" on.
* When I1 is in the on "I" position, the generator
is operational, but has voltage output only if L2
is on.
* The machine is connected to the mains supply
even if the I1 switch is in the "O" position, and
therefore there are electrically live parts inside
it. Carefully follow the instructions given in this
manual.
* 1 : Supply cable.
* F1 : air filter (pressure regolator)
Fig. 2
3.0 TECHNICAL DATA
3.1 IDENTIFICATION
The data plate stamped on the metal structure, see ch.
10.0 complies with the IEC 974-1 and EN 60974-1 inter-
national standards and contains the following information:
* Manufacturer's name and address.
* SELCO trademark
* ( Type ) Model
* ( N° ) Serial number
* ( ) The power source for plasma cutting com-
prises a frequency converter followed by a transformer
and rectifier that transforms input voltage into direct
current.
* (EN 60974-1, EN 50192) Safety standard applied.
* (OUTPUT) Output current and voltage ranges available.
* ( ---- ) Direct current.
* ( 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 cut current.
* ( U2 ) Conventional load voltage.
* ( U0) Rated no-load voltage.
* Plasma cutting
* ( ) 3input phases.
* ( I.CL. H ) lnsulation 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
componente with fingers and against the intro-
duction of foreign matters with diameter 12,5
mm.
IPX3 Casing protected against rain falling 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.
3.2 Technical characteristics
Above data are referred to environment al 40°C
TECHNICAL CHARACT.
Power supply voltage
Delayed fuse
Rated power
Cutting current (x=60%)
(x=100%)
Cutting voltage (x=60%)
No-load voltage
Pilot arc current
Operating pressure
Flow rate
Protection class
Insulation class
Construction regulations
Dimensions (LXPXH)
Weight
GENESIS 60
3x400 V (440V) 50/60 Hz
16 A
8.32 KW
60 A
50 A
124 V
260 V
22 A
5 bar
180 l/min
IP 23
H
EN 60974-1; EN 50199
EN 50078; EN 50192
180x430x300 mm
19 Kg

19
4.0 TRANSPORT - UNLOADING
Never underestimate the weight of the equip-
ment, see 3.0 (TECHNICAL DATA).
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.
Once it has 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.
5.0 INSTALLATION
5.1 GENERAL RULES
Choose an adequate installation area by following the crite-
ria provided in Section "1.0 WARNINGS-PRECAUTIONS-
GENERAL ADVICE".
Do not position the power source and the equipment on
surfaces with inclination exceeding 15° with respect to
the horizontal plane.
Protect the installation from heavy rain and sun. The
machine protection degree (IP 23) is effective against
water that falls down in a direction forming an angle up
to 60° with the vertical line.
5.2 ELECTRIC CONNECTION TO THE SUPPLY
MAINS
The equipment is provided with a single electric connec-
tion with a 5m cable positioned in the rear part of the
power source.
Size table of the power source input cables and fuses:
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.
* Verity the existence of the earthing in the used plant
and the good condition of the socket/s
* lnstall only plugs that are homologated according to
the safety regulations.
5.3 CONNECTING THE EQUIPMENT COMPONENTS
Keep to the safety regulations contalned in sec-
tion 1.0 WARNINGS-PRECAUTIONS-GENERAL
ADVICE.
Connect the componente carefully, in order to
avoid power losses.
5.4 SETTING UP
1. Place the generator in a dry, clean place with suitable
ventilation.
2. Connect up the compressed air supply with a 1/4 inch
to the air inlet P1 in the filter unit F1 (Fig.2). The pres-
sure must ensure at least 5 bars with a flow rate of at
least 180 litres a minute.
Securely connect the earth cable connector to the
generator as shown in figure 4.
3. Position the earthing clamp onto the piece to be cut,
ensuring that it makes a good electric connection (Fig. 4).
4. Check that all the components of the torch are present
and correctly fitted and connect the torch fitting to the
connector on the generator as shown in figure 3.
Insert the male fitting (torch side) into the correspon-
ding female fitting (machine side). Align the locating
tooth (A) on the housing and insert the ring nut (B)
which must be compatible. To permit screw-tightening
of the ring nut (B), the tool provided (D) must be first
inserted and pressed into the hole (C) in order to
release the anti-rotation lock. This operation must be
performed until the ring nut has been completely tigh-
tened. To disconnect the torch, first release the anti-
rotation lock by inserting the tool provided (D) into the
hole (C).
Fig. 3
POWER SOURCE
Rated voltage
Voltage range
Delayed fuses
Power supply cable
GENESIS 60 3x400 V
400 V ±15%
340 - 460 V
16 A 500 V
4x4 mm2
POWER SOURCE
Rated voltage
Voltage range
Delayed fuses
Power supply cable
GENESIS 60 3x440 V
440 V ±15%
374 - 506 V
16 A 500 V
4x4 mm2

20
5. Switch on the system, ensuring the LED's are working
correctly and some display.
If operating faults occur in the generator it will be inhi-
bited until normal operating conditions are restored.
Press the gas test pushbutton (T2 in Fig 1) in order to
remove residual impurities from the compressed air
circuit, then lift and turn the knob to adjust the pres-
sure (F1 Fig.2) until the display D2 shows a pressure
reading of 5 bars (carry out the operation keeping the
gas test button pressed down, so as to make the adjust-
ment with air circulating in the piping).
6. Set the value of the cutting current with the potentio-
meter, keeping in mind the thickness to be dealt with.
7. Press for a moment the torch button so as to generate
the pilot arc; release the control, checking the machi-
ne is correctly operating with the display panel. It is
advisable not to keep the arc lit to no purpose without
making contact, so as to prevent wear on the electro-
de and the nozzle. If you continue to use it like this the
apparatus itself will turn off the pilot light after about 6
seconds.
In the case where a fault is found during the above
phases, check the LED's, the display and if necessary
consult the chapter "Possible electrical faults" in the
manual.
Fig. 4
6.0 PROBLEMS - CAUSES
6.1 POSSIBLE CUTTING DEFECTS
6.2 POSSIBLE ELECTRICAL FAULTS
See chapter 2.1 for problems that generate an alarm
code.
If you have any doubts or problems, do not hesitate to
consult your nearest Selco technical service centre.
7.0 ROUTINE MAINTENANCE
Prevent metal powder from accumulating near the aera-
tion fins and over them.
Disconnect the power supply before every
operation!
Carry out the following periodic controls on the power
source:
* Clean the power source inside by means of low-pressu-
re compressed air and soft bristel brushes.
* Check the electric connections and all the connection
cables.
For the maintenance or replacement of pla-
sma torch components, and/or earth cables:
* Disconnect the power supply before every operation.
* Check the temperature of the componente and make
sure that they are not overheated.
* Always use gloves in compliance with the safety stan-
dards.
* Use suitable spanners and tools.
* For torch maintenance, keep carefully to the direc-
tions shown under instructions for use of the torch
enclosed with this manual.
DEFECT
Insufficient penetration
The cutting arc goes out
CAUSE
- Cutting speed too high
- Current set too low
- Earth clamp with inefficient
contact
- Thickness of piece excessive
- Electrode, nozzle or diffuser
worn
- Air pressure too high
- Cutting speed too low
- Insufficient air flow
- Defective pressure switch
- Supply voltage too low
Substantial burr formation
Nozzle overheating
- Inadequate air pressure
- Cutting speed too low
- Nozzle eroded
- Electrode eroded
- Insufficient air quantity
DEFECT
Apparatus fails to come on
(Yellow LED L1 off)
Pilot arc fails to ignite (with
yellow LED L1 on)
Pilot arc fails to ignite (with
yellow LED L1 and red LED
L2 on)
Fails to transfer from pilot arc
to cutting arc
Lack of power output
CAUSE
- Incorrect mains supply
- Break in the contacts of the
torch button (check the con-
nection of the torch attach-
ment is working after having
cut off the power supply)
- Torch parts subject to wear
out of action
- Air pressure too high
- Possible problems in control
circuits
- Possible problems in control
circuits
- Arc sensors faulty (board
15.14.260)
- Protective devices triggered
(see chapter on "Functions of
controls")
- Possible problems in control
circuits

21
Tighten the componente 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 and in the contact joints.
8.0 THEORETICAL OUTLINE
OF PLASMA CUTTING
A gas assumes the plasma state when it is brought to an
extremely high temperature and ionizes wholly or partly,
thus becoming electrically conductive.
Although the plasma exists in every electric arc, by the
term "plasma arc" we refer specifically to a torch for wel-
ding or cutting that uses an electric arc, made to pass
through the constricting neck of a suitable nozzle, to heat
a gas coming out of this, so as to take it to the plasma state.
Fig. 5 Manual plasma cutting plant
8.1 Plasma cutting torch
Initially, for plasma cutting, a torch was used with a front
end structure as in Fig.6 and two types of gas: a first one
for the formation of the plasma (A) that passes between
the electrode (1) and nozzle (2) and is forced to exit in an
ionized form through the hole, and a second one (B), that
acts to cool the torch and further thins out the dimensions
of the plasma arc, which at its centre (C), easily manages
to reach the temperature of 10.000°C.
With new types of torch and with medium-low power
levels (processes that use less than 150A for cutting),
today it is possible to use only compressed air as the cut-
ting gas, as well as the cooling gas: the complete process
thus becomes much cheaper (Fig.7).
Fig. 6 Functional diagram of a first-generation torch
Fig. 7 Functional diagram of an up-to-date torch for small
and medium power
8.1.1 Plasma cutting process
The cutting action is obtained when the plasma arc, made
very hot and highly concentrated by the design of the
torch, transfers onto the conductive piece to be cut, clo-
sing the electrical circuit with the generator. The material
is first melted at a high temperature of the arc, and then
removed by the high exit velocity of the ionized gas from
the nozzle.
The arc can have two different states: that of the transfer-
red arc, when the current passes through the piece to be
cut, that of the pilot arc or non-transferred arc, when this
is sustained between the electrode and the nozzle.
8.1.2 Caracteristics of a generator for plasma cutting
A generator for plasma cutting carries out the following
operations:
- ignites the pilot arc (for this you can use either a dis-
charge of high frequency between electrode and nozz-
le, or special torches with retractable electrode);
- supplies the current and voltage to the pilot arc neces-
sary to sustain it;
- checks the transition from the pilot arc to the cutting arc;
- supplies the current required for cutting to the cutting
arc;
- oversees all the operations and suitably controls the air
valve and alarms.
The piece to be cut is connected to the positive pole of
the cutting circuit, as is the nozzle, while the electrode is
connected to the negative pole.
The above-mentioned process allows cutting of all con-
ductive materials, and thus also the non-ferrous metals for
which cutting by an oxyacetylene process is impossible.
9.0 CUTTING SPECIFICATIONS
In plasma cutting, the thickness of the material to be cut,
the speed of cutting and the current supplied by the
generator have values which are related to each other;
these depend on the type and quality of the material,
type of torch as well as the type and condition of the elec-
trode and nozzle, distance between nozzle and piece,
pressure and impurity of the compressed air, cut quality
required, temperature of the piece to be cut, etc.
In the diagrams as in Fig.8 and Fig.9, we can see that the
thickness to be cut is inversely proportional to the cutting
speed, and that both these values can be increased with
an increase in current.

MILD STEEL
STAINLESS STEEL
ALUMINIUM
* High quality cut
Fig. 8
Fig. 9
1
2
3
4
8
10
15
1
2
3
4
8
10
15
20
50
50
50
50
50
50
50
60
60
60
60
60
60
60
60
7800
3700*
2500*
1800
700
600
250
10500
6000
3000
2500*
1000*
800*
400*
200
22
Thickness (mm)
1
2
1
2
3
1
2
3
4
6
8
10
15
1
2
3
4
6
8
10
15
20
Current (A)
30
30
40
40
40
50
50
50
50
50
50
50
50
60
60
60
60
60
60
60
60
60
Speed (mm/min)
1700
700
3000*
1400
1000
6400
2400*
1500
1200
850
700
450
250
10500
6000
3000*
1700*
1200*
900*
750*
350
200
1
2
3
4
6
8
10
1
2
3
4
6
8
10
15
50
50
50
50
50
50
50
60
60
60
60
60
60
60
60
10100
5000*
3000*
2000
1200
950
700
14000
10000
4800
3000*
1900*
1600*
1400*
600
Thickness (mm)
1
1
2
3
1
2
3
4
Current (A)
20
30
30
30
40
40
40
40
Speed (mm/min)
2400
4000*
1500
1200
6700*
3200*
2200
1100
Thickness (mm)
1
2
3
4
1
2
3
4
1
2
3
4
Current (A)
20
20
20
20
30
30
30
30
40
40
40
40
Speed (mm/min)
1500
600
400
300
3000
1200
750
500
5000*
2000
1700
1200

23
10.0 NOMINAL DATA
A-90 TORCH
1.0 TECHNICAL DETAILS
2.0 INSTALLATION
Turn off the generator.
Connect the torch attachment to the correponding
coupling on the generator by completely screwing on the
locking ring.
3.0 SETTING UP FOR USE
Fig.1 Torch body assembly
Before starting work, it is necessary to carry out the follo-
wing checks and work:
1) Check that the generator is turned off.
2) Check that all the parts of the torch are working. For
the various parts that make up the torch body (Fig.1),
the sequence of correct assembly is 1-2-3-4-5-6.
3) To fit the electrode (No.2), use the key, taking care to
avoid excessive tightening that could damage the
thread of the components.
The electrode must be unscrewed only after the post-
cutting air flow is finished, and therefore with the elec-
trode itself cooled.
4) Check that the air diffuser, or "swirl-bush" (No.3) is
working correctly, which must always show access
holes free of obstruction; the use of a defective air dif-
fuser would cause overheating, with consequent
damage to the components of the torch body.
5) The diameter of the hole in the tip (No.4) is chosen
according to table 1.
Never use a tip with a hole diameter less than that
recommended; this could cause overheating with con-
sequent damage to the torch body.
6) With the spare parts assembled, check that by scre-
wing the outer nozzle (No. 5) to the torch body the
corresponding alarm on the generator is cut off; finally
check that by unscrewing the nozzle the alarm is trig-
gered; these checks should be carried out with the
generator on, taking care not to press the torch button.
7) With manual cutting, the standard spacing spring
(No.6) is used, and on request a spacer with 4 feet is
available, for cutting with template (see detail 024 of
the exploded drawing of parts).
8) The compressed air used must be filtered and maintai-
ned at a high level of purity; humid air, oil and other
contaminative agents must be removed, by making use
of suitable driers and anti- oil filters.
Thus the torch is set up for the cutting operation.
In any case it is necessary to also follow what is shown
in the instruction manual for the generator, above all in
the paragraphs "General precautions", "Connecting up"
and "Normal maintenance".
Table 1 Choice of appropriate tip
Principle of operation
Version
Protection device
Current (x = 60%)
(x = 100%)
Pilot arc current
Pressure
Air quantity
Ignition of pilot arc with high
frequency
Monogas (air or nitrogen)
External nozzle not screwed
signal
90A
70A
22÷29A
5÷5.5 bars
180 Iitres/min
Tip diameter
Tip Ø 1.1
Tip Ø 1.4
Tip Ø 1.7
Range of current usable
40÷60A
50÷80A
70÷90A

24
4.0 USING THE TORCH
4.1 Inclination and speed of the torch during cutting
The torch is generally held perpendicular to the workpie-
ce during all the cutting phases; obviously, whenever it is
required to carry out chamfering or inclined cutting, the
torch must be tilted to a suitable inclination.
The 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 materi-
al which could damage the tip.
4.1.1 Puncturing
In some cases it is necessary to puncture a hole in the
material using plasma cutting. In this way, the wear on the
parts which are subject to deterioration will be increased,
and it becomes very important to try to work to avoid the
return of spray, which can be dangerous, especially with
sheet metal over 10 mm. thick. We suggest starting with
the torch inclined sideways, so as to point the spray out-
side the cutting area, avoiding damage and overheating of
the torch body.
Immediately remove any material accumula-
ted on the tip or on the ceramic hood.
Caution: plasma cutting is a process with a high thermal
element, which takes both the piece to be cut and the
end parts of the torch to extremely high temperatures.
4.1.2 Circular cutting
For the preparation of flanges and opening holes, it is pos-
sible to use a pair of compasses, equipped with rotating
heads and movement on wheels. The centering is simpli-
fied by the presence of three different guides, one magne-
tic, one pointed, and one passing through the central hole.
4.1.3 Practical advice
We advise igniting the pilot arc away from the workpiece,
and then moving near until the cutting arc is struck; stri-
king a cutting arc repeatedly and directly by contact with
the workpiece creates an increase in temperature of the
torch body.
Avoid turning off the generator before the end of the
post-cut cooling flow, to avoid overheating of the compo-
nents of the torch.
5.0 MAINTENANCE AND INSPECTION
Wear on the electrode is not only determined by the cutting
time and the current, but also by the number of start-ups.
It is advisable to replace the electrode before the tungsten
insert in the point is completely worn out.
The tip, that is always of a size suggested under table 1,
has an average life similar to that of an electrode, and is
replaced when an irregular hole is present which is larger
than the nominal one (this can cause slanted cuts of poor
quality).
Electrode and tip are replaced simultaneously to prolong
their active life.
Working with electrode and tip which are too spoiled can
cause damage to the torch body.
It is important to pay special attention to the fitting of the
electrode and tip in order not to irreparably damage the
torch.

I
T
A
L
I
A
N
O
E
N
G
L
I
S
H
D
E
U
T
S
C
H
F
R
A
N
Ç
A
I
S
E
S
P
A
Ñ
O
L
Genesis
60
TAVOLE RICAMBI
SPARE PARTS TABLES
ERSATZTEILTAFELN
VUES DES PIECES DETACHEES
TABLAS DES REPUESTOS

RICAMBI - SPARE PARTS - ERSATZTEILE -
PIECES DETACHEES - REPUESTOS GENESIS 60 TAV.01

ITALIANO
POS.DESCRIZIONE CODICE
1 Pannello plastico frontale 01.04.26201
2 Pannello plastico posteriore 01.05.220
3 Fondo plastico 01.06.100
4 Supporto per filtro regolatore 01.14.227
5 Cofano serigrafato 03.07.060
6 Trasformatore 05.11.260
7 Ventilatore 07.10.014
8 Interruttore 09.01.008
9 Elettrovalvola 09.05.001
10 Manopola 09.11.009
11 Presa fissa 10.13.020
12 Ponte diodi 14.10.161
13 Diodi 14.05.078
14 Kit scheda arco pilota 15.18.014
15 Scheda ingresso 15.14.266
16 Gruppo inverter primario 14.60.063
17 Scheda H.F. 15.14.192
18 Scheda filtro 15.14.264
19 Pannello comandi FP121 15.22.121
20 Attacco centralizzato 19.06.007
21 Cinghia 21.06.004
22 Filtro regolatore 24.02.010
23 Varistore 11.26.006
ENGLISH
POS.DESCRIPTION CODE
1 Pastic front panel 01.04.26201
2 Plastic back panel 01.05.220
3 Bottom 01.06.100
4 Filter regulator holder 01.14.227
5 Silk-screen panel 03.07.060
6 Transformer 05.11.260
7 Fan 07.10.014
8 Switch 09.01.008
9 Solenoid valve 09.05.001
10 Knob 09.11.009
11 Fixed socket 10.13.020
12 Diode jumper 14.10.161
13 Diodes 14.05.078
14 Pilot arc p.c. board kit 15.18.014
15 Inlet board 15.14.266
16 Primary inverter unit 14.60.063
17 H.F. card 15.14.192
18 Filter card 15.14.264
19 Control panel FP121 15.22.121
20 Connector 19.06.007
21 Belt 21.06.004
22 Filter regulator 24.02.010
23 Varistor 11.26.006
DEUTSCH
POS.BESCHREIBUNG CODE
1 Stirnseitiges Plastikpaneel 01.04.26201
2 Hinterteil Plastikpaneel 01.05.220
3 Bodenteil 01.06.100
4 Filterregler-halter 01.14.227
5 Siebdruck seitenteil 03.07.060
6 Trafo 05.11.260
7 Ventilator 07.10.014
8 Schalter 09.01.008
9 Elektroventil 09.05.001
10 Ballengriff 09.11.009
11 Fixen Griff 10.13.020
12 Diodenbrücke 14.10.161
13 Diode 14.05.078
14 Kit Platine arc pilote 15.18.014
15 Eingangsplatine 15.14.266
16 Einheit Primärinverter 14.60.063
17 H.F.-Karte 15.14.192
18 Filterkarte 15.14.264
19 Bediennungsfeld FP121 15.22.121
20 Zentralanschluss 19.06.007
21 Riemen 21.06.004
22 Filterregler 24.02.010
23 Varistor 11.26.006
FRANÇAIS
POS. DESCRIPTION CODE
1 Panneau avant plastique 01.04.26201
2 Panneau arriere plastique 01.05.220
3 Fond 01.06.100
4 Support filtre regulateur 01.14.227
5 Panneau avec serigraphie 03.07.060
6 Transformateur 05.11.260
7 Ventilateur 07.10.014
8 Interrupteur 09.01.008
9 Soupape electrique 09.05.001
10 Bouton 09.11.009
11 Prise inamovible 10.13.020
12 Pontet diodes 14.10.161
13 Diode 14.05.078
14 Kit Pilotbogenplatine 15.18.014
15 Platine entree 15.14.266
16 Groupe inverseur primaire 14.60.063
17 Carte H.F. 15.14.192
18 Carte filtre 15.14.264
19 Panneau de reglage FP121 15.22.121
20 Connecteur 19.06.007
21 Courroie 21.06.004
22 Filtre regulateur 24.02.010
23 Varistance 11.26.006
ESPAÑOL
POS.DESCRIPCION CODIGO
1 Panel frontal plástico 01.04.26201
2 Panel posterior plástico 01.05.220
3 Fondo 01.06.100
4 Soporte filtro regulador 01.14.227
5 Panel con serigrafia 03.07.060
6 Transformador 05.11.260
7 Ventilador 07.10.014
8 Interruptor 09.01.008
9 Electrovalvula 09.05.001
10 Botón 09.11.009
11 Enchufe fijo 10.13.020
12 Puente diodos 14.10.161
13 Diodo 14.05.078
14 Kit tarjeta arco piloto 15.18.014
15 Tarjeta ingreso 15.14.266
16 Grupo inversor primario 14.60.063
17 Tarjeta H.F. 15.14.192
18 Tarjeta filtro 15.14.264
19 Panel de control FP121 15.22.121
20 Conectro 19.06.007
21 Correa 21.06.004
22 Filtro regulador 24.02.010
23 Varistor 11.26.006

TORCIA A-90 - A-90 TORCH - BRENNER A-90 - TORCHE A-90 - PORTAELECTRODO A-90 TAV.02

ITALIANO
POS.DESCRIZIONE CODICE
000 Torcia plasma A-90 mt.6 81.20.018
001 Distanziale a molla CV11 82.23.104
002 Ugello esterno PC109 82.23.091
003 Tip diametro 1.1 PD101-11 82.23.065
Tip diametro 1.4 PD101-14 82.23.066
Tip diametro 1.7 PD101-17 82.23.067
004 Diffusore aria marrone PE101 82.23.082
005 Elettrodo PR101 82.23.050
006 Guarnizione OR EA131 82.23.123
007 Corpo torcia A-90 PF109 82.23.012
010 Impugnatura nera TP10 82.23.132
012 Spinetta macro EA185 82.23.140
013 Molla micro BX13 82.23.142
014 Macro BX1 82.23.141
015 Pulsante BW100 82.23.143
017 Cavo aria corrente M6 PH109 82.23.163
018 Guaina protezione M6 PQ11 82.23.150
023 Attacco maschio centralizzato 19.06.002
024 Distanziale a 4 piedi CV14 82.23.106
ENGLISH
POS.DESCRIPTION CODE
000 A-90 plasma torch, 6 metre 81.20.018
001 Spring spacer CV11 82.23.104
002 External nozzle PC109 82.23.091
003 Tip, 1.1 diameter PD101-11 82.23.065
Tip, 1.4 diameter PD101-14 82.23.066
Tip, 1.7 diameter PD101-17 82.23.067
004 Air diffuser, brown PE101 82.23.082
005 Electrode PR101 82.23.050
006 Seal OR EA131 82.23.123
007 Torch body A-90 PF109 82.23.012
010 Handgrip, black TP10 82.23.132
012 Micro pin EA185 82.23.140
013 Micro spring BX13 82.23.142
014 Micro BX1 82.23.141
015 Push button BW100 82.23.143
017 Air flow tube M6 PH109 82.23.163
018 Protective sheath M6 PQ11 82.23.150
023 Male coupling, centralised 19.06.002
024 Spacer with 4 feet CV14 82.23.106
DEUTSCH
POS.BESCHREIBUNG CODE
000 Plasmabrenner A-90 - 6 m 81.20.018
001 Feder-Distanzstück CV11 82.23.104
002 Äußere Düse PC109 82.23.091
003 Tip Durchmesser 1.1 PD101-11 82.23.065
Tip Durchmesser 1.4 PD101-14 82.23.066
Tip Durchmesser 1.7 PD101-17 82.23.067
004 Luftverteiler, braun PE101 82.23.082
005 Elektrode PR101 82.23.050
006 O-Dichtung EA131 82.23.123
007 Brennerkörper A-90 PF109 82.23.012
010 Griff schwarz TP10 82.23.132
012 Stift für Mikroschalter EA185 82.23.140
013 Feder für Mikroschalter BX13 82.23.142
014 Mikroschalter BX1 82.23.141
015 Druckknopf BW100 82.23.143
017 Luft-Strom-Kabel M6 PH109 82.23.163
018 Schutzmantel M6 PQ11 82.23.150
023 Zentralisierter Steckanschluß 19.06.002
024 4-füßiges Distanzstüdk CV14 82.23.106
FRANÇAIS
POS.DESCRIPTION CODE
000 Torche plasma A-90 6 m 81.20.018
001 Entretoise à ressort CV11 82.23.104
002 Buse externe PC109 82.23.091
003 Tip diamètre 1.1 PD101-11 82.23.065
Tip diamètre 1.4 PD101-14 82.23.066
Tip diamètre 1.7 PD101-17 82.23.067
004 Diffuseur air marron PE101 82.23.082
005 Electrode PR101 82.23.050
006 Joint OR EA131 82.23.123
007 Torche A-90 PA109 82.23.012
010 Poignée noire TP10 82.23.132
012 Cheville micro EA185 82.23.140
013 Ressort micro BX13 82.23.142
014 Micro BX1 82.23.141
015 Touche BW100 82.23.143
017 Câble air courant M6 PH109 82.23.163
018 Gaine de protection M6 PQ11 82.23.150
023 Fixation mâle centralisée 19.06.002
024 Entretoise à 4 pieds CV14 82.23.106
ESPAÑOL
POS.DESCRIPCION CODIGO
000 Portaelectrodo plasma A-90 m.6 81.20.018
001 Distanciador de resorte CV11 82.23.104
002 Inyector externo PC109 82.23.091
003 Tip diàmetro 1.1 PD101-11 82.23.065
Tip diàmetro 1.4 PD101-14 82.23.066
Tip diàmetro 1.7 PD101-17 82.23.067
004 Difuso aire marrón PE101 82.23.082
005 Electrodo PR101 82.23.050
006 Guarnición OR EA131 82.23.123
007 Cuerpo portaelectrodo
A-90 PF109 82.23.012
010 Empuñadura negra TP10 82.23.132
012 Clavija micro EA185 82.23.140
013 Resorte micro BX13 82.23.142
014 Micro BX1 82.23.141
015 Pulsador BW100 82.23.143
017 Cable aire corriente M6 PH109 82.23.163
018 Vaina protección M6 PQ11 82.23.150
023 Enchufe macho centralizado 19.06.002
024 Distanciador de 4 pies CV14 82.23.106

SCHEMA ELETTRICO GENESIS 60 400V - ELECTRICAL DIAGRAMS -
SCHALTPLAN - SCHEMA ELECTRIQUE - DIAGRAMA ELÉCTRICO TAV.03

SCHEMA ELETTRICO GENESIS 60 440V - ELECTRICAL DIAGRAMS -
SCHALTPLAN - SCHEMA ELECTRIQUE - DIAGRAMA ELÉCTRICO TAV.04

DDIICCHHIIAARRAAZZIIOONNEEDDIICCOONNFFOORRMMIITTÀÀ
CONFORMITY CERTIFICATE
KKOONNFFOORRMMIITTÄÄTTSSEERRKKLLÄÄRRUUNNGG
DECLARATION DE CONFORMITE
DDEECCLLAARRAACCIIÓÓNNDDEECCOONNFFOORRMMIIDDAADD
La ditta/ Company/ Die Firma /L'entreprise / La firma
SELCO S.R.L. - Via Palladio, 19 - 35010 ONARA (Padova) - ITALY,
dichiara che l'apparecchio tipo
hereby declares that the apparatus type
erklärt, daß das Gerät Typ
déclare que l'appareil type
declara que el aparato tipo
è conforme alle direttive:
conforms to the standards:
den folgenden Richtlinien entspricht:
est conforme aux directives:
es conforme a las directivas:
e che sono state applicate le norme:
and that the regulations have been duly applied:
und daß folgende Normen angewendet wurden:
et que les normes ci-contre ont été appliquées:
y que se han aplicado las normas:
Ogni intervento o modifica non autorizzati dalla SELCO S.R.L. faranno decadere la validità di questa dichiara-
zione.
Any operation or modification that has not been previously authorized by SELCO S.R.L. shall invalidate this cer-
tificate.
Jede von der Firma SELCO S.R.L. nicht genehmigte Änderung hebt die Gültigkeit dieser Erklärung auf.
Toute intervention ou modification non autorisée par SELCO S.R.L. annulera la validité de cette déclaration.
Toda reparación, o modificación, no autorizada por SELCO S.R.L., hará decaer la validez de esta declaración.
Onara (Padova).
lì /dated/den / le / ......................................................
CCEE--9977
Genesis 60 S/N...............
73/23/CEE
89/336/CEE
92/31/CEE
93/68/CEE
EN 50078
EN 50192
EN 50199
EN 60974-1
Rappresentante Legale Selco
Selcos legal representative
Rechtlicher Vertreter von Selco
Représentant légal Selco
Representante legal de Selco
...................................................................................................................
Lino Frasson