E
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I
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REPAIRS MANUAL
Genesis 1700, Genesis 1700RC
Genesis 1700TLH, Genesis 1700BRC
Genesis 1700BLH
Cod. 92.08.025
Edition: 1.0
Rev: 27/02/2007
SELCO s.r.l.
Via Palladio, 19
I – 35019 ONARA DI TOMBOLO(PD) Italy
TEL. +39 049 9413111
FAX. +39 049 9413311
email: info@selcoweld.com
How to contact Selco Service Department.
SELCO s.r.l
Service Department
c/o SELCO 2
Via macello, 61
I – 35013 CITTADELLA (Padova) Italy
TEL. +39 049 9413111
FAX. +39 049 9413311
email: service.dept@selcoweld. com
All translation, reproduction and adaptation rights, total or
partial and by any means (including photostat copies,
films and microfilms), are reserved and forbidden without
the written authorisation of Selco S.r.l.
2
INDEX :
1) PURPOSE OF THE MANUAL…………………….….. 3
2) WARNINGS, PRECAUTIONS AND
GENERAL NOTICES FOR PERFORMING REPAIRS ....... 4
3) INSTRUMENTS AND CONVENTIONS
FOR PERFORMING DIAGNOSIS AND REPAIR,
ASSEMBLING/DISASSEMBLING INSTRUCTIONS . … 5
4) USE AND ROUTINE MAINTENANCE OF POWER
SOURCES AND ACCESSORIES, TECHNICAL DATES… 7
5) MACHINE DESCRIPTION…………………………..10
6) DESCRIPTION OF BLOCK DIAGRAM……………..20
7) WIRING AND CONNECTION DIAGRAM…………27
8) DESCRIPTION OF DIAGNOSTIC
INDICATIONS …………………………………..30
9) SET-UP PARAMETERS...…………………………….32
10) DESCRIPTION, TESTING AND REPLACEMENT OF
THE ELECTRONIC BOARDS, CURRENT
CALIBRATION…………………………………………..35
11) SPARE PARTS LIST…………………………………56
12) NOMINAL DATA…………………………………...62
1) PURSPOSE OF THE MANUAL
This manual is designed to provide authorised service
centres with the basic information necessary for
performing repairs on the models Genesis 1700, Genesis
1700RC, Genesis 1700TLH, Genesis 1700BRC and
Genesis 1700BLH.
In order to avoid serious injury to persons or damage to
things, this manual must be used only by qualified
technicians.
Selco S.r.l. accepts no liability for any injury to persons or
damage to things that may occur during performance of
repairs, even after reading or practical application of this
manual.
For a detailed description of the operation, use and
ordinary maintenance of the machine, please refer to the
"Instructions for use and maintenance manual" which must
always accompany the machine. The purchaser must
follow the directions contained in the above manual.
Failure to do so will exempt Selco from all liability.
The operations described in this manual require the use of
a digital multimeter, an DC ammeter clamp and a basic
knowledge of how the machine works. Basic
electrotechnical knowledge is also required.
Repair consists in identification of the faulty part,
included in the list of available spare parts, and
replacement of it.
In the event of failure of an electronic board,
repair entails replacement of the board and
not replacement of the faulty electronic
component on the board.
Do not carry out modifications or maintenance not
scheduled in this manual.
If the problem cannot be solved by following the
instructions provided in this manual, contact the Selco
Service Department or send the machine to Selco for
repair.
3
2) WARNINGS, PRECAUTIONS AND
GENERAL NOTICES FOR PERFORMING REPAIRS
Repairs must be performed by qualified personnel only.
Before performing the repair, you should read and
assimilate the contents of this manual, in particular the
safety precautions.
Avoid performing repairs without the presence of another
person able to provide help in the event of an accident.
The repair of a machine requires access to its internal parts
and consequently removal of some of the protective
panels. Additional precautions are therefore necessary with
respect to use of the machine for welding in order to
prevent possible injury or damage caused by contact with
- live parts
- moving parts
- parts at high temperature
LIVE PARTS
CAUTION
When handling internal parts of the machine,
remember that opening of the switch does not
prevent the risk of electric shocks: the machine
must be unplugged from the power supply.
Wait approx. one minute before carrying out work on the
internal parts as the capacitors may be loaded at high
voltage.
CAUTION
When taking measurements, remember that the
measuring instruments can be live and you should
therefore avoid touching their metal parts.
CAUTION
When TIG operation with HF start is selected in
model Genesis 1700TLH and Genesis 1700BLH,
its generates a series of high voltage impulses
(approx. 10,000V) to strike the welding arc.
Consequently, when an arc striking test in TIG with HF
discharge is not specifically scheduled in the diagnostic
phases, you are advised to disconnect the terminals FN1
and FN2 of the HF board 15.14.286 (only for Genesis
1700TLH and Genesis 1700BLH). After performing the
repair, remember to reconnect FN1 and FN2 of board
15.14.286 before re-closing the machine, then run a few
welding tests, including arc striking in TIG HF mode.
4
CAUTION
MOVING PARTS
Keep your hands well away from the fan when the
machine is connected to the power supply. Ensure that the
machine is unplugged and that the fan is at a standstill
before replacing it.
CAUTION
PARTS AT HIGH TEMPERATURE.
When handling internal parts of the machine, remember
that some of them may be very hot. In particular avoid
contact with heat sinks.
3) INSTRUMENTS AND CONVENTIONS FOR
PERFORMING DIAGNOSIS AND REPAIR
3.3) Conventions.
By convention, when a measurement has to be taken
3.1) Instruments for basic diagnosis
between two points, for example a ← b, the arrow point
indicates where to apply the red tip of the multimeter
(a),while the black tip is applied at the other end (b).
When a double arrow appears between two measuring
The following are required:
-
a multimeter with the following scales:
Ohm: from 0 ohm to a few Mohm
Diode testing
Direct voltage (Vdc): from mVdc to 1000 Vdc
Alternating voltage (Vac): from 10 Vac to 700Vac
NOTE: You are advised to use an instrument with
automatic scale since it is not theoretically possible to
predict the electrical quantity to be measured when the
machine has broken down.
points (e.g.: c ↔ d), the voltage to be measured is
alternating (normally at 50 Hz), therefore it does not
matter in which order the multimeter terminals are
applied.
In drawings and tables, when a voltage measurement
appears referring to terminals of components such as
DIODES, BJT, MOSFET and IGBT, the multimeter is used
in "diode test" mode (these measurements are always taken
with the machine switched off and normally give values in
the range +0.10 … +0.90Vdc). In this case the following
symbol is affixed beside the value to be measured
Junction measurement (multimeter in "diode test"
mode)
The following symbols will be used in the same way:
-
An DC ammeter clamp at least in class 2.5 with
e.o.s. 1000A pk.
-
Alternatively to the ammeter clamp, a shunt can
be used with value 120 mV @ 700 A.
NOTES:
* Remember that other types of shunts can also be used,
but accuracy is reduced with higher capacities, whereas
with lower capacities the measurement must be taken
quickly to avoid overheating of the shunt
AC or DC voltage measurement (multimeter in
voltmeter mode)
Resistance
measurement
ohmmeter mode)
(multimeter
in
Current measurement (ammeter clamp or shunt
+ multimeter in millivoltmeter mode)
Frequency
measurement
frequencymeter mode)
(multimeter
in
* Once fitted, the shunt is at welding potential
* The ammeter clamp is preferable as it is more practical
3.2) Repair tools
-
Complete set of fork spanners
Complete set of pipe spanners for hexagonal nuts
Complete set of blade screwdrivers
Complete set of Phillips screwdrivers
Complete set of Allen keys
Crimper for insulated wire terminals (blue, red
and yellow)
Pliers for AMP contacts
Tweezers and cutting nippers - type commonly
used for electronic components
Tongs (dimensions suitable for closing gas pipe
clamps)
Welder for electronic components, minimum
power 50 W
Portable electric drill
The measuring conditions (power source on/off, MMA/TIG
operating mode, etc.) are always clearly indicated beside
the values to be measured.
The connector terminals are indicated by the name of the
connector followed by a slash and the number of the
terminal; for example CN1/2 indicates terminal 2 of
connector CN1.
Unless otherwise specified, all the measurements must be
performed with the boards fitted, together with their
connections.
Remember that the first of the tests to be
performed is the VISUAL CHECK!
The visual check reduces troubleshooting
times and directs any subsequent tests towards
the damaged part!
5
3.4)
Static load.
Use of grid load can speed up fault tracing and machine
testing.
Just remember that a fixed power resistor applied to
machine's output is somewhat equivalent to a welding arc,
but only inside of a narrow output voltage range, whose
center value can be determined by the formula:
STICK WELDING:
V OUT = 20 + 0.04 x I OUT
Es.:
22Vdc @ 50A
24Vdc @ 100A
28Vdc @ 200A etc.
DC TIG WELDING:
V OUT = 10 + 0.04 x I OUT
Es.:
12Vdc @ 50A
14Vdc @ 100A
18Vdc@200A etc.
If output voltage goes too much above or below the rated
value, the generator could either saturate or go into arc
force or other special features could be performed (such as
anti-flashing): in both cases real output current could be
much different from expected value and the generator
could even show an intermittent output power.
Grid load resistor's rated power is also important, 'cos a
24Vdc @ 100A grid load produces 2400W to be
dissipated by air cooling.
So, when using grid load, pay attention to both
output current & output voltage and use
correct resistance value & power!
6
4) USE AND ROUTINE MAINTENANCE OF POWER SOURCES AND ACCESSORIES, TECHNICAL DATES
Use and routine maintenance (excerpt from the "Instructions for use" manual provided with each power
source).
4.1 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.
The productor 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.
4.1.1 Operator and other persons' protection
The welding process is a noxious source of radiations,
noise, heat and gas emissions. Persons fitted with
pacemakers must consult their doctor before undertaking
arc welding or plasma cut operations.
If the above prescription is not observed, the manufacturer
accepts no liability for any damages sustained in the event
of an accident.
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
protection 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
operations immediately.
Other persons' protection:
Position a fire-retardant partition to protect the
surrounding 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 earphones.
4.1.2 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 infiammable 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
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
containers under pressure.
Don’t use this machine to defrost pipes.
4.1.3 Protection against fumes and gases
Fumes, gases and powders produced during the
welding process can be noxious for your health.
Do not use oxygen for the ventilation.
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 weld
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.
4.1.4 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.
7
4.1.5 lnstalling the apparatus
Comply with the local safety regulations for the
installation 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
generators 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 the
area to be welded as possible.
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.
8
4.2.0 ELECTROMAGNETIC COMPATIBILITY (EMC)
This device is built in compliance with the indications
contained in the harmonized standard EN60974-10, to
which the operator must refer for the use of this apparatus.
lnstall and use the apparatus keeping to the
instructions given in this manual.
This device must be used for professional
applications only, in industrial environments It
is important to remember that it may be
difficult to ensure the electromagnetic
compatibility in other environments.
4.2.1 Installation, use and area examination
The user must be an expert in the sector and as
such is responsible for installation and use of the
equipment according to the manufacturer's
instructions.
lf any electromagnetic disturbance is noticed, the
user must soave the problem, if necessary with
the manufacturer'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
fitted with pacemakers or hearing aids.
4.2.2 Emission reduction methods
MAINS POWER SUPPLY
The welding power source must be connected
to the supply mains according to the
manufacturer'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
operating doors and covers must be closed and fixed.
The welding power source must not be modified in any
way.
EQUIPOTENTIAL CONNECTION
The earth connection of all the metal component in the
welding installation and near it must be taken in
consideration.
However, the metal component connected to the
workpiece will increase the risk of electric shock for the
operator, if he touches said metal component and the
electrode at the same time.
Therefore, the operator must be insulated from all the
earthed metal component.
The equipotential connection must be made according to
the national regulations.
EARTHING THE WORKPIECE
When the workpiece is not earthed for electrical safety
reasonsor due to its size and position, the earthing of the
workpiece may reduce the emission. It is important to
remember that the earthing of the workpiece should
neither 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.
4.3.0 RISK ANALYSIS
Risks posed by the
machine
Risk of wrong installation
Electrical risks
Risks connected with
electromagnetic
disturbances produced
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 60974-5
Standard
Application of the EN
60974-10 Standard
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.
9
5) MACHINE DESCRIPTION
5.1) FRONT PANELS GENESIS 1700, GENESIS
1700RC and GENESIS 1700 BRC.
These constant current inverter power sources are able to
perform the following types of welding with excellent
results:
- MMA.
- TIG with remote arc striking by high frequency
(TIG HF START) and control of the gas supply by
the torch button.
- TIG with contact ignition with reduction of short
circuit current (TIG LIFT-START) and control of
gas delivery by means of torch button (selectable
from set-up).
In inverter welders, the output current is unaffected by
variations in the supply voltage and the length of the arc,
and is perfectly levelled, giving the best welding quality.
The generator is equipped with:
- positive (+) and negative (-) socket
- a front control panel
- a rear panel
- a fitting for the torch button connector (TLH)
- a gas socket for the torch (TLH)
- a gas coupling on the rear side of the welding
power source for the connection with the gas
cylinder (TLH)
- a rear connector for remote control (RC and
TLH).
* L2 : Safety device warning light yellow led.
lndicates that the safety devices like thermal cutout.
With "L2" on, the power source remains connected to the
supply mains, but does not supply output power.
"L2" 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.
"L2" is connected to the following alarm codes:
E01
Thermal alarm given by the NTC fitted on the
dissipator.
Automatic reset.
E03
Condensers thermal alarm (controlled at software
level).
Automatic reset.
E11
Machine not recognised. The machine locks out.
E20
IIC error. The 24C16 memory could be faulty.
Automatic reset*
E21
Loss of data or
Automatic reset*
memory
not
initialised.
* Alarm displayed for 3 sec.
* L3 : Voltage output warning light (work) red led.
Indicates the presence of output voltage.
* P1: Potentiometer for setting the welding current.
Allows you to continuously adjust the current both in TIG
and in MMA welding. This current stays unchanged when
the supply and welding conditions vary within the allowed
ranges. In MMA welding, the presence of HOT-START and
ARCFORCE means that the average output current may be
higher than that set.
* S1: welding selection key.
Permits selection of the welding procedure. Switch-on of
the led confirms the selection.
L4 on: electrode welding (MMA)
L5 on: TIG LIFT welding
* S2: measurements key.
Permits display of the welding current or voltage on D1.
Switch-on of the led near the symbol confirms the
selection.
* L1 : Voltage warning light green led.
Comes on with the start switch (Fig.4/5) "I1" in position "I"
and indicates that the plant is on and there is voltage.
10
* Display D1.
Shows the welding current or the value of the welding
parameter chosen with "E1" on the drawing "G1". This is
used to give alarm and error messages and to input the
setup parameters.
* E1 : Welding current, welding parameters and set-up
values setting encoder and key.
Allows you to continuously adjust the current both in TIG
and in MMA welding. This current stays unchanged when
the supply and welding conditions vary within the allowed
ranges.
In MMA welding, the presence of HOT-START and
ARCFORCE means that the average output current may be
higher than that set.
Allows you to change the value, shown on "D1", of the
parameter selected with "E1" on the drawing "G1".
Allows you to specify the required setup line and to vary
the value.
Permits access to the SETUP and welding parameter
values.
If "E1" is pressed at length, it permits access to the set-up
parameters.
If pressed for a short time, it selects in sequence the
welding parameters presented in the graph "G1" with value
shown by "D1" and variable with "E1".
I Welding current
HOT START % MMA, adjustable from 0 to 500% of I
ARC FORCE % MMA, adjustable from 0 to 500% of I
Switch-on of the corresponding led in the graph confirms
the selection.
* Set-up parameters.
By pressing "E1" for longer than 3s you access the set-up menu confirmed by a central "0" on the display "D1
By rotating "E1" the set-up line is varied, by pressing "E1" the required line is confirmed, by rotating "E1" the value is varied, by
pressing "E1" the value is confirmed, and so on.
If lines "9" and "99" are set and "E1" is pressed, all the set-up parameters go to the factory-set values.
To quit set-up and save the values set, return to the line “0” and press “E1”.
By pressing "E1" for longer than 3s in MMA operation, you access the following set-up values (Genesis 1700 RC):
11
5.2) FRONT PANELS GENESIS 1700TLH and
GENESIS 1700BLH
* L3 : Voltage output warning light (work) red led.
Indicates the presence of output voltage.
* S1: welding selection key.
Permits selection of the welding procedure. Switch-on of
the led confirms the selection.
L4 on: electrode welding (MMA)
L5 on: TIG 2-stage or timed (TIG TIMER) welding
L6 on: TIG 4-stage or Bilevel welding
In two-stage mode depression of the button causes the gas
to flow and activates the voltage on the electrode; when
the button is released the current goes to zero in the slope
down time; once the arc is switched off, the gas flows for
the postgas time.
* L1 : Voltage warning light green led.
Comes on with the start switch (Fig.6) "I1" in position "I"
and indicates that the plant is on and there is voltage.
* L2 : Safety device warning light yellow led.
lndicates that the safety devices like thermal cutout.
With "L2" on, the power source remains connected to the
supply mains, but does not supply output power.
"L2" 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.
"L2" is connected to the following alarm codes:
E01
Thermal alarm given by the NTC fitted on the
dissipator.
Automatic reset.
E03
Condensers thermal alarm (controlled at software
level).
Automatic reset.
E11
Machine not recognised. The machine locks out.
E20
IIC error. The 24C16 memory could be faulty.
Automatic reset*
E21
Loss of data or memory not initialised. Automatic
reset*
* Alarm displayed for 3 sec.
12
In four-stage mode initial depression of the button causes
the gas to flow, performing a manual pre-gas time; when
released, the voltage is present on the torch, striking the
arc and performing the weld. If the button is pressed again,
the current slope down begins; final release of the button
will start the post-gas time.
In TIG TIMER, which can be selected from set-up,
operation is similar to the 2T but the maximum welding
time is fixed from set-up. After this time the current slope
down begins.
In BILEVEL, which can be selected from set-up, the welder
can weld with 2 different currents: "I1" current set on
panel and "I2" set from set-up.
On first pressing the torch button, the pre-gas starts, the
arc strikes and the initial current will be used when
welding.
On first releasing it, the raising ramp of the welding current
"I1" occurs. If the welder now presses and releases the
button quickly, "I2" can be used; by pressing and releasing
it quickly again, "I1" is used again, and so on.
If you press the button for a longer time, the lowering
ramp for the current starts, thus reaching the final current.
By releasing the button again, the arc goes out and the gas
continues to flow for the post-gas stage.
* S2: TIG welding mode selection button.
Switch-on of the led confirms the selection.
L7 on: constant current TIG DC welding.
L8 on: pulsed current TIG DC welding (0.5Hz-20.0Hz,
default =4.0Hz).
L9 on: medium frequency pulsed current TIG DC welding
(20Hz-2500Hz, default =100Hz).
* Display D1.
Shows the welding current or the value of the welding
parameter chosen with "E1" on the drawing "G1". This is
used to give alarm and error messages and to input the
setup parameters.
* E1 : Welding current, welding parameters and set-up
values setting encoder and key.
Allows you to continuously adjust the current both in TIG
and in MMA welding. This current stays unchanged when
the supply and welding conditions vary within the allowed
ranges. In MMA welding, the presence of HOT-START and
ARC-FORCE means that the average output current may
be higher than that set.
Allows you to change the value, shown on "D1", of the
parameter selected with "E1" on the drawing "G1".
Allows you to specify the required setup line and to vary
the value.
Permits access to the SETUP and welding parameter
values.
If "E1" is pressed at length, it permits access to the set-up
parameters.
If pressed for a short time, it selects in sequence the
welding parameters presented in the graph "G1" with value
shown by "D1" and variable with "E1".
I =
f =
Td =
Welding current
Pulsing frequency (0.5Hz-20Hz, default=4.0Hz
for pulsed mode. 20Hz-2500Hz, default=100Hz
for medium frequency pulsed mode).
Current fall time (0.0s-10.0s, default 0.0)
Switch-on of the corresponding led in the graph confirms
the selection.
13
* Set-up parameters.
By pressing "E1" for longer than 3s you access the set-up menu confirmed by a central "0" on the display "D1".
By rotating "E1" the set-up line is varied, by pressing "E1" the required line is confirmed, by rotating "E1" the value is varied, by
pressing "E1" the value is confirmed, and so on.
If lines "9" and "99" are set and "E1" is pressed, all the set-up parameters go to the factory-set values.
To quit set-up and save the values set, return to the line "0" and press "E1".
By pressing "E1" for more than 3s in MMA mode you access the set-up values on p. 19.
By pressing "E1" for longer than 3s in TIG operation, you access the following set-up values:
Note: in TIG with the Genesis 1700, there are no Parameters in the set-up from 2 to 40.
14
5.3)REAR CONTROL PANEL
5.4) TECHINCAL SPECIFICATION
.
I1: Off/On switch
Turns on the electric power to the welder.
It has two positions, "O" off, and "I" on.
WARNING
*
*
With the I1 switch in the "I" on position, the
welder is operational, and gives a voltage
between the positive (+) and negative (-)
clamps.
The welder is connected to the mains supply
even if the I1 switch is in the "O" position, and
therefore there are electrically live parts inside
it. Carefully follow the instructions given in this
manual.
.
5.5) TRANSPORT - UNLOADING
* 1 : Supply cable.
* 2 : Gas socket for connection to bottle.
* C1: Military-type connector.
Never underestimate the weight of the
equipment,
see
technical
characteristics.
Never make the cargo pass or leave it
suspended 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.
5.6) INSTALLATION
Choose an adequate installation area
by following the criteria provided in
Section "1.0 SAFETY" and “2.0
ELECTROMAGNETIC COMPATIBILITY
(EMC)”.
Do not position the power source and
the equipment on surfaces with
inclination exceeding 10°
with respect to the horizontal plane.
Protect the installation from heavy
rain and sun.
The fan only starts once the system
has warmed up.
15
5.7) ELECTRIC CONNECTION TO THE SUPPLY
MAINS
The equipment is provided with a single electric
connection with a 2m cable positioned in the rear part of
the power source.
Size table of the power source input cables and fuses:
*: Fuses with a 25A rating are required to be able to carry
out 120A electrode welding continuously and to make
maximum use of the potential of the power source. 20 A
fuses are sufficient for welding, with a normal use factor
(40%), electrodes of 2.50, 3.25 and also 4.00 mm, as well
as for TIG welding at every intensity and use factor up to
80%.
-
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
provided 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.
Connection for TIG welding (Fig. 8)
- Separately connect the torch gas pipe connector to the
gas distribution.
The protection gas flow is adjusted
using the tap normally located on the
torch.
5.8) CONNECTING THE EQUIPMENT
COMPONENTS
Keep to the safety regulations contalned in
section “4.1.0 SAFETY”.
Connect the componente carefully, in order to
avoid power losses.
Connection for MMA welding (Fig.7)
The connection shown in the figure produces
reverse polarity welding. To obtain straight
polarity welding, invert the connection.
16
- Connect the gas pipe from the cylinder to the rear gas
inlet.
5.9) ACCESSORY– RC100 (Genesis 1700 RC/TLH)
The RC100 device is a remote control for display and
adjustment of the welding current and voltage.
Operation of the RC100 remote control is activated when
it is connectedto the connector on the Selco power
sources. This connection can be made also with the system
switched on.
When connected, the RC100 remote control will display
the current value set on the system control panel.
The RC100 remote control consists of:
* D1: 7-segment display for display of the main parameter.
* E1: adjustment encoder.
* L1: welding current pilot light: green led.
* L2: welding voltage pilot light: green led.
* L3: voltage output (work) pilot light: red led.
* 1: 6 m connection cable.
With the RC120 control connected, the power source
control panel remains enabled to perform any
modification.
* SET-UP
The following set-up parameters are specifically designed
for the RC120 control:
43
minimum current (pedal fully raised)
44
maximum current (pedal fully pressed)
RC200 remote control (G 1700 RC/TLH)
The RC200 device is a remote control that permits display
and variation of all the parameters available on the control
panel of the power source to which it is connected.
Operation of the RC200 remote control is activated when
it is connected to the connector on the Selco power
sources. This connection can be made also with the system
switched on.
When connected, the RC200 remote control will display
the same parameters as those selected on the system
control panel.
The RC200 remote control consists of:
* D1: LCD display for parameter display. A typical RC200
screen shows:
A. An icon to identify the parameter displayed.
B. The value of the parameter displayed with the
unit
of measurement.
With the RC100 control connected, the power source
control panel remains enabled to perform any
modification. The modifications on the power source
control panel are also shown on the RC100 control and
vice versa.
RC120 remote control (G 1700 TLH)
The RC120 device is a pedal remote control for
adjustment of the welding current.
When the pedal is pressed, the arc is switched on and the
welding current is adjusted.
The pedal adjustment range can be set from the set-up of
the power source connected to it.
Operation of the RC120 remote control is activated when
it is connected to the connector on the Selco power
sources. This connection can be made also with the system
switched on.
When the RC120 is connected, the system front panel will
display the minimum current set.
The RC120 remote control consists of:
* 1: adjustment pedal.
* 2: connection cable.
C. The actual welding voltage and current
measurements.
An example is given below:
* T1: Four buttons for selection and variation of the
welding parameters.
A. With the left and right buttons the parameters to be
modified and/or displayed are selected. The choice is
between the parameters that can be modified directly also
from the front panel (for example in TIG DC on the
Genesis 1700 TLH, the choice is between welding current,
slope-down and postgas). The left and right buttons are not
provided with autorepeat function.
B. With the up and down buttons the value of the
parameter selected is modified. The up and down buttons
are provided with autorepeat function at progressive
speed.
With the RC200 control connected, the power source
control panel remains enabled to perform any
modification. The modifications on the power source
control panel are shown also on the RC200 control and
vice versa. If the variation is made from the power source
control panel, after 5 seconds the system automatically
returns to display of the main parameter. This does not
happen in the case of variation from RC200.
17
* SET-UP
The following set-up parameters are specifically designed
for the RC200 control:
42 defines the variation step on up-down (default value: 1)
48 defines the buzzer tone (0-10, default value: 5)
49 defines the LCD display contrast
5.10) Possible faults in the MMA welding
SELCO TORCHES ST17 U/D - ST26 U/D (G 1700 TLH).
The Selco torches ST17 - ST26 version U/D (UP DOWN)
permit adjustment of the welding current directly from the
torch handgrip.
The handgrip features 3 buttons:
* P1: torch button.
* P2: "up" button (allows you to increase the welding
current).
* P3: "DOWN" button (allows you to reduce the welding
current).
The UP DOWN adjustments can be made either with the
arc switched off or during the various welding phases.
With the torches ST17 - ST26 U/D connected to the
power source, all the functions of the front panel and any
other remote controls connected remain enabled.
5.11) Possible faults in the TIG welding
5.12) Possible electrical failures
If you have any doubts or problems, do not hesitate
to consult your nearest technical service centre.
18
5.13) NECESSARY ORDINARY MAINTENANCE
Prevent metal powder from accumulating near the
aeration 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 pressure compressed air and soft bristel
brushes.
* Check the electric connections and all the
connection cables.
For the use and maintenance of the pressure
reducers, consult the specific manuals.
For the maintenance or replacement of torch
componente TIG, electrode holder and/or
earth cables:
* Check the temperature of the componente and make
sure that they are not overheated.
* Always use gloves in compliance with the safety
standards.
* Use suitable spanners and tools.
Note: Failure to perform said maintenance will
invalidate all warranties and exempt the manufacturer
from all liability.
19
6) DESCRIPTION OF THE BLOCK DIAGRAM.
Genesis 1700TLH – BLOCK DIAGRAM
a) Master switch.
b) Varistor
c) EMI input filter.
d) Input rectifier.
e) DC LINK capacitor.
f) Zero Voltage Switching Phase Switching Full Bridge Inverter.
g) Primary current transformer.
h) Power transformer.
i) Output rectifier.
j) Voltage doubler.
k) Shunt.
l) Output filter.
m) HF transformer (only for Genesis 1700TLH and 1700BLH).
n) HF striking unit (only Genesis 1700TLH and 1700BLH).
o) Switching auxiliary transformer.
p) Syncronization unit.
q) Inverter control unit.
r) Microprocessor unit.
20
6.1) INPUT FILTER.
WARNING
The single-phase power supply voltage 230Vac – 50/60Hz
is fed to the input filter board 15.14.371.
A varistor is inserted between the two phases, i.e. an
electronic component which when an instantaneous
voltage of a value higher than 275V appears on its
terminals, starts to conduct extremely quickly, absorbing
the peak current in order to limit the said overvoltage and
thereby protect the other parts of the machine.
This process is not destructive for the component if the
energy caused by the voltage peak is modest, as in the
case of lightning strikes. If however there is a high
overvoltage which lasts beyond a certain time, the varistor
is unable to withstand this energy and will burn out.
When accessing parts inside the machine, remember
that opening the circuit-breaker does not prevent the
danger of electric shocks.
Therefore:
IT IS ADVISABLE TO PULL OUT THE POWER PLUG.
This happens for example if the machine is mistakenly
connected to a 400Vac line voltage or after overvoltages
caused by generating sets with an inappropriate and
unstabilised output.
The filter circuit consists of passive components such as a
toroidal inductor and various capacitors, some of which
are earthed. The filter has the twofold job of keeping the
radio-frequency emissions of the machine within the
regulation limits and of making it immune to interference
from the power supply.
21
6.2)
RECTIFIER BRIDGE.
The rectifier bridge has the job of making the first power
conversion and in particular of making an AC/DC
conversion.
The sinusoidal input voltage is rectified by a Graetz bridge
rectifier which feeds a bank of smoothing capacitors.
Thus, the capacitor bank forms a DC LINK or a connection
between the rectifier stage and the inverter stage on which
a constant voltage difference is present.
The value of the DC LINK voltage can be easily calculated
by the following equation:
VBUS =
2 x Vac = 1.41x 230 =325Vdc
Therefore, a continuous voltage of 325V is present on the
bus.
The DC voltage thus obtained will be the input voltage for
the following inverter stage.
22
6.3) INVERTER STAGE.
The inverter stage is the second power conversion block.
This stage carries out the DC/AC conversion allowing an
AC voltage to be obtained at a frequency of 100 kHz.
The AC voltage is fed to the transformer primary. Since the
dimensions of the transformer are inversely proportional to
the frequency of the voltage applied, the fact of switching
at high frequency makes it possible to have transformers of
small dimensions and with lower magnetic losses
compared to the 50/60HZ mains frequency transformers.
The transformer, in addition to adapting the voltage and
current levels, also allows the galvanic insulation required
by the applicable regulations to be obtained between the
user and the mains.
The inverter provided by Selco for the Genesis 1700
machines is a resonant inverter of the Zero Voltage
Switching type. Therefore, the switchings of the electronic
switches are made when the voltage is nil, thus reducing
the switching losses and increasing the efficiency of the
system. The regulation of the output power is done by the
Phase Switching technique.
The inverter control is achieved by the microprocessor
which sends the signals to the driver board of the inverter
which controls the full bridge inverter.
23
6.4) OUTPUT STAGE
The AC voltage and current generated by the inverter stage
and supplied to the secondary are fed to a rectifier which
carries out the final AC/DC power conversion.
The power is now available for the welding process and is
filtered in order to give a voltage and/or current value as
close as possible to the ideal wave forms required by the
welding process
In the Genesis 1700TLH and Genesis 1700BLH models
there is a transformer for the high frequency and a suitable
HF board.
These devices have the job of generating a high frequency
arc in order to obtain more efficient striking of the arc.
24
6.5) AUXILIARY FEEDER
A switching feeder is used to generate all the voltage levels,
+24Vdc, +15Vdc, +12V, +5V, necessary to feed the
various electronic boards.
The feeder is supplied by the DC voltage of the DC LINK
and by means of a switching stage provides a stabilised
feed. Therefore, the output voltages are constant even in
the presence of variations, within certain limits, of the
input voltage.
25
6.6) TORCH CONTROL SIGNALS
The control signals coming from the torch:
UP = rise in current
DOWN = reduction in current
PT = torch push-button
follow the following route.
UP
DOWN
PT
GND
C
N
1
C
N
6
C
N
4
C
N
2
µC
Protezione
Protection
Filter Board
Main Board
Front Panel
By pressing the torch buttons (UP, DOWN or PT) the
corresponding signal is brought to the low logic level
(about 0V). The conductors of the external controls are
connected to connector CN1 found on the output filter
board 15.14.356.
The filter board connector CN1 is connected to the main
board connector CN6.
The control signals are not processed in the main board
but only pass through it, finishing on connector CN4. A
passive circuit is present on the main board (shown in the
figure with the name of Protection) which prevents
damage to the subsequent logic.
The main board connector CN4 is connected to the front
panel.
The front panel contains the microprocessor which reads
the control signals (UP, DOWN, PT) reaching connector
CN2, processes them and performs the necessary
operations.
26
7) WIRING AND CONNECTION DIAGRAM
27
28
29
8) DESCRIPTION OF DIAGNOSTIC INDICATIONS
For the meaning and use of the various controls, please refer to the respective user manuals; only the diagnostic indications are
described in this section.
8.1) External diagnostic indications of Genesis 1700
ALIMENTAZIONE
(POWER SUPPLY)
POTENZA DI
USCITA
(OUTPUT POWER
ENABLE)
ALLARME
(ALARM)
8.2) External diagnostic indications of Genesis 1700RC and BRC
ALIMENTAZIONE
(POWER SUPPLY)
POTENZA DI
USCITA
(OUTPUT POWER
ENABLE)
ALLARME
(ALARM)
8.3) External diagnostic indications of Genesis 1700TLH and BLH
ALIMENTAZIONE
(POWER SUPPLY)
ALLARME
(ALARM)
30
POTENZA DI
USCITA
(OUTPUT POWER
ENABLE)
The microprocessor present on the front panel board monitors the state of the equipment and informs the operator via the
LEDs and the display present on the front panel itself.
POWER SUPPLY LED (GREEN).
Indicates the on/off status of the machine. Always illuminated if the panel, and therefore the machine, is correctly supplied.
THERMAL + PROTECTIONS LED (YELLOW).
Indicates the equipment alarm status. Never illuminated unless a problem is present. The type of alarm is indicated by a code
on the display itself (see following table).
DISPLAY.
When switched on the generator performs an “AUTOTEST” during which the display indicates the size of the generator “170”
and immediately afterwards, the display briefly indicates the software version installed (e.g.: u01).
The display indicates the welding parameters requested by the operator (using the various buttons) and immediately afterwards
the striking of the arc is displayed, showing the true value of the current supplied.
When the yellow LED is illuminated, an error code (e.g. E00) appears on the display.
Indication
Type of error
heat
Action
E01
High
internal
temperature.
sink Leave the generator to cool. If the error persists: remove upper casing,
check fan, check NTC on main board.
E03
Generator overload with
reference to the planned
temperature cycle.
Leave the generator to cool.
If the error persists: disconnect and reconnect the machine and perform
a MASTER RESET*. If the error still persists: replace the main board
15.14.370
E11
Machine not recognised.
Check that the correct software version is installed. Check that the front
panel is being correctly supplied.
E20
Memory error
(flashes 10 times and then
disappears)
Disconnect and reconnect the machine and perform a MASTER RESET*.
If the error persists, the machine works but is no longer capable of storing
the changed parameters or of retrieving the last configuration used in
welding. Replace the main board 15.14.370.
E21
Data loss or memory not
initialized.
IIC memory damaged. Replace the front panel.
E41
Voltage out of range
[only Genesis 1700BLH]
The power supply voltage is not correct. Therefore check the
connections to the power supply and the value of the voltage between
ALT10 and ALT11.
*N.B.: to perform a MASTER RESET, refer to the procedure in the following section.
The optimum generator cooling is achieved by leaving the machine on TIG 2T with the torch button released (open circuit
voltage = 0Vdc).
31
9) SET-UP PARAMETERS
For the Genesis 1700RC, 1700TLH, 1700BRC and 1700BLH generators, microprocessor board 15.14.369 is present. The
settings on the front panel are incremented by those present within the SET-UP, which is accessed in the following manner:
Switch on the machine.
The machine performs an “AUTOTEST” during which only the green power supply LED remains illuminated, “170” is
shown on the display followed by the software version (e.g.: u01), and the machine is then ready according to the last
welding conditions set.
Select the type of process (MMA or TIG 2/4T) using the “PROCESS” button.
Press the “PARAMETERS” button for at least 3 seconds.
The display shows a “0”.
By turning the current encoder (knob on the panel), it is possible to set figures from “0” to “99” and by pressing the
“PARAMETERS” button it is possible to see the value of the associated parameter, as indicated in the following tables:
Param.
MMA PROCESS
Description/Meaning
Pre-set
0
Save changes and exit SET-UP.
-
-
1
Resetting of all the parameters up to 49 to the default value.
-
-
2
Selection of the type of electrode.
0
3
Hot Start added in percentage of the welding current
0 - 5*
(see table below)
0 – 500%**
4
Arc force added in percentage of the welding current
0 – 500%**
5
6
Arc extinction voltage.
0 – 99.9V
Anti-sticking enablement (if active, after a few moments of arc- 0 = inactive
force the machine goes to anti-sticking, otherwise it remains on 1 = active
arc-force).
57.0V
7
Arc-force entry threshold.
8.0V
PARAMETERS NOT USED
40
32
Range
Magnitude displayed during the welding.
42
Current rise/reduction step with the torch up/down.
43
44
48
Minimum current value with pedal raised.
Maximum current value with pedal fully depressed.
RC-200 buzzer frequency.
49
RC-200 LCD contrast.
0.1 – 99.9V
80%
30%
----0 = real current [A]
1 = real voltage [V]
2 = no
measurements
0 – 170A
0
1
3 – 170A
3 – 170A
0 - 10
3A
170A
5
0 – 15
12
---------
PARAMETERS NOT USED
-------
99
Resetting of all parameters (only use if errors persist on the
display - see sect. 6.2) [MASTER RESET].
-
-
*NOTE: Type of electrode in MMA welding.
Parameter value n° 2 in Type of electrode
MMA
0
1
2
3
4
5
basic
rutile
cellulose
stainless steel
aluminium
cast iron
** NOTE: In any case the maximum current output is limited to 170A both in MMA and in TIG.
TIG PROCESS
Description/Meaning
Param.
Range
Preset
0
Save changes and exit SET-UP.
-
-
1
Resetting of all parameters up to 49 to the default value.
-
-
2
PRE-GAS time
0.0 – 25.0s
0.1
3
Initial current in absolute value or in percentage of the welding
current [%]
Reference scale of the initial current, in absolute value [A] or in
percentage of the welding current [%]
Rise time
Welding current I2 in bi-level in absolute value or in percentage
of the welding current (also see parameter n° 7)
1-500
50
0=A
1=%
0.0 – 10.0s
1 -500
1
4
5
6
0.0
50
7
Current I2 reference scale in bi-level, in absolute value [A] or in 0 = absolute value (A).
percentage of the welding current [%] or disenabled.
1 = % of welding current I1
NOTE: the bi-level, when active, replaces the TIG 4T welding.
8
50
9
Back current in pulsed TIG and fast-pulse TIG in absolute value
1 - 100
[A] or in percentage of the current (also see parameter n° 9).
Reference scale of the back current in pulsed TIG and fast-pulse 0 = absolute value (A)
TIG in absolute value or in percentage of the welding current
1 = % of the welding
[%].
current I1.
10
Slow pulsed frequency. Also accessible directly from the panel.
0.5 – 20.0 Hz
4.0
11
Slow pulsed Duty Cycle.
20 – 80%
50
12
Fast pulsed frequency. Also accessible directly from the panel.
20 – 999Hz
1.00 – 2.5kHz
100
13
Descent time(s). Also accessible directly from the panel.
0.0 – 10.0s
0.0
14
Final current in absolute value or in percentage of the welding
current (see parameter n° 15)
Reference scale of the final current, in absolute value (A) or in
percentage of the welding current [%].
1 – 500
50
15
16
POST-GAS time. With 0s we have synergetic POST-GAS
whose time varies based on the d.c. current set. The
minimum is 1.6s and the time rises until it reaches 5.85s
at 170A.
0 = absolute value (A).
1 = % of the welding
current I1.
0.0 – 25.0s
OFF
1
1
SYN
33
17
Current reference during the HF striking.
18
Enables starting in TIG LIFT
19
Time-delay welding time (by setting 0.0s the machine works on
standard TIG 2T; by setting a time longer than 0, the TIG 2T is
replaced by “TIG timer”.
Enables/Disenables immediate re-starting if the Torch Button is
pressed during the descent time.
20
21
--------40
-
-
-
34
Easy joining time setting: after the start, for the given time,
pulsed welding is done with synergetic parameters. In bi-level
the time does not count, with control by the torch button.
PARAMETERS NOT USED
Magnitude displayed during the welding.
3 -170A
100
ON or OFF
OFF
0 – 99.9s
OFF
ON or OFF
ON
0.0 – 25s
OFF
-----------------------0 = real current [A]
1 = real voltage [V]
2 = no measurement
---------
PARAMETERS NOT USED
---------------------------
99
Resetting of all parameters (only use in case of persistent errors
on the display - see section 6.2) (MASTER RESET).
-
0
-
By rotating the knob on the panel it is possible to change the value of the parameter selected in the previous step; the
new value is confirmed when the “Parameters” button is pressed.
It can be seen from the table that some parameters do not really have an associated value: by selecting one of these
parameters and pressing the “Parameters” button, the associated operation is carried out (e.g.: by entering SET-UP,
selecting the “1” parameter and pressing the “Parameters” button, we return to the values set at the factory for all the
parameters).
Access is not allowed to the parameters labelled as “not used”; i.e. nothing happens when the “Parameters” button is
pressed.
To store the changes made to the parameters and to exit the SET-UP menu, return to parameter “0” and press the
“Parameters” button; otherwise, if the machine is directly switched off no changes will be stored in relation to the last
confirmed configuration of the parameters.
After exiting SET-UP, the machine returns to normal operation, possibly taking account of the configuration of the set
parameters.
10) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS, CURRENT
CALIBRATION
The normal working conditions of the boards making up the generator are illustrated in the following sections and the standard
values are given for the electrical parameters found at the main points of the boards themselves.
All the measurements indicated can be made with a digital multimeter.
It should be remembered that the first test to be performed is a VISUAL CHECK !
The visual check reduces the fault-finding times and guides any subsequent action towards the
damaged part !
In general, the points to be visually checked are:
- Input filter area
- Electrolytic smoothing capacitors
- Any traces of smoke found inside the casing
- Power and signal connections
- Overall state of the boards.
WARNING
Unless otherwise specified, before making any of the measurements described below on the Genesis 1700TLH and
Genesis 1700BLH, disconnect the HF circuit (FN1 & FN2 on board 15.14.311, inside the TLH module).
WARNING
When the machine is connected to the mains, the main circuit-breaker is live, independently of its position (open or
closed) ! Therefore, it is advisable to pull out the power plug before touching anything inside the generator !
It is also necessary, because of the possible presence of capacitors charged to a high voltage, to wait for about one
minute before being able to work on the internal parts !
35
10.1) Input filter PC board 15.14.3714
(GENESIS 1700,1700RC, 1700TLH)
DESCRIPTION
This board contains a varistor to protect the EMC filter circuitry, the smoothing capacitors and the slots for the connection of
the HF board against power surges.
INSTRUMENTS REQUIRED
- Visual analysis
- Multimeter with tip for microfit
BOARD
Functional part
Component
Supply voltage
Generator/
Mode
ON
DC Link
ON
-
-
Test Point
ALT11 ↔ ALT22
+V ← -V
Value
230Vac + 15%
Type of
measure
Note
V
325Vdc + 15%
V
HF board supply
ON
-
NOTE: * HF board disconnected:
Electrolytic capacitors have a 470µF capacity.
36
CN2/2 ← CN2/4
325Vdc + 15%
V
*
10.2) Input filter PC board 15.14.37141
(GENESIS 1700BLH, 1700BRC)
DESCRIPTION
This board contains a varistor to protect the EMC filter circuitry, the smoothing capacitors and the slots for the connection of
the HF board against power surges. Unlike board 15.14.3714, this input filter board is mounted on the BI-LEVEL generators
and has a suitable capacitive BUS.
INSTRUMENTS REQUIRED
- Visual analysis
- Multimeter with tip for microfit
BOARD
Functional part
Component
Test Point
Value
Supply voltage
Generator/
Mode
ON
-
ALT11↔ ALT22
230Vac + 15%
DC Link
ON
-
+V ← -V
Type of
measure
Note
V
325Vdc + 15%
V
HF board supply
ON
-
CN2/2 ← CN2/4
325Vdc + 15%
*
V
NOTE: * HF board disconnected:
Electrolytic capacitors have a 2200µF capacity.
●
●
Soldered jumpers K1 and K3 must be OPEN
Soldered jumper K2 must be CLOSED.
37
10.3) Main PC board 15.14.370
DESCRIPTION
The following circuits are present on this board:
Auxiliary power supply.
Input rectifier bridge.
Power inverter.
Output rectifier.
INSTRUMENTS REQUIRED
Set of fillet-head screwdrivers
Set of pipe spanners for hexagonal nuts
Multimeter
BOARD
L1
+V
-V
CN2
CN3
L2
P+
ALT10
ALT20
PTC1
L3
Rectifier
Bridges P
PTC2
L4
PCN5
CN6
CN7
L5
38
L6
L7
L8
Gate Resistance
Functional part
Generator/
Mode
Component
Test Point
Input Voltage
ON
-
ALT10 ↔ALT20
DC Link
ON
-
+V ← -V
325Vdc
Gate Restistance
OFF
ON
R110
R130
R161
R169
L1
-
4.7kohm
4.7kohm
4.7kohm
4.7kohm
ON
ON
L2
L3
L4
L5
-
ON
ON
ON
ON
In MMA
L6
-
ON
In MMA
L7
-
ON
In MMA
L8
-
ON
In MMA
-
CN2/1 ← CN2/2
+15Vdc
Supplies voltage
Inverter driver*
Fan supply
Rectifier bridge
PTC**
ON
OFF
OFF
Value
Type of
measure
230Vac + 15%
ALT10 ← P+
0.4V
ALT20 ← P+
0.4V
P- ← ALT10
0.4V
P- ← ALT20
0.4V
V
Ω
V
When the
fan is ON
and with
connector
connected.
Measured at
25°C
PTC1
PTC1/1↔ PTC1/2
75ohm
Ω
PTC2
PTC2/1↔ PTC2/2
75ohm
Ω
Ω
NTC
OFF
-
CN5/1 ↔ CN5/2
12kohm
SHUNT
ON
SH
CN7/2 ← CN7/1
0V @ 0A
25mV @ 50A
45mV @ 100A
80mV @ 170A
Open circuit
ON
Output terminals
+ ← +85Vdc+ 5Vdc
voltage
Notes:
* In MMA mode. If you are in TIG mode the LEDs are ON when you press the torch button.
** In 15.14.3702 board the two PTC are sobstitued form two 47Ω resistances.
Relay
Note
Measured at
25°C
V
V
MMA mode
Pre load Resistance
PCB of 15.14.3702 board
*** All the measurements can suffer a variation of + 10%.
39
ISTRUZIONE D’USO DEI KIT
(Sostituzione del diodo secondario e monoscheda
Genesis 1700, 1700RC, 1700TLH, 1700BRC, 1700BLH).
ATTENZIONE
COMPONENTI SENSIBILI ALLE SCARICHE
ELETTROSTATICHE!
OGNI VOLTE CHE SI SMONTA LA
MONOSCHEDA DAL DISSIPATORE,
SOSTUIRE L’INTERFACCIA TERMICA CON
UNA NUOVA.
Istruzioni sostituzione diodo secondario
1. Rimuovere la scheda filtro monoscheda
15.14.370.
2. Rimuovere i connettori della monoscheda,
compresi i flat del pannello frontale, le
connessioni del trasformatore e dell’NTC.
3. Togliere le viti S4,S5,S6,S7 di fissaggio modulo di
potenza e le viti S1, S2, S3, S8, S9, S10, S11 ,S12
ed S13 di fissaggio scheda di potenza.
4. Rimuovere il diodo secondario, senza smontare
le barre rame del trasformatore, sarà sufficiente
allargarle.
5. Rimuovere l’interfaccia termica del modulo di
potenza. (ATTENZIONE: Non riutilizzabile).
6. Pulire adeguatamente con solvente sia il
dissipatore che il modulo di potenza della
scheda.
7. Mettere del grasso termico* sotto il nuovo diodo
e montarlo sul dissipatore, ricollegando anche le
barre rame e facendo attenzione al verso di
montaggio.
8. Fissare le viti tra diodo e dissipatore e tra diodo e
barre rame con una coppia di 1.7Nm.
9. Evitare di toccare l’interfaccia termica a mani
nude, usare i fogli di protezione in dotazione.
10. Verificarne l’integrità* (ATTENZIONE: UNA SUA
PIEGA PREGIUDICA L’AFFIDABILITA’ DELLA
RIPARAZIONE!)
11. Appoggiare l’interfaccia termica sul dissipatore
senza i due fogli di protezione.
12. Spalmare pasta termica sotto i due ponti a diodi.
13. Rimontare la monoscheda fissando per primo il
modulo di potenza usando le quattro viti in
dotazione viti
S5,S6,S9 ed S10 (solo
improntandole leggermente).
14. Poi improntare tutte le altre.
15. Serrare le viti del modulo di potenza con una
coppia di 2.2Nm.
16. Serrare le altre viti tolte precedentemente
con una coppia di 2Nm, ricollegare i flat
precedentemente disconnessi e l’NTC.
40
INSTRUCTIONS FOR USE OF KITS
(Replacement of secondary rectifier diode Genesis
1700, 1700Rc, 1700TLH, 1700BRC, 1700BLH).
CAUTION
-
COMPONENTS SENSITIVE TO
ELECTROSTATIC
WHENEVER YOU DISSAMBLE THE
MAINBOARD FROM DISSIPATOR,
REPLACE THE THERMIC INTERFACE
WITH A NEW ONE!
To replace the secondary diode.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Remove the filter board of mainboard
15.14.370.
Remove the connector from the mainboard,
including the flat connector of the front panel,
the transformer connections and NTC
connection.
To remove the power module screws S4, S5, S6,
S7 and the S10, S11, S12 and S13 card fasting
screws.
remove the secondary diode, without
disassembling the transformer copper bars, it will
be sufficiently widen them.
Remove the thermic interface of the power
module (CAUTION: NOT RE-USABLE).
Thoroughly clean the dissipater and the
mainboard power module with solvent.
Apply thermic grease* below the new diode and
fit it on the dissipater, also reconnecting the
copper bars and ensuring correct assembly
direction.
fasten the screws between diode and dissipator
and between diode and copper bars with torque
of 1.7Nm.
Avoid touching the thermic interface with your
bare hands: use the protection sheets provided.
Check that the thermic interface is in perfect
condition* (CAUTION: IF FOLDED, THE REPAIR
WILL NOT BE RALIABLE!).
Rest the thermic interface on the dissipator
without the two protection sheets.
Spread thermic paste on the dissipator without
two protection sheets.
Refit the main board, first fixing the power
module using the four screws provided S5, S6,
S9 and S10 (only tightening a bit).
Bit other screws.
Tighten the power module screws with a torque
of 2.2Nm.
Tighten the other screws with a torque of 2Nm
and reconnect the flat and NTC.
41
T1
T2
T3
T4
Flat 1
Flat 2
S13
S1
S12
S2
S11
S3
S10
S9
S8
NTC
S7
S4
S5
Sensore di corrente
Current Sensing
42
S6
AVVERTENZE
1)
2)
3)
a)
Rimuovere le viti S1,S2,S3,……..,S13.
Non togliere le torrette T1, T2, T3 e T4,
La scheda mandata in riparazione deve avere i
flat, i ponti a diodi, modulo di potenza e le
quattro torrette T1, T2, T3 e T4.
ATTENTION
1)
2)
3)
Remove the screws S1, S2, S3,…..,S13
Not remove the tower T1,T2,T3 and T4.
The board sends in repair must have flat, bridge
rectifier, power module and four tower T1, T2,
T3 and T4 connected.
Montaggio ponte a diodi ( Assemble bridge recitfier)
Posizionare i ponti a diodi nelle ferritoie della scheda e
spalmarci la base con il grasso termico.
Applicare l'interfaccia termica sul dissipatore centrandola
ai fori.
Set the bridge rectifier in their location and spread the
base of bridge rectifier with thermic grease.
Apply the thermic interface on the dissipator hit their
location.
Nota: Le schede che vengono spedite in riparazione
devono aver i ponti a diodi montati, il modulo di potenza
e le torrette. Utilizzare imballi adeguati per il trasporto
Note: The board sent in repair must be with bridge
rectifier connected., the power module and the tower.
You use adequate packages for the transport.
43
b)
Montaggio Scheda Snubber (Assemble Snubber Board).
c)
Inserire il cavo primario corto del trasformatore attraverso il sensore di corrente.
(Insert the short primary conductor across the current sensor).
Far passare il primario cavo corto del trasformatore
attraverso il sensore e fissarlo al morsetto.
Fissare l'altro primario e fascettare.
44
Insert the short primary conductor across the current
sensor and fix it on the terminal.
Fix another primary conductor and wrap it.
10.4) PC board for Genesis 1700 front panel 15.14.385
DESCRIPTION
Logic board with signalling and setting functions.
INSTRUMENTS REQUIRED
Set of fillet-head screwdrivers
Multimeter
NOTE
It is recommended, for a correct diagnosis, to remove the front panel and to connect it externally to the connectors. Be
especially careful not to create short-circuits.
BOARD
Functional part
Generator/ Mode
Component
Test Point
Value
Type of
measure
Supply voltage
ON
-
CN2/11← CN2/12
+5Vdc
Supplies voltage
ON
L1
-
ON
Green LED
ON
L3
-
ON
Output voltage
present
Note
V
* Note: All the measurements can suffer a variation of + 10%.
45
10.5) PC board for Genesis 1700TLH, Genesis 1700BRC, Genesis 1700BLH and Genesis 1700 front
panel 15.14.369
DESCRIPTION
Microprocessor board with monitoring and display functions. Receives the UP, DOWN and PT signals and unblocks the output
power.
INSTRUMENTS REQUIRED
Set of fillet-head screwdrivers
Multimeter
NOTE
It is recommended, for a correct diagnosis, to remove the front panel and to connect it externally to the connectors. Be
especially careful not to create short-circuits.
BOARD
46
CN2/1
CN1/1
CN4/1
Note: Once the front panel has been removed, the operator will have the soldered side of the front panel 15.14.369 shown in
the figure in front of him. Make the measurements on this side, being especially careful not to create short-circuits with the tips
of the multimeter.
47
Functional part
Supply voltage
Supply voltage
UP*
Generator/ Mode
Component
Test Point
Value
ON
-
CN1/2 ← CN1/1
CN2/11 ←CN2/12
CN4/1←CN4/2
+5Vdc
+5Vdc
+15Vdc
Note
Type of
measure
V
ON
L4
-
ON
Green LED
ON
L5
-
ON
MMA mode
ON
-
CN2/18 ← CN2/2
+5Vdc
V
0Vdc
UP button
released
UP button pressed
V
DOWN**
ON
-
CN2/19 ← CN2/2
+5Vdc
0Vdc
PT
ON
-
CN2/20 ←CN2/2
+5Vdc
V
V
V
0Vdc
DOWN button
released
DOWN pressed
PT button released
PT button pressed
V
Inverter power
unlocking
ON
-
CN2/16 ←CN2/2
+0.7Vdc
V
+5Vdc
+0.7Vdc
MMA mode
TIG mode.
Torch button
released
V
TIG mode.
Torch button
pressed
Notes:
*Check that every time the UP button on the torch is pressed, the current value shown on the display rises.
** Check that every time the DOWN button on the torch is pressed, the current value shown on the display decreases.
*** All the measurements can suffer a variation of + 10%.
48
10.6) HF Board 15.14.286
DESCRIPTION
This board generates a series of high voltage pulses which are used for remote arc striking in the TIG AC and DC processes.
INSTRUMENTS REQUIRED
Multimeter
BOARD
Welding module configuration (set at the factory, the module is found on the soldered side of the board):
Soldered jumpers (factory setted): K1 = OPEN
Note: In the machine produced before 2003 K1 is CLOSED.
49
Functional part
Generator/
Mode
Component
Test Point
Value
OFF
MF3
S ← D
+0.4Vdc
S ←G
10kohm
D10
A ← K
+0.5Vdc
V
S1
G ← K
13ohm
Ω
D1
A← K
+0.5Vdc
D2
A←K
Auxiliary
supplies
HF output
OFF
Type of
measure
Note
Ω
+0.5Vdc
Supply voltage
ON
---
TP7 ← TP6
+400Vdc
V
V16
Auxiliary
transformer
HF command*
ON
L1 = ON
TP6← TP2
+19Vdc
V
V17
L2 = OFF
CN1/2←CN1/4
L2 = ON
0Vdc
V
+3Vdc
V
Torch button
released
Last 2sec with torch
button pressed**
*WARNING! Before making this measurement, disconnect the HF circuit (FN1 & FN2) in order to prevent damage to people
or things due to HF discharges!
** Notes: The control signal (+3Vdc) lasts for about 2 sec. after the torch button is pressed, but only if the arc is not struck. If
an output current is established during these 2 seconds, the signal is immediately cut off. Therefore this test is conducted
without striking the arc, holding the torch in the air.
ADVICE to help to make the measurements:
CN1 can also be reached from the soldered side of the HF board.
Power Supply
Fuse
V16
-
High Voltage power supply for HF and Overimposition board
V17
-
HF board internal auxiliary supply
***: All the measurements can suffer a variation of + 10%.
50
Related Circuit
10.7) Doubler Board 15.14.330
DESCRIPTION
This board doubles the output voltage in order to optimise the dynamic arc control and to ensure excellent striking of the arc
under any welding conditions.
INSTRUMENTS REQUIRED
Set of the pipe spanners for hexagonal nuts.
Multimeter.
BOARD
Functional part
Generator/ Mode
Component
Diodes
OFF
D1
D2
A
A
←
←
K
K
0.4V
0.4V
D3
A
←
K
0.4V
D4
A
←
K
0.4V
ON
---
Test Point
PZ4 ← PZ1
Value
85V + 5V
Type of
measure
Note
V
Note: All the measurements can suffer a variation of + 10%.
51
10.8) Snubber Board 15.14.350 and secondary diode test
DESCRIPTION
Snubber board for secondary diodes.
INSTRUMENTS REQUIRED
Set of fillet-head screwdrivers
Multimeter.
BOARD
Functional part
Diodes
Secondary diodes
Generator/
Mode
OFF
OFF
Component
Test Point
Value
D1
A ← K
0.5V
D2
A ←K
0.5V
-
PZ2 ← PZ1
0.3V
PZ3 ← PZ1
0.3V
Note: All the measurements can suffer a variation of + 10%.
52
Type of measure
Note
10.9) Output filter board and UP, DOWN , PT buttons 15.14.356
DESCRIPTION
This board performs a filtration for EMC purposes on the secondary and also filters the button control against any interference
due to the HF.
INSTRUMENTS REQUIRED
Set of fork spanners
Set of pipe spanners for hexagonal nuts
Multimeter
BOARD
Functional part
Supply voltage
Generator/
Mode
Component
Test Point
Value
ON
-
CN2/2←CN2/1
+24Vdc
Type of measure
Note
V
Note: All the measurements can suffer a variation of + 10%.
53
10.10) Input Voltage Doubler Board 15.14.426
DESCRIPTION
This microprocessor board receives the 230Vac or 115Vac mains input voltage. If the input voltage is 115V, it doubles it so
that there is a DC link voltage of 325Vdc.
INSTRUMENTS REQUIRED
Set of fork spanners
Set of pipe spanners for hexagonal nuts
Multimeter
BOARD
PZ3
L1
Functional part
MF1
Generator/
Mode
ON
Component
Test Point
Value
-
PZ1↔PZ3
230Vac*
LED power supply
ON
-
-
ACCESO
MOSFET
OFF
MF1
S ←D
0.5V
S ←G
0.6V
Supply voltage
Note: All the measurements can suffer a variation of + 10%.
54
PZ1
Type of
measure
V
Note
* 115Vac in
dual voltage
case
10.11) TIG Torch board15.14.3581
DESCRIPTION
This board is installed on TIG torch and it have UP, DOWN e PT button.
INSTRUMENTS REQUIRED
Set of fillet-head screwdrivers
Multimeter
BOARD
Functional part
PT – Torch button
Generator/
Mode
ON
Component
Test Point
Value
SW1
PZ1←PZ4
+5Vdc
0 Vdc
UP button
ON
SW2
PZ2←PZ4
+5Vdc
0 Vdc
DOWN button
ON
SW2
PZ3←PZ4
Type of
measure
V
V
V
V
+5Vdc
V
0Vdc
Note
Button
released
Button pressed
Button
released
Button pressed
Button
released
Button pressed
V
Note: All the measurements can suffer a variation of + 10%.
55
11) SPARE PARTS LIST.
56
57
58
59
60
61
12) NOMINAL DATA
62
63
Selco s.r.l. – Via Palladio, 19
35010 Onara di Tombolo(Padova) – Italy
Tel. +39 049 9413111 – Fax. +39 049 9413311
e-mail: info@selcoweld.com
64