Repair Manual Genesis 502-Gb(1)

REPAIRS MANUAL ENGLISH

Genesis 502 GSM(TLH/PME)

Cod. 92.08.017 Edition: 01/00

SELCO s.r.l.Via Palladio, 1935010 ONARA DI TOMBOLO (Padova) ItalyTel. 0499413111Fax 0499413311

INDEX :

1) GUARANTEE CONDITIONS . . . . . . . . . . . . . . . . . . .762) PURPOSE OF THE MANUAL . . . . . . . . . . . . . . . . . .773) MACHINE TECHNICAL SPECIFICATIONS . . . . . . . .774) DESCRIPTION OF MACHINE PARTS . . . . . . . . . . . .785) DESCRIPTION OF MACHINE OPERATION . . . . . . .83

LAY-OUTS OF CARDS . . . . . . . . . . . . . . . . . . . . . . .115

6) DESCRIPTION OF DIAGNOSTIC INDICATIONS : . .132- EXTERNAL - INTERNAL

7) AVAILABLE SPARE PARTS . . . . . . . . . . . . . . . . . . . .1348) WARNINGS, PRECAUTIONS, GENERAL

INFORMATION ON EXECUTING REPAIRS . . . . . . .1379) DIAGNOSTIC AND REPAIR INSTRUMENTS

AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13710) DIAGNOSIS PROCEDURE : . . . . . . . . . . . . . . . . . . .138

- LEVEL 1- LEVEL 2

11) PARTS DISMANTLING AND RE-INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

12) OPERATING TESTS AND SETTINGS . . . . . . . . . . . .14613) TELEPHONE ASSISTANCE

REQUEST PROCEDURE . . . . . . . . . . . . . . . . . . . . .148

1) GUARANTEE CONDITIONS.

To specify the present warranty conditions , we remind thatSELCO does not repair under warranty the damages a) resulting from attempts by personnel not allowed by SELCO

to install, repair or service the products b) resulting from improper use or connection to incompatible

equipmentc) in products that have been modified or integrated with other

products when such modification or integration can be thecause of the failure.

76 Guarantee conditions

2) PURPOSE OF THE MANUAL

The purpose of this manual is to provide authorised technical ser-vicing centres the information required for repairing Genesis 502GSM (TLH and PME) .To avoid serious damage to people and things, this manual mustbe used strictly by qualified technicians.What is involved in a repair job?: identifying the faulty part - asthis part is included in the list of available spare parts - andreplacing it according to the procedures described below.If an electronic card is faulty, repair entails replacing the cardand not replacing the faulty electronic component on the carditself.We suggest two diagnosis procedures on two levels: at the firstlevel, simple initial action instruments/tools are used, at the se-cond level, more sophisticated instruments/tools are used. Level two obviously ensures a quicker, surer diagnosis.

Purpose of the manual - Machine technical specifications 77

TECHN.CHARACT.

Power supply voltage(50/60Hz)Max. absorbed power(x=60%)Max. absorbed currentDelayed fuses 500VEfficiencyPower factorMMA/TIG welding current (x= 60%)(x=100%)MIGwelding current (x= 60%)(x=100%)Adjustment rangeDC MMADC TIG DC MIGNo-load voltageProtection degreeInsulation classConstruction standards

GENESIS 502 GSM

3x400V +10% -15%

23.2kW

41.9A40A0.870.80

500A400A

500A400A

6A/20V-500A/40V6A/10V-500A/30V

15A/15V-500A/39V

90VIP23H

EN60974-1EN50199

GENESIS 502 PME

3x400V +10% -15%

23.2kW

41.9A40A0.870.80

500A400A

500A400A

6A/20V-500A/40V

15A/15V-500A/39V

90VIP23H

EN60974-1EN50199

3) MACHINE TECHNICAL SPECIFICATIONS .

78 Description of machine parts

4) DESCRIPTION OF MACHINE PARTS.

4.1) Power source G 502 GSM consists of the following parts:(see fig. 1-2-3-4) :

a) input filter card (15.14.202)b) ON switch (I1)c) contactor (TEL1)d) pre-loading resistance (R1)e) rectifier bridge (P1, P2 and P3)f) voltage levelling capacitors (C1 , C2 and C3)g) power inverter h) IGBT driver card (15.14.218)i) power inverter control and protection circuits card

(15.14.201)j) control logic card (15.14.149)k) resonance inductance (L1)l) power transformer (T1)m) secondary rectifying circuit and snubber card (15.14.223)n) welding current transducer (Hall effect sensor) (HALL)o) output filter (15.14.174)p) welding current levelling inductance (L2)q) fansr) auxiliary transformer (AUX1)s) front panel (FP91 - FP111 - FP62 - FP73)t) H.F. transformer (HF)u) H.F. discharge generation card (15.14.192)v) TIG gas solenoid-valve (ELV)

Parts t), u) and v) are not supplied with the PME (FP108 orFP136) version as the TIG H.F. function is not present.

In the multi-function version (FP62 or FP73) and PME (FP108 orFP136), in addition to the preceding circuits, the following isalso supplied:

w) interface card with wire feeder (15.14.162)

In the version with robot interface ( FP73), in addition to thepreceding circuits, the following is also supplied:

x) auxiliary transformer for FP73 (AUX2)

Operating principle. Power passes through the following stages:a first AC/DC conversion by the input rectifier bridge (e), anadditional DC/AC conversion at high frequency effected by theinverter (g), transfer by isolating transformer (I) to the output cir-cuits and, finally, a last AC/DC conversion by the output rectifier(m). An arc sparking circuit in TIG with high voltage pulse (t) isprovided.

c) e) f) g) l)

k)

m) n)

o)

p)

t)u)w)

j)

a)

b)

q)

h)d)

r)

s)

i)

FIG. 1 - G 502 GSM (multi-function version)

Description of machine parts 79

s)

FIG. 2 - G 502 GSM (TLH version)

s)

x)

FIG. 3 - G 502 GSM (multi-function version with robot interface)


s)

FIG. 4 - G 502 PME (PME version)

Description of machine parts 81

WF103 wire feeder


4.2) The WF103 wire feeder consists of the following parts (seefig. 5):

a1) Gearmotor unit with encoder b1) Motor control card (15.14.147)c1) Front panel FP60 (15.14.148)d1) Reed sensor card (15.14.173)e1) Auxiliary transformer for WF103f1) MIG gas solenoid valve (EV)

NOTE : The previous drawing also shows the optional card82.08.087 and the optional connector J12 (complete withcables n. 19 - 20) for using the push-pull torch.

a1)

d1)c1)

e1) f1)

b1)

FIG. 5 - WF103 wire feeder

Description of machine operation 83

5) DESCRIPTION OF MACHINE OPERATION.

5.0) General methods explainedUnless otherwise specified, when a measurement is taken be-tween a pair of terminals, e.g. a-aa, it is understood that the redprobe (or the oscilloscope probe) is placed on the left terminal(on a in this example), whereas the black probe (or the groundlead of the oscilloscope) is placed on the right terminal (on aain this example).

FIG. 6

In the figures, when an arrow is shown between two measuringpoints, the tip indicates where to place the red probe (or theoscilloscope probe), whereas the black probe (or the oscillosco-pe ground wire) is placed at the other end. The connector terminals are indicated with the name of theconnector itself, followed by a bar and the terminal number;e.g. CN1/2 is terminal 2 of connector CN1.

When measuring a signal on the pins of the integrated circuits,the latter are numbered as follows:

84 Description of machine operation

5.1) Input filter card (15.14.202) (a) (see fig. 7)

Supply voltage 3 x 400 Vac is applied to the terminals of card15.14.202 (a) (see fig. 8) , which contains the mains over-volta-ges suppression circuit, consisting of three varistors (see note 1)and the radio-noise suppression circuit (see note 2) connected toground. The PE terminal of the card, to which the yellow-green powercable is connected, is electrically connected to the machinesmetal parts, both via a yellow-green cable and via a metalcolumn.

IMPORTANT ! : When the machine is connected tothe mains, the filter card is powered, irrespective ofthe position of the power switch. We, therefore,advise you to unplug the power plug before acces-sing the machines internal parts.

NOTE 1 : If the electrical component know as a varistor is pla-ced between the two power supply phases, when an instanta-neous voltage in excess of 460 V appears on its terminals, thevaristor very rapidly becomes conductive, absorbing a currentpeak which is sufficient to limit the said over-voltage and it thusprotects the other parts of the machine.This process has no destructive effect on the component if theenergy generated by the voltage peak is low, as in the case ofatmospheric lightning strikes. If, however, over-voltage is highand prolonged, the varistor cannot dissipate this high energyand blows. This happens if, for example, the machine is wrongly connectedto 460 Vac mains voltage, or following over-voltage caused bynon stabilised power units of inadequate capacity.

NOTE 2 : The radio noise suppression circuit has two purposes:to keep the machines radio frequency emissions within limitsspecified by standards and to ensure machines immunityagainst the same type of problems caused by any electronicdevices connected to the same power supply source.The filter consists of a network of capacitors, some of which aregrounded, and two toroidals inductors.

c) e)

a)

b)

d)

FIG. 7


FIG. 8 (card 15.14.202)


5.2) On switch (b) - contactor (c) - pre-loading resistor (d). (seefig. 9)

The three power phases at output of card 15.14.202 (400 Vacbetween cables n 1 , 2 , 3) are switched by contactor (c). Voltage obtained from the only two phases (400 Vac betweencables n 1 , 2), used to power the control circuits and the auxi-liary devices, is switched by the power switch (b). When the power switch is ON, the contacts of contactor L1-T1e L2-T2 are short-circuited respectively by cables n 1 - 40 andby cables n 2 -00 - 22 - the latter in series with the pre-loadingresistors (d) (= two 100 Ohm in series).As immediately after the machine is powered-up the contacts ofthe contactor stay open for a certain time (a few seconds), thebank of levelling capacitors C1 and C2 is pre-loaded through theabove circuit .The contactor coil is commanded by 230 Vac supplied by the auxi-liary transformer (the coil is switched by the power switch contactand by a triac fitted on card 15.14.201 as shown in fig. 10) . At the end of pre-loading, card 15.14.201 commands thepower contactor to close, and therefore, 0 V is measured at theends of the contactor coil during pre-loading, and 230 Vacafter pre-loading.

IMPORTANT ! : When accessing the internal partsof the machine, remember that opening the onswitch does not mean that the risk of electricalshocks is avoided. We, therefore, advise you tounplug the power plug.

c) e)

a)

b)

d)

FIG. 9


c) e) f) g)

j)

a)

b)

q)

h)d)

r)

i)

FIG. 10


5.3) rectifier bridge (e) - voltage levelling capacitors card (f). (see fig. 11)

When the contactor is closed, the 3-phase supply voltage isapplied to the rectifier bridge (400 Vac between cables n 40 ,22 , 33), consisting of three integrated modules (see fig. 12),with its output (+ = cable n 5 , - = cables n 6) connected tothe bank of capacitors laid out in two groups of 2 capacitors inseries with each other.When the machine is in open circuit status, the voltage recti-fied at the ends of the above capacitors (between cable n. 5(+) and cable n. 6 (-) is levelled at 560 Vdc (= 400 Vac x 2),whereas when the power source is at full load, the voltage hasa 300 Hz ripple, (see fig. 13). The voltage on each capacitor is half the value of the rectifiedvoltage (between + and -).

c) e) f) g)

a)

b)

h)d)

FIG. 11


FIG. 12

FIG. 13


f) g) l)

k)

m) n)

o)

p)

t)

h)

FIG. 14

5.4) power inverter (g) - driver card of IGBTs (h) - power invertercontrol card (i) - resonance inductance (k) - power transformer (l)- welding current transducer (Hall effect sensor) (n) . (see fig. 14)

The direct voltage at the terminals of the voltage levelling capa-citors is applied to the power inverter. The inverter consists of two IGBT power modules, each housingtwo IGBTs as shown in the diagram in fig. 15. By using a mul-timeter set for the diode test, and referring to the previousfigure, you can check all the connections of the four IGBTs,obtaining

C - E = OPENE - C = 0.4

and using a multimeter set to Ohm :B - E = 10 kOhm

(however, even if this test is positive, the inverter may never-theless by faulty).Card 15.14.218 generates the command signals to the powerIGBTs; the signal shown in fig. 16 (power source set to MMAand without output load) is obtained between the four pairsof small cables on the left. The frequency of these signalsvaries according to the current supplied by the power sourceand is in the range from approximately 47 kHz at low load to30 kHz at maximum load.

IMPORTANT ! : While current is supplied at theoutput of the power source, we advise you to mea-sure the command signals of the power IGBTs.

IMPORTANT ! : The measuring instrument must notbe grounded (see chapter 9).

IMPORTANT ! : If one of the IGBT modules fails,card 15.14.218 must also be replaced simulta-neously.

The voltage between the Collector and Emitter of the powerIGBTs connected between ~ and - is shown in fig. 15 (do not takethis measurement on the IGBTs connected between + and ~). Important: the signal of the module on the top is different fromthe one on the bottom .Card 15.14.181, also houses the switch-off circuit consisting oftwo auxiliary IGBTs and two diodes cooled by a radiator. Fig. 15shows how to check the connections of the switch-off IGBTs,by using a multimeter set for the diode test :

C - E = OPENE - C = 0.4

and using a multimeter set to Ohm :B - E = 22 Ohm

(however, even if this test is positive, the inverter may by faulty).The command to the auxiliary IGBTs is supplied by 15.14.218;the signal shown in fig. 16 is measured between two pairs ofsmall cables on the right (power source set to MMA andopen circuit at output).


The overall effect of a correctly operating switch-off circuit is togenerate a voltage signal between the Collector and Emitter ofthe IGBTs of the top module, with soft slope-up and slope-down(not steep as in the case of the bottom module). The powerinverter control card 15.14.201 regulate the welding currentaccording to the current reference it receives from card 15.14.149(reference signal = 1V in TP8 or in CN2/13 of card 15.14.149,means that welding current request = 100 A; ground = TP2 -see fig. 17) and the current supplied by the power source recevedfrom the Hall sensor (signal from Hall sensor = 1 V in CN1/2 ofcard 15.14.201 means 125 A supplied ; ground = CN1/3 seefig. 18) .The signal received from the Hall sensor is amplified and trans-mitted to card 15.14.149.Moreover, card 15.14.201 provides the Hall sensor with thefollowing supply voltages:

CN1/4 + 15 Vdc CN1/1 - 15 Vdc

both measured with respect to CN1/3 (ground) .The power inverter output consists of an inductive-capacitiveload and a power transformer. The capacitors are fitted on thecard 15.14.205 , whereas inductance L1 is located at the frontof the machine.Power transformer T1 transfers power to the output circuits.The current supplied on the above load can be measured onTP3 of card 15.14.201 indicated in fig. 18 ; (the signal at theindicated point is actually rectified current).The ground is easier to obtain on the stabiliser indicated in fig. 18.The wave shapes for power transformer current are shownbelow for the following cases:

(NOTE : when examining the preceding wave shapes, remem-ber that they may be affected by electromagnetic noise of va-rying intensity).Card 15.14.201 checks the level of the rectified voltage, at theterminals of the voltage levelling capacitors (inverter sectioninput voltage) by sending to the control logic card (15.14.149)either an overvoltage alarm signal if the value exceeds approxi-mately 670 Vdc, or an undervoltage alarm signal if the value isbelow 440 Vdc. The previous values correspond respectively to about 470 Vacand 310 Vac of mains power. A voltage value in excess of thepermissible limits must continue for a few seconds to trip thealarm. The above mentioned signals can be obtained in TP2 (overvol-tage alarm) and TP1 (undervoltage alarm) from card15.14.201 (or in CN2/2 and CN2/3) :

9.5 (+/-1)V if alarm is NOT active (see note)0 if alarm is active.

(ground on card 15.14.201)

Further, the following triacs are fitted on the card :- power supply to power source fan (SVP)- power supply to cooling unit (SCHUKO rear

socket) (SWCP)- contactor coil command (STP)

These circuits operate as follows (see fig. 19) .When the machine is powered up, the control logic card(15.14.149) sends to card 15.14.201 the command for powe-ring the triacs supplying the fans and the cooling unit (+5Vdc =ON respectively in CN2/6 and in CN2/7 of card 15.14.201; 0= OFF) . As a result, the following must be obtained in MMA :

0 Vac between terminal T1 of power switch (cable n 23) and CN4/9 of card 15.14.201 (cable n 03) with the cooling unit ON

and

230 Vac between terminal T1 of power switch(cable n 23) and CN4/1 of card 15.14.201 (cable n 04)

in TIG or MIG :230 Vac between terminal T1 of power switch(cable n 23) e CN4/9 of card 15.14.201 (cablen 03) with the cooling unit ON

and

230 Vac between terminal T1 of power switch(cable n 23) e CN4/1 of card 15.14.201 (cablen 04)

When changing over from TIG or MIG to MMA, the cooling unitis immediately turned OFF. If no welding is done for five minutes while TIG or MIG is selec-ted, the commands to the cooling and fan units are cancelled.Furthermore, card 15.14.201 commands the coil of the powercontactor a few seconds after the machine is powered up (230Vac between the terminals of the contactor coil, i.e. betweencables n 4 and 9 at end of pre-loading time).

welding I 0 A50 A250 A500 A

Fig. 18AFig. 18BFig. 18CFig. 18D


FIG. 15

FIG. 15A FIG. 15B


FIG. 16 (Card 15.14.218)

FIG. 17 (Card 15.14.149)

FIG. 16A FIG. 16B FIG. 16C


FIG. 18A FIG. 18B

FIG. 18C FIG. 18D

FIG. 18 (Card 15.14.201)

c) e) f) g)

j)

a)

b)

q)

h)d)

r)

i)

FIG. 19

TP3 (current flowing in theprimary winding of the powertransformer) :


5.5) Control logic card (j) (see fig. 20)

The main purpose of the control logic card is to generate thecurrent reference signal for the power inverter control card, byprocessing the information for the welding parameters acquiredoutside. This information is received from the following, according tosystem configuration:

A - RC10/RC08 (front panel FP62 or FP73)B - front panel FP91/FP111/FP108/FP136

Case A : Received data include those that can be set on the key-board. Transmission is effected digitally through the two opticfibres connected to the connectors of fig. 22 (blue terminal toblue connector; grey terminal to black connector) and to J20(see fig. 21). If RC08/RC10 fails to receive or receives incor-rectly, it displays the alarm message. This can occur also if themicroswitches of card 15.14.149 are incorrectly configured (seefig. 23). (See NOTE 1) .Case B : Received data include those that can be set on thepanel. Transmission is effected digitally via the flat cable con-nected to CN6 on15.14.149.If FP91/FP11/FP108/FP136 fails to receive or receives incor-rectly, it displays the alarm message. This can occur also if themicroswitches of card 15.14.149 are incorrectly configured (seefig. 23).

Moreover, other information can be received from remote con-trols if operation with external reference is selected :

- RC16/RC12 (front panel FP62 or FP91 or FP111)

- RC07 (with WF103 wire feeder, wire bundle and interface card 15.14.162)

In the case of RC16, the received data is the welding currentreference in MMA or TIG (with the external reference selectedon RC10/RC08 or on front panel FP91 or FP111); in the case ofRC12, the welding start signal is received in addition to the cur-rent reference. The current reference (analog signal in valuerange of 0 to 5 Vdc) and the start signal (relay contact OPEN=OFF, CLOSE = ON) are received via the flat cable connectedto CN6 of card 15.14.149. The value of requested current andthe information on the presence of the start signal are transmit-ted for display from 15.14.149 to RC08/RC10 or to front panelFP91 or FP111, as the case may be.The card also supplies 5 Vdc power for the potentiometers insi-de RC16 and RC12. This 5 Vdc can be measured directly onthe connector of the front panel between points A and B.The data received via RC07 are the wire speed reference andthe correction of welding voltage level in MIG (with the exter-nal reference selected on RC10/RC08). The data, acquired from the wire feeder, are transmitted firstlydigitally via two optic fibres of the cable bundle and, later, viathe connection, inside the machine, between the connector(J23 on the machine rear panel - see fig. 21) and card15.14.162 (blue terminal to blue connector, grey terminal toblack connector).Further, card 15.14.162 performs switching of the 42 Vacpower for the wire feeder, through a relay. When operating in MIG, 42 Vac is measured between cablesn 43 (fuse-holder terminal) and n 45 (connector CN2 ofcard 15.14.162; this voltage is measured at the same condi-tions also between terminals C and E of the connector if fuseF2 = 6.3 A is OK.

t)u)w)

j)

s)

i)

FIG. 20


The main power supplies of the card are measured as followswith respect to TP2 (= ground) (see fig. 22) :

TP5 = +15VdcTP12 = -15VdcTP1 = +5Vdc

The current reference processed by card 15.14.149 is measu-red on the TP8 of the card itself (1V = 100A), with respect toTP2 (ground).The power release signal is measured between pin 8 of inte-grated circuit IC15 and TP2 (0= power cut out; 5 Vdc =power released).When the power is released the card commands, lighting of LEDL3 on the front panel.The 15.14.149 card also measures welding voltage for the follo-wing purposes:in MMA :

- hotstart function (current increase at first impact of electrode on piece)

- arc-force function (increase of current at short-circuit of electrode on piece)

- anti-stick protection function (if the short-circuit at the previous point continues)

in TIG (lift) :- current limitation when electrode short-

circuitedin TIG (h.f.) :

- current increase following sparkingin MIG :

- adjustment of welding average voltage

and, in general, display of arc voltage on RC or on the frontpanel.Therefore, with the power source set to MMA, voltage ofapproximately 80 Vdc should be measured between cablesn 72-73 of connector CN5. When the machine is configuredto multi-function or PME, the card receives also voltage outputby WF103 to take a more accurate measurement, taking intoaccount the voltage drop on the cable bundle (electrical conti-nuity between the Binzel MIG connector of the wire feederand CN5/11 of card 15.14.159 = cable n 46).Card 15.14.149 also measures welding current, obtaining thesignal from card 15.14.201 for the following purposes :

- display of welding current on RC or front panel- processing of the "arc present" signal for the

robot interface panel (contact between R-S terminals of connector FP73)

- protection if current level exceeds the maximumspecified level for a few tenths of a second.

Other outputs of the card:- h.f. discharge command to card 15.14.159

(see par. 5.8)- command of TIG solenoid-valve (24 Vac between

output cable n 24 of the transformer and cable n 26, terminal CN7/5, of card 15.14.149)

- fan command to card 15.14.201 (see par. 5.2)- cooling unit command to card 15.14.201

(see par. 5.2)

Card inputs :- signal coming from the pressure switch (CN5/2

= 0 with respect to TP2 if pump is operating)for control of the cooling liquid shortage alarm(see Note 2)

- overvoltage and undervoltage signals coming from card 15.14.201 for control of the relevant alarms

- thermal protection signal coming from the threeovertemperature detection devices one on the radiator of the inverter and two of the output rec-tifier, connected in series. This signal is taken to card 15.14.218 (CN2), goes through it and reaches pc-board 15.14.149 via the flat cable connected to CN2.

Another important function of the card is to galvanically isolatethe signal coming from the TIG torch push-button. The following are present between CN4A/3 and CN4A/4:

24 Vdc when push-button is released 0 when push-button is pressed

NOTE 1 : Functional verification of an optical fibre cable is verysimple: expose one end to a flashing light (e.g. a lamp with itsbeam interrupted by waving a finger over the end of the opticalfibre) and check the brightness variation at the other end.

NOTE 2 : The signal coming from the pressure switch (through4-pole connector J35 on rear panel FP71, see fig. 21) indicatesthe presence of pressure in the hydraulic circuit, but not if aliquid flow is also present (a flowmeter would be necessary todo this).Of the two contacts, the N.O. (normally open) contact is the oneused and therefore :open contact = pressurised circuitclosed contact = non pressurised circuit


FIG. 21

FIG. 22 (Card 15.14.149)

f) g) l)

k)

m) n)

o)

p)

t)u)

connectionwith thecable bundle

w)j)

h)

s)

i)


FIG .23 - PROGRAMMING OF DIP-SWITCHES FOR CARD 15.14.149 FOR THE GENESIS GSM SERIES

GENESIS 502 GSM with FP91/FP111(version TIG DC)

GENESIS 502 GSM with FP62 or FP73 without kitfor connection of WF103(version TIG DC with RC08, RC10 or SW SELCO)

GENESIS 502 GSM with FP62 or FP73 with kit forconnection of WF103 (code 74.04.003)(MULTI-FUNCTION version with RC08,RC10 orSW SELCO)

GENESIS 502 PME with FP136 (FP108)


f) g) l)

k)

m) n)

o)

p)

h)

FIG. 24

5.6) secondary rectifying circuit and snubber card (m) - outputfilter (o) - welding current levelling inductance (p) (see fig. 24)

The secondary rectifying circuit, which serves to convert tran-sformer output current into direct current, consists of twogroups of three modules (see fig. 25). Each group, connected toa terminal on the power transformer, rectifies the correspondingcurrent half-wave. The snubber card consists of a diode-capaci-tor-resistance circuit (see fig. 25) , and serves to protect the diodes. The levelling inductance improves continuity of welding current.The output filter consists of both a resistive-capacitive circuit fit-ted to card 15.14.174 and capacitors connected directly be-tween the + and - output terminals of the power source. Themain purpose is to prevent the h.f. discharge from entering thepower source and help starting of the electrical arc. The voltage feedback signal received by card 15.14.149 is alsoobtained from card. 15.14.174 via cables n 72-73.


FIG. 25


5.7) Auxiliary transformer (r ) (see fig. 26)

This is used to generate voltages supplying systems auxiliary cir-cuits (fan, etc.) and the electronic cards, commencing from theinput voltage of 400 Vac.Fuse F1 (4A, 250V), accessible from the machine rear panel,protects the transformer itself. 230 Vac is generated by the primary winding and, therefore, itis not isolated with respect to mains voltage. It powers :

- the fan (when commanded by the control logic)- the cooling unit (when commanded by the

control logic)- the H.F. discharge generation card (CN2/1 -

CN2/4)- the contactor (when commanded by the

control logic)

The 42 Vac transformer secondary winding (for powering thewire feeder when commanded by the control logic) is protectedby fuse F2 (6.3 A, 250V), accessible from the machine rearpanel.

j)

q)

r)

FIG. 26


5.8) H.F. transformer (t) - H.F. discharge generation card (u) (see fig. 27)

The H.F. discharge generation circuit (card 15.14.192) and theH.F. transformer create a set of high voltage pulses (several thou-sand volts) to spark the TIG H.F. welding arc. These pulses, generated commencing with the 230 Vac presentbetween CN2/1 - CN2/4 (cables n 0 - 23) , begin when the cardreceives - in CN1 - the command supplied by card 15.14.149 andare repeated until the current is sparked and, in any event, for nolonger than a maximum time of approximately 3 s.The command signal measured between CN1/1 - CN1/2 is ofapproximately 4 Vdc.During H.F. discharge on card 15.14.192, the signal (points S1-A,S1-B in fig. 28) is present at the ends of the thyristor.

f) g) l)

k)

m) n)

o)

p)

t)u)w)

j)

h)

s)

i)

FIG. 27


FIG. 28 (Card 15.14.192)


5.9) Fan (q) - TIG gas solenoid-valve (v) (see fig. 29)

The two fans, powered on 230 Vac single-phase (when comman-ded by the control logic, see paragraph 5.4), thrusts air from thefront to the rear of the machine.The solenoid-valve, powered on 24 Vac (when commanded bythe control logic) also has a gas flow direction as shown by thearrow on the valve body.

c) e) f) g)

j)

a)

b)

q)

h)d)

r)

FIG. 29


t)u)w)

j)

s)

i)

FIG. 30

s)

FIG. 31


s)

x)

FIG. 32

s)

FIG. 33


5.10) Front panel (s) - auxiliary transformer for FP73 (x)(see fig. 30-31-32-33)

FP91 - FP111 (see fig. 31) : FP 111 is the latest development of the FP91 panel.These are local interfaces for MMA - TIG machines and, therefore, enable the operator to view/modify welding data (they have noadjusting function).There is, however, an exception to the above: data received from RC12 or RC16 transit only through the panel and are acquireddirectly by the control logic card (15.14.149) which returns the data to the panel, for display purposes, in digital form by a 40-wayflat cable. The settable parameters are listed in the following table (FP111):

The procedure used and the set parameters are stored in the memory, recalled and controlled when the machine is powered up.If they are found to be altered during control, the card shuts down the machine and displays the alarm.The panel is powered by 12 Vac (cables n 94 - 95 of CN2) auxiliary transformer and internally generates +5Vdc, the presenceof which is signalled by a green LED on the front panel.

FP108 - FP136 (see fig. 33) : FP136 is the latest development of the FP108 panel.These are local interfaces for MIG - MMA machines and, therefore, enable the operator to view/modify welding data (they have noadjusting function).The settable parameters are listed in the following table (FP108-FP136):

The procedure used and the set parameters are stored in the memory, recalled and controlled when the machine is powered up.If they are found to be altered during control, the card shuts down the machine and displays the alarm.The panel is powered by 12 Vac (cables n 94 - 95 of CN2) auxiliary transformer and internally generates +5Vdc, the presenceof which is signalled by a green LED on the front panel.

FP62 (see fig. 30) : data coming to and from RC10 or RC08 (connected to the connector on the right) and those coming from RC12or RC16 (connected to the connector on the left) transit only through the panel and are acquired or transmitted directly by the con-trol logic card (15.14.149) .This also applies to data transmission to and from the PC, via the 9-way connector located at the top (RS232). The welding programof RC10 or RC08 can be updated via this connector.Power supplied by the auxiliary 12 Vac transformer (cables n 94 - 95 of CN2) is transferred to pins C and E of the connectorat the right, to supply RC08/RC10.

predef.0.0500.0100

60.241000.240.08

handgrip80

handgrip5011

minmax

ParameterPre-gas timeInitial currentIncrease time tuWelding current IBack current IbPulse time tpFrequency tp & tbBack time tbDecrease time tdFinal current IfPost-Gas timeHot-StartArc-ForceBilevel I2 currentSelect remote controlSelect bilevelI minI max

ums%sAAs

HzssAs%%AnnAA

min0.02

0.066

0.0220

0.020.06

0.0006

66

max25.020010.0maxmax2.005002.0010.0max25.0100100max

maxmax

NoteIt can be set from setup onlyPercentage on the welding current, setup only

Pulsed and fast pulsePulsed only In fastpulse only, repr. by leds Tpulse and TbackPulsed only

Combined with the only potentiometer provided knobMMA, settable from setup onlyMMA, settable from potentiometerConstant current only, setup only0=RC12 1=RC16 only setup0=2T 1=4TRemote control adjustment Remote control adjustment

ParameterHot-StartArc-ForcePost-Gas timeInitial increased percentage Crater filler percentage Select synergetic curveSoft Start percentage InductanceBurn Back timeWire speedSynergetic voltage offsetWelding voltage in manual mode

predef.80

handgrip2

10080S015050

0.061

handgriphandgrip

um%%s%%n%%s

m/min.VV

min000

2020S0110120.01

-9.85

max10010010

200200P30100100

122

+1055.5

NoteMMA, It can be set MMA, It can be set from potentiometerIn MIG, only setupOnly setupOnly setupIn MIGIn MIGIn MIG SHORTIn MIGIn MIGIn sinergyc MIG


FP73 (see fig. 32) : The notes regarding FP62 apply here with the exception of what was said concerning the connector on the left.The following applies to this connector:

DIGITAL SIGNALS

NOTE : The following should be considered for the signals below:J4 = J1 = J3 = 2-3 or J4 = J1 = J3 = 1-2

IMPORTANT : All eight programs should first have been stored.

In the first case C = closed, A = open

In the second case C = closed, A = open

ANALOG SIGNALS

Pin conn.

R-S

"J-K

"

A-F

"B-F

"C-F

"D-F

"

IN/OUT

OUT

"OUT

"

IN

"IN

"IN

"IN

"

Type

Relay contact"Relay contact"

Relay contact"Relay contact"Relay contact"Relay contact"

Jumper

J8

"J7

"

J2

"J4

"J1

"J3

"

Config. jumper2-3

1-22-3

1-2

2-3

1-22-3

1-22-3

1-22-3

1-2

State

contact closed when arc sparked

contact open when arc sparkedcontact closed when RC10 indicates alarm and LED L2 is lighted

contact open when RC10 indicates alarm and LED L2 is lightedon panelLED L3 lighted on panel when contact closed

LED L3 lighted on panel when contact openSelected program number.See Note.""

""

"

B - FACACACAC

C - FAACCAACC

D - FAAAACCCC

Program12345678

B - FCACACACA

C - FCCAACCAA

D - FCCCCAAAA

Program12345678

Pin conn.

T - V

U - V

Signalrange0 - 10/24Vdc

0 - 10/24Vdc

Setting potentiometerP1

P2

Effect

Min to MAX variationof speed reference onRC10Min to MAX variationof voltage referenceon RC10


WORK PIECE PRESENCE SIGNAL

Note: the function is enabled

The front panel is powered on 5 Vdc by card 15.14.149.It is also powered on 24 Vac (CN3/1 - CN3/2) and 20 Vac (CN3/3 - CN3/4) by an auxiliary transformer installed only in the caseof FP73.The panel generates 24 Vdc which can be measured at the appropriate point in the figure 34, and 24 Vdc which can be chec-ked between + and - of the power source output when the piece search function is enabled.Power supplied by the auxiliary 12 Vac transformer (cables n 94 - 95 of CN2) is transferred to pins C and E of the connectorat the right, to supply RC08/RC10.

Diagrams for remote commands RC07, RC12 and RC 16 are shown below.

Pin conn.

N-P

"

IN/OUT

OUT

"

Type

Relay contact"

Jumper

J9

"

Config. jumper2-3

1-2

State

contact closed when out + and - of the power source areshort-circuited. See Note.contact open when out + and - of the power source areshort-circuited. See Note.

Pin conn.

G-F

"

IN/OUT

IN

"

Type

Relay contact"

Jumper

J6

"

Config. jumper2-3

1-2

State

when the contact is closed, the piece search function is enabled

when the contact is open, the piece search function is enabled


FIG. 34 (Card 15.14.190)

FIG. 35

Electrical diagram RC07



PEDAL

POTENTIOMETERCONNECTOR


a1)

d1)c1)

e1) f1)

b1)

FIG. 36

5.11) Gearmotor unit with encoder (a1) - motor control card(15.14.147) (b1) - Reed sensor card (15.14.173) (d1) - MIG gassolenoid-valve (f1) (see fig. 36)

Card 15.14.147 receives the command from MIG torch push-button (push-button ON = 0 V , push-button OFF = 35 Vdcbetween CN3/9 - CN3/10 of card 15.14.147; cables n 3 - n.4).It transmits the command to the power source and receivesfrom it the start signal and speed reference digitally through twooptic fibres connected to J4 (fig. 37) and to the connectors infig. 38 (blue terminal to blue connector; grey terminal to blackconnector). The cable bundle, also supplied with two opticfibres, effects connection between the wire feeder and powersource. (For a functional check of the optic fibres, see note 1 atpoint 5.5).The card internally generates voltages 5 Vdc , +15 Vdc , -15Vdc which can be measured at the points indicated in fig. 38(with respect to ground). Card 15.14.147 controls motor speed, at all times comparingthe speed reference with the encoder feedback signal. Theencoder is powered by 15.14.147 (5 Vdc between cables n 21- n 20 (= ground) and supplies variable frequency signal inlinear manner according to speed (at 11m/min 2,6kHz , see fig.38A ; at 22m/min 5,2kHz see fig. 38B between cables n 19- n 20 (= ground).The voltage supplied by the card to the motor terminals(cables n 22 - n 23) is about 17,5Vdc at 11m/min, andabout 35Vdc at 22m/min (without wire feeding), and is gene-rated commencing with 42 Vac supplied by the power sourcevia the cable bundle.

The card receives - via the serial line of front panel FP 60 - thespeed reference and the arc voltage correction set by RC07 (onRC08/RC10, if the outside reference is selected) and transmitsthese data to the power source.The power source, in turn, transmits them to RC08/RC10 fordisplay. It receives also the following commands from front panel FP60 :- wire feed (pin 11 of IC8 integrated circuit) :

push-button OFF = +5 Vdc push-button ON = 0 )

- gas test (pin 2 of IC6 integrated circuit) : push-button OFF = +15Vdc push-button ON = 0 )

Furthermore, it receives the current ON signal from card15.14.173 (the following are measured at the ends of theglass ampoule :

+5 Vdc = wire feeder not supplying current0 = wire feeder supplying current )

which is used for soft-start control (see NOTE).The card directly commands the MIG gas solenoid-valve (com-mand ON = 24 Vac; command OFF = 0 between CN3/7 -CN3/11 ; cable n 5 - cable n 6) .It supplies, to the push-pull torch auxiliary card, the commandsynchronised with the start of the gearmotor unit (36 Vac be-tween cables n 13 - 15 when the gearmotor is operating andthe push-pull torch is connected).

NOTE : Soft-start operating mode can be clearly verified if youset it at 20-30% value and press the torch push-button a fewseconds after the end of the previous welding operation, if any.With the power source in open circuit state (no welding), thesoft-start value is maintained for five seconds, and speed thenchanges to the set value.

connection withthe cable bundle(rear part of WF103)


FIG. 37

FIG. 38

FIG. 38A FIG. 38B


d1)c1)

b1)

FIG. 39

5.12) Front panel FP60 (15.14.148) (c1) (see fig. 39)

Its function is to convert into digital form the speed referenceand voltage correction received from RC07, and to galvanicallyisolate the digital signal by means of the opto-isolators andtransmit it via serial line to card 15.14.147.(Remember that the value set with RC07 can be read on the dis-play of RC08/RC10, if the outside reference is selected).The card generates 5 Vdc for powering its own internal circuitsand the potentiometers of RC07 (5 Vdc between pins A-B ofthe connector).The gas test and wire feeder push-buttons are also located onthe panel.


a1)

e1) f1)

FIG. 40

5.13) Auxiliary transformer for WF103 (e1) (see fig. 40)

It supplies power to the cards commencing from 42 Vac recei-ved from the power source via the cable bundle. It also supplies 36 Vac to 15.14.147 for powering the push-pulltorch.

LAY-OUTS OF CARDS

116 Lay-outs of cards

Card 15.14.201 side A (Fig. 41)

Lay-outs of cards 117

Card 15.14.201 side B (Fig. 41)


Card 15.14.201 side C (Fig. 41)


Card 15.14.213 side A (Fig. 42)


Card 15.14.213 side B (Fig. 42)


Card 15.14.202 (Fig. 43)


Card 15.14.181 (Fig. 44)


Card 15.14.192 (Fig. 45)


Card 15.14.149 side A (Fig. 46)


Card 15.14.149 side B (Fig. 46)


Card 15.14.149 side C (Fig. 46)


Card 15.14.149 side D (Fig. 46)


Card 15.14.147 side A (Fig. 47)


Card 15.14.147 side B (Fig. 47)


Card 15.14.148 side A (Fig. 48)


Card 15.14.148 side B (Fig. 48)

132 Description of diagnostic indications

Fig. 49

6) DESCRIPTION OF DIAGNOSTIC INDICATIONS.

6.1) Diagnostic indications external (see fig. n 49)

Whatever the front panel, it has three indicator-lights (red) withthe following diagnostic functions :

Further explanations of the above: GREEN LED: This LED lights if +5Vdc is present on card

15.14.149 .

Therefore, if the machine is connected to the mains

and if the master switch is closedand if the power circuits of card 15.14.149

are operating

then the green LED is on

Vice versa if the green LED is off

then either the machine is not connected correctly to the power mainsor the master switch is openo or the circuits powering card 15.14.149 are not operating

YELLOW LED : This LED is OFF when the machine is opera-ting normally. When it is on, it indicates that an alarm is trip-ped thus cutting off current supply from the machine. Thealarm which may be tripped are as follows (for their mea-nings, consult the machine functional description) :

Status under normal conditionsON

OFF

LIGHTED with voltage at output

Meaning

Machine poweredand master switchclosedProtection deviceNOT activeAlways lighted inMMALighted in TIG bet-ween 1T and 2T(in 2T) or between2T and 3T (in 4T)

Code (see note)(FP91/FP111/FP108/FP136)00 11121516192022

Alarm full description(RC08/RC10)

Communications interruptedCoolant shortagePower module overtemperatureOvervoltageUndervoltageOvercurrentData memory errorCommunications error

Position

L1

L2

L3

Color

GREEN

YELLOW

RED

Description of diagnostic indications 133

Therefore if 00

then either the 40-way flat cable connection tocard 15.14.149 is not correctly fitted (FP91/PF111/FP108/FP136)or the optic fibres are interrupted (section inside the power source or cable RC08/RC10)or card 15.14.149 has failed

Therefore if 11

then or the power source is not supplying power to the cooling unitor the pump has failedor water cooling level is too low

Therefore if 12

then or the machine has exceed the work cyclelimitsor the fan has failedor air flow is obstructed from the outsideor the thermal devices are faulty

Therefore if 15 or 16

then either the power supply has exceeded thepermissible limitsor the contactor is not closingor the rectifier bridge has failed or card 15.14.201 has failed

Therefore if 19 (01 in case of FP108)

then either overly high welding parameters were selectedor card 15.14.201 has failed

Therefore if 20

then the front panel (FP91/FP111/FP108/FP136) has failed

Therefore if 22

then either the microswitches of card 15.14.149are not configured correctlyor the 40-way flat cable for connection to card 15.14.149 is not correctly fitted

RED LED : Lighted when the machine supplies voltage at out-put.Therefore - the LED is always lighted in MMA.- in TIG :

if the torch push-button was pressedand if 24 Vac are present between CN4A/1 and CN4A/2

on pc-board 15.14.149 (the torch push-button un-coupling relay transmits the command and the control circuits are operating)

and if card 15.14.149 has failed

then the red LED is lighted between 1 T and 2 Tin TIG 2T or between 2T and 3T in TIG 4T .

Vice versa if the red LED is OFF

then either the torch push-button is not closing thecontactor there is no electrical continuity in the cables coming from the torch push-buttonor 24 Vac are not present between CN4A/1 and CN4A/2 on pc-board 15.14.149or card 15.14.159 has failed

- in MIG :if the torch push-button was pressed

and if if WF103 transmits the command to the optic fibre cables of the cable bundle

and if if the optic fibres of the cable bundle and insidethe power source are not interrupted

and if card 15.14.149 is functioning

then the Red LED is lighted between 1 T and 2 Tin MIG 2T or between 2T and 3T in MIG 4T .

Viceversa if the red LED is OFF

then either the torch push-button is not closing the contactor there is no electrical continuity in the cables coming from the torch push-button or WF103 fan has failedor the optic fibres of the cable bundle andinside the power source are interruptedor card 15.14.149 has failed

134 Available spare parts

7) AVAILABLE SPARE PARTS : power source .(see TAB. 01)

NOTES : In the exploded view drawing, spare parts with num-bers 026, 030, 031, 032, 060 cannot be supplied separately,but are part of set 061, which is supplied as a single unit.On the contrary the parts identified by n. 029, 057, 062 can beprovided separately.For power components, also order 16.03.102 (thermal paste).

TAB. 01

SPARE PARTS GENESIS 502 GSM

001 Socket 08.26.009002 Delayed fuse 6x30 6.3A 250V 08.25.220

Delayed fuse 6x30 4A 250V 08.25.215003 Fuse carrier 08.25.250007 Solenoid valve 09.05.001009 Wirings 49.02.745012 Rear plastic panel 01.04.251013 Assembled rear panel 01.05.216014 Fan PAPST7450 07.10.010016 Handle support 20.04.002017 Handle 01.15.012018 Upper cover 03.07.034020 H.F. card 15.14.192021 Remote control switch 09.02.010022 Resonant filter 500A 15.14.202025 Resonant logic card 15.14.201027 30F condenser 600MKF 13.03.020029 Diode bridge 14.10.152033 Antivibration foot 21.04.005034 Lower cover 01.02.055035 Filter out card 15.14.174036 H.F. transformer 05.03.015038 Resonant inductor 05.04.212040 Leveling inductor 05.04.213041 Switch 09.01.008042 Inverter transformer 05.02.012043 Microprocessor card 15.14.149044 Toroidal transformer 05.11.565045 Capacitor 12.06.110

046 Secondary unit 14.60.055047 Hinode sensor 11.19.003048 Front plastic panel 01.04.253049 Assembled front panel 01.04.252051 Centralized adaptor 19.06.005052 Fixed socket 10.13.020053 Knob 09.11.009054 Plug 10.01.151055 Front control panel FP62 74.04.005057 Secondary filter unit 15.14.223061 Primary inverter group 14.60.054062 Diode 14.05.076

Available spare parts 135

TAB. 02

AVAILABLE SPARE PARTS : WF 103 wire feeder . (see TAB. 02)

NOTE 1 : The current version of pieces 015 , 016 and 022 hasa 10 mm diameter pin, whereas the diameter was 8 mm on theprevious version. In the second case, all three pieces must bereplaced.

SPARE PARTS WF103 WIRE FEEDER

002 Solenoid valve 09.05.001005 Plug for special connector 10.01.150006 Fixed plug, 70 mm2 10.13.054007 Connection, 3/8, bevelled,

with rubber holder 19.50.022008 Ring nut for connection 3/8 19.50.013010 Panel, plastic, rear 02.02.018011 Rear panel 02.02.020012 Panel, side, right 02.04.065013 Slide closure 20.04.036015 Swivelling wheel 04.06.003016 Lower cover 02.04.067017 Rin nut 20.02.006018 Reel for coil 20.02.003019 Handle support 20.04.002020 Handle 01.15.002021 Upper cover 02.04.068022 Motor card 15.14.147023 Reed sensor card 15.14.173024 Panel, side, left 02.04.066025 Auxiliary transformer 05.11.056026 Gearmotor, 120W, 4 rollers

with encoder 07.01.013027 Tip 19.01.015028 Tip, gas, axial 19.01.002029 Pipe, 91 mm 19.01.021030 Panel, front 02.02.021031 Panel, plastic, front 02.02.019033 Control panel 15.22.033035 Fast coupling 19.50.043036 Flange for adapter 19.01.031

136 Available spare parts

TAB. 03

AVAILABLE SPARE PARTS : WF 103 wire feeder . (see TAB. 03)

NOTE 2 : In the first versions of the wire feeder, piece 022 usedto be fitted on the gearmotor without an aluminium plate (nowsupplied). In this case, to replace the piece, code 01.14.208 (= aluminiumplate) must be ordered.

SPARE PARTS REDUCTION GEAR, 4 ROLLERS, 120W WITH ENCODER

001 Reduction gear, complete 07.01 013004 Protection grid 07.01.182005 Brush 07.01.176009 Pressure unit, complete 07.01.225015 Tightner cast piece, right 07.01.167016 Tightner cast piece, left 07.01.168017 Wire-tightner gear 07.01.117018 Bush for wire-tightner gear 07.01.219019 Upper roller 07.01.140020 Roller washer 07.01.220021 Special key, 4x5 07.01.208022 Clast pece 07.01.186.01023 Middle wire threader 07.01.161 024 Rear wire threader 07.01.159

Rear wire threader for aluminium 07.01.160026 Middle gear 07.01.290028 Lower roller, 0.6-0.8 07.01.227

Lower roller, 1.0-1.2 07.01.130Lower roller, 1.6 with core 07.01.131Lower roller for aluminium, 12-1.6 07.01.132Lower roller for aluminium, 0.8-1.0 07.01.135

Warnings, precautions, general information - Diagnostics and repair instruments and tools 137

8) WARNINGS, PRECAUTIONS, GENERAL INFORMATION ON EXECUTING REPAIRS

Repairs may be executed by qualified personnel only.

Before attempting any repairs, we advise you to read andunderstand the information in this manual, especially in regardto safety recommendations.

Do not carry out any repair unless another person is presentwho can provide help in case of an accident.

To repair equipment, access is necessary to the internal parts of themachine, and to obtain this, some protective panels have to beremoved. Therefore, some extra precautions are necessary, overand above those applying to normal use of the machine forwelding, in order to prevent any damaged caused by contact with:

- Live parts- moving parts- parts at high temperature

- Live parts:

IMPORTANT!: When accessing parts inside themachine, remember that turning off the switch willnot prevent the danger of electric shocks. We the-

refore advise you to remove the plug and wait for about aminute before attempting any job.Further, as capacitors charged with high voltage may be pre-sent, wait about a minute before working on the internal parts.

IMPORTANT!: When taking measurements,remember that the measuring instruments them-selves can become live and, therefore, do not touchtheir metal parts.

IMPORTANT!: when the TIG mode is selected, themachine generates a series of high voltage pulses(approximately 10.000 V) to spark the welding arc.

When an arc sparking test in TIG with H.F. discharge is notexpressly included in the diagnostic procedure, you are advi-sed to disconnect the connector CN2 from board 15.14.192.

- Moving parts:

IMPORTANT!: Keep your hands well away from thefan when the machine is connected to the powersupply. Make sure that the power plug is removedand that the fan is idle before replacing it.

- Parts at high temperature:

IMPORTANT!: When you have to handle internalparts of the machine, remember that some couldbe at high temperature. In particular, do not touchcooling radiators.

9) DIAGNOSTICS AND REPAIR INSTRUMENTS AND TOOLS.

9.1) Diagnostics instruments and tools

9.1.1) Level 1

You will need the following:

- a multimeter with the following scales:Ohm : from 0 to a few MohmDiode testDirect voltages (Vdc): from mVdc to 1000 VdcAlternate voltages (Vac): from 10 Vac to 700 Vac

NOTE : We recommend you to use an instrument with anautomatic scale, because, if the machine faulty, in theory, thelevel of the electrical value to be measured cannot be foreseen.

- a shunt of 500 A @ 60 mV .

NOTE : Remember that other values may be equally suitable,but you will sacrifice accuracy at larger capacities, whereas onlow capacities, rapid measuring is necessary to prevent theshunt overheating.

9.1.2) Level 2

In addition to the instruments and tools recommended at theprevious point, you will also need the following:

- an oscilloscope with the following characteristics : - two channels- 100MHz of passband - time base up to 200ms, and ROLL option for the

trigger- a probe with the following characteristics :

- attenuation of 10:1 - insulating voltage to ground of at least 600Vrms.

- a probe with the following characteristics :- attenuation of 100 : 1 - insulating voltage to ground of at least 1000Vrms .

IMPORTANT !: Any connection to the ground, whe-ther direct or through the metal frame of the oscil-loscope must be eliminated. However, we adviseyou to make a ground connection for the oscillo-scope through an in-series capacitor-resistorcircuit, where C = 10 nF 1600 V, R = 220Kohm 1W.

138 Diagnosis procedure

TAB. 04

Load n.1)2)3)4)5)6)7)8)9)

10)

Resistance (Ohm)8.8 8.84.4

1.760.880.440.440.220.220.15

Power (KW)0.22 0.22 0.44 1.1 2.2 4.4 4.48.8 8.8

13.1

SELCO normalised loads

NOTE : When designing an electrical panel containing loads fortesting welding equipments, there must be a facility for inputtingseveral loads (as listed in the table) in parallel by means ofswitches.In the remainder of this manual, we shall use the symbol + forinputting two loads in parallel (e.g. 3 + 8 means inputtingnormalised loads 3 and 8 in parallel).

9.2) Static load

If the static loading facility is available, it considerably simplifiesthe output current check.If this is not feasible, the same tests can be run with the TIGwelding technique, but this is more difficult.

IMPORTANT!: with static load, in order to avoiddamage, disconnect the H.F. generation circuit follo-wing the directions given in chapter 8 (Warnings,precautions ).

IMPORTANT!: on static load, in order to preventtripping either the arc-force function, overheatingprotection, or saturation at generator output, load

value must be adapted according to the supplied current. For G 502 GSM , with reference to the SELCO normalisedloads (see TAB. 04), the following loads are required , depen-ding on the delivered current :

9.3) Repair tools- full set of fork wrenches - full set of pipe wrenches for hexagon nuts- full set of screwdrivers for single-slot screws- full set of screwdrivers for cross-slot screws- complete set of Allen keys - a torque cross-slotted screwdriver for M3 screws

with facility for setting tightness torque in the range1 to 2 Nxm 0.1 with precision of 0.1 Nxm.

- a pair of crimping pliers for insulated terminals (blue, red and yellow)

- a pair of pliers for AMP contacts.

- a pair of pincers and nippers suitable for electroniccomponents.

- a bigger pair of nippers for cutting small gauge steelsheet.

- a pair of pincers suitable for tightening the gas pipeend rings.

- long jawed pincers (to remove the tube of the Binzeladapter)

- a soldering iron for electronic components with minimum capacity of 50 W.

- an unwelding station - off-the shelf unwelding tracce may be used instead.

- a portable electrical drill

10) DIAGNOSIS PROCEDURE .

10.1) General notesIn view of the machines complexity, before carrying out a dia-gnosis, knowledge and understanding is required of the machi-ne functions as already described. Therefore, in regard to thediagnosis procedure, consult the information in the paragraphdescribing the functions of the machine. In this section, we shalljust provide some guide-lines to help you make the best use ofwhat we said up to this point, and to provide a useful informa-tion exchange tool during contacts with Selcos ServicingDepartment.

10.2) DiagnosisIn the following table, L = level (= 1 or 2)

Current (A)50

150260350500

Load n.4+5

4+5+84+5+6+8

4+5+6+106+7+8+9

CHECKS G 502 GSMPower inverter checkCheck of rectifier bridge connections

Check of condition of contacts of contactor and pre-loading resistorCheck of diode connections of the secondary rectifying circuitVisual check of 15.14.218 and power modules.Check of power IGBT connections * tester set for diode testing** tester set to OhmCheck of connections of switch-off circuit components** tester set to Ohm

Measurement of open circuit voltage at power sourceoutput (in MMA)Measurement of output cables of card 15.14.218(open circuit in MMA)Measurement of C - E voltage of the power IGBTs connected to - (open circuit in MMA) Measurement of current supplied by the inverter (in MMA)Current adjustment checkMeasurement of current output by the power source(in MMA at static load or in TIG HF or LIFT)Current read on FP or RC

Voltage read on FP or RC

Measurement of Hall sensor power

Measurement of welding current reference and feedback signalsFunction check in TIG H.F. (not for PME)Check if LED L3 of FP is onTorch check (replacement test)Check of torch fitting condition Check of CN4A/3-CN4A/4, card 15.14.149

Check of presence of command signal in IC1 of card15.14.192Check of thyristor of card 15.14.192

Correct result

K-A = 0.4A-K=OPENOK e200 OhmK-A = 0.4A-K=OPENOKC - E = OPEN*E - C = 0.4*B - E = 10 KOhm**C - E = OPEN*E - C = 0.4*B - E = 22 Ohm**80 V

fig. 16

fig. 15

fig. 18

I measured =I setI read =I measuredV read =V measured+15Vdc -15Vdc1V=100A1V=125A

OKOKOK24 / 0Vdc push-but-ton pressed /released1.5Vdc

fig. 28

Paragraph

5.3

5.2

5.6

---5.4

5.4

5.4

5.4

5.4

5.4

5.4

5.4

5.5 e 6.1---

5.5

5.8

5.8

Effective result L

1

1

1

11

1

1

2

2

2

1

1

1

1

1/2

1111

1

2

If the information in this manual and the procedure described here were insufficient to identify the faulty part, first write the effectivelychecked data in the "Effective result" column, and then compile the part below.

The malfunction occurs in MMA TIG MIG and the symptoms are as follows

Then, send the information contained here by fax to the following number : Fax : +39(0)499413311

or by E-mail to the following address: [email protected]

Function check of WF103Check if LED L3 of FP is onVoltage check at auxiliary transformer inputVoltage check at motor terminals (without wire of welding )Encoder power supply check(frequency) Check of encoder feedback signal

OK42 Vac17.5Vdc 11m/135Vdc 22 m/1+5 Vdc fig. 38

5.5 e 6.15.135.11

5.115.11

111

11/2

140 Parts dismantling and re-installation procedure

11) PARTS DISMANTLING AND RE-INSTALLATIONPROCEDURE : power source . (see fig. 50)

11.0) General notes : Dismantling and reassembly operationsare described here only for special parts or parts calling for spe-cial attention. To identify the parts, refer to the exploded view drawing and therelevant identification numbers it contains (see fig. 50).

11.1) Upper cover (018)

- remove the eye-bolts and the handle (017) if present. - remove the screws on each side and on the upper part of the

casing.- A yellow-green ground cable is located at the top of the ca-

sing and must be detached to free the casing completely.

To refit, carry out these jobs in reverse order. IMPORTANT ! : Dont forget to fix the yellow-greencable to the cover before refitting the coverdefinitively.

11.2) Plastic front panel (048)

Remove : - the front panel FP62 , FP73 , FP91 or FP111 (055)- the lower plate of the front panel bearing the symbol of the

TIG torch, + and -

To refit, carry out these jobs in reverse order.

11.3) Plastic rear panel (012)

Remove : - the rear panel FP93 .- the two screws fitted at the side and under the last fin.

11.4) Switch (041) - Knob for switch (053)

- Remove the knob, by unscrewing the securing screw locatedparallel with respect to the axis of the small shaft

- Remove the front panel FP62, FP73, FP91 or FP111 (055) - Unscrew the two switch fixing screws


11.5) Power supply cable

- Partially unscrew the two securing screws of the cable gripper(008) to release the power cable.

- Unscrew the screws of the terminal board on input of card15.14.202 (022).


11.6) Lower cover (034)- Unscrew and remove the antivibration foot (033) .- A yellow-green ground cable is connected to the inner face of

the lower cover and must be detached to free the casing com-pletety.


IMPORTANT ! : Dont forget to fix the yellow-greencable to the cover before refitting the coverdefinitively.

11.7) Inverter block 14.60.054 (061)

This part can be dismantled only after : - removing the lower cover (034)- removing the pc-board 15.14.192 (020)- removing the pc-board 15.14.218 (026)- unscrewing the screws for fixing the vertical metal plate on

which the pc-board 15.14.192 is mounted so that the plate can be moved from its place (this operation gives access to the hidden screw)

- Remove the capacitor (027) together with the supporting bracket- Disconnect the two cables connecting the resonance induc-

tance and the power transformer.- Disconnect the cables (n.22 , n.33 , n.40 , n. 5 , n. 6 ) of the

rectified bridge (029) and pass them through the hole of theintermediate metal plate.

- Disconnect the connector CN1 of pc-board 15.14.205 (030) - Disconnect the connector CN2 of pc-board 15.14.218 (031)

and pass it through the hole of the metal plate situated under-neath.

- Disconnect the connectors CN1 , CN2 , CN4 of pc-board15.14.201 (025) and pass them through the hole of the interme-diate metal plate.

- Remove the two screws fixing the inverter block to the inter-mediate metal plate.

- Remove the two screws fixing the inverter block to the lowermetal plate.

- Take out the inverter block (061)


IMPORTANT ! : When assembling, take great careno to reverse cables n. 5 (= +) and n. 6 (= -) (seefig. 51).

11.8) Diodes of secondary rectifying circuit (062)- Remove the copper bars above the diodes- Back off the screws securing the component to the radiator

Assembly:

- thoroughly clean the radiator and apply a thin uniform layerof thermal paste (code 16.03.102) on the surface of thepower component;

- fix the power component on the radiator by means of thescrews.

IMPORTANT! To insert the component correctly asindicated in fig. 52, the component terminals must becorrectly identified using a tester set to diode testing.

NOTE : the torque wrench is not necessary for reassembling thediodes. When fixing to the copper bars, however, you shouldtake the precaution of first applying all the screws and tighteningthem afterwards.

11.9) Fan (014)

The fan can be disassembled only after removing the rear pla-stic panel.

- Remove the four securing rivets of the metal rear panel (013),using a drill, and remove the panel.

- remove the two fan securing screws.


Parts dismantling and re-installation procedure 141

11.10) Varistor (on board 15.14.202) (022)

Begin to dismantle only after checking the condition of the tracks,of the other electronic components, and of the securing holes forthe part.

Assembly/disassembly do not require any particular precautions.

11.11) Diode bridges (on inverter unit 14.60.054) (029)

When assembling, carefully clean the radiator, and thenapply auniform but not excessive layer of thermal paste (code16.03.102) on the surface of the power component. Secure thepower component on the radiator, with the screws.

IMPORTANT ! : To connect the part correctly, checkthe marks on each terminal of the part (~ , + , - ,see fig. 12).

11.12) Hall effect sensor (047)

The probe can be dismantled only after removing (or at least,moving aside) the front plastic panel (048).

- Disconnect power cable+- using a drill, remove the two securing rivets from the front

metal panel- withdraw the probe from the copper bar.


11.13) Fixed socket (052)

For the + socket, we advise you to first remove the Hall effectsensor (047) .

IMPORTANT ! : When assembling, check if the three5 nF capacitors in triangle lay-out (between +, - andground) are connected correctly and, in particular,make sure there are no short-circuits between thecapacitor terminals.

11.14) TIG central socket (051)

- Disconnect the two pins connector J43.- Disconnect the gas pipe.- Disconnect the power cable.- Unscrew the ring nut.


11.15) Front panels FP62 , FP73 , FP91 or FP111 (055)

- Remove the switch knob (053)- Remove the four securing screws of the front panel.- Remove the card connectors.


11.16) Solenoid valve (007) - Nipple (005)

The probe can be dismantled only after removing the rearmetal panel (013) .

- Unscrew the nipple - Unscrew the two screws securing the solenoid valve suppor-

ting bracket - Disconnect cables n.24 , n.26 and the yellow-green cable- Disconnect the gas pipe- Unscrew the two screws securing the solenoid-valve to the

support bracket - Unscrew the elbow connection


IMPORTANT!When mounting the front nipple, use only LOCTITE577 joint sealing compound or ordinary TEFLONsealing tape.

11.17) Control logic card 15.14.149 (and 15.14.162) (036)

Replacement is very simple.

IMPORTANT ! : When assembling, remember to fitthe optic fibre connectors correctly

Blue terminal to blue card connectorGrey terminal to black card connector


Fig. 50


FIG. 51

FIG. 52


PARTS DISMANTLING AND RE-INSTALLATION PRO-CEDURE : WF 103 wire feeder . (see fig. 53)

11.18) Rotating wheel (015)

- Remove the lower cover (016) by unscrewing the four secu-ring screws at the corners of the plate and the other fouraround the central pin.

- Unscrew the nut securing the wheel to the cover.


11.19) Flange for Binzel adapter (036)

- Remove the three screw securing the flange for the Binzeladapter (036)

- Remove the two hexagon head screws at the side of theBinzel adapter(036) flange


11.20) FP60 Control panel (033)

Do not attempt dismantling unless you have removed the Binzeladapter (036) flange.

- Remove the two quick-fit connections (035)- Remove the eight screws securing the panel to the front metal

frame (030)- First lightly loosen the panel from its position, and then di-

sconnect connectors CN1 and CN7.


11.21) Plastic front panel (031)

Do not attempt dismantling unless you have removed the FP60control panel (033).

11.22) Binzel adapter (028) - tip (027)


- Remove the nut securing the tip to the gearmotor block (026)- Disconnect connector J11- Cut the gas tube securing tie and disconnect the gas tube- Remove the adapter-tip unit- Unscrew the tip to remove it from the adapter


IMPORTANT ! : When assembling, check if the Binzeladapter (028) projects from the front panel at least asmuch as the adapter flange (036).

11.23) 91mm tube (029)

- Place a screwdriver at roller output and push it toward theoutside of the tip

- Remove it from outside of the adapter, using long jawed pincers.

11.24) Gearmotor unit (026)


- Remove the nut securing the tip to the gearmotor block (026)- Disconnect the motor power cables n. 22 and n. 23 - Remove the J10 connector of the encoder- Unscrew the four securing screws of the gearmotor block (026)

IMPORTANT ! : Check if the insulating plastic ele-ments are present on the four securing holes in thegearmotor support plate. Further, make sure nopart of the gearmotor, after it is installed, comesinto contact with the wire feeder frame.

IMPORTANT ! : Correct fitting direction of theencoder J10 connector: cable n. 20 toward thedoor.

IMPORTANT ! : If, following installation of the gear-motor unit, the wire is pushed in opposite to correctdirection, just change over cables n. 22 and n. 23.

11.25) Motor control card 15.14.147 (022)

Replacement is very simple.

IMPORTANT ! : When assembling, remember to fitthe optic fibre connectors correctly

Blue terminal to connector of blue cardGrey terminal to connector of black card


Fig. 53

146 Operating tests and settings

12) OPERATING TESTS AND SETTINGS.

Preliminary conditions: - fit the shunt on the ground cable.- select scale mVdc on the multimeter - select MMA welding and the appropriate static load, if available, otherwise select TIG welding.

12.1) Measurement and setting of minimum current.

Not necessary.

12.2) Measurement and setting of maximum current.

Case RC08/RC10 : Set 250 A with RC08/RC10 . Switch RC08/RC10 in "MEAS" (= MEASUREMENT) .Using potentiometer P3 (see fig. 54) of card 15.14.201, make sure that the current read by the external instrument becomes thesame as that read on the RC08/RC10 (which may not necessarily be 250 A) .Using potentiometer P1 (see fig. 54) of card 15.14.201 , set both currents to 250 A.Repeat the previously described settings, but to a value of 500 A.Case FP91/FP111 :The information we gave you in the previous case also applies here. However, this time, the switching to "MEAS" is executed auto-matically by the front panel about 5 seconds after the last setting.

12.3) Measurement and setting of maximum current, selecting the reference from the outside.

Not necessary.

Operating tests and settings 147

Card 15.14.201 (Fig. 54)

148 Telephone assistance request procedure

13) TELEPHONE ASSISTANCE REQUEST PROCEDURE

If the repair technician has difficulty in determining the faulty part needing replacement, s/he may contact Assistenza Tecnica (A.T.)SELCO (Selco technical service department).Information may be given by telephone or fax, calling the following numbers:

Tel. : +39(0)499413111

Fax : +39(0)499413311

of via the E-mail to :

[email protected]

In any event, for increased efficiency in communicating information and to save time, we advise you to use the following diagnosticform.

Repair Manual Genesis 502-Gb(1)

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Transcript of Repair Manual Genesis 502-Gb(1)