Selco Genesis 240 TLH - User Manual

REPAIRS MANUAL
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Genesis
240
Genesis
240 TLH

Summary

GUARANTEE CONDITIONS

PURPOSE OF THE MANUAL

MACHINE TECHNICAL SPECIFICATIONS

DESCRIPTION OF MACHINE PARTS

G 240 circuit parts

Lists the circuit parts of the G 240 model.

G 240 TLH additional circuits

Lists additional circuits present in the TLH version.

DESCRIPTION OF MACHINE OPERATION

5.1) Master switch and input filter

Explains the master switch and input filter functions and safety.

5.2) Rectifier bridge, power inverter, and transformer

Details the function of rectifier bridge, power inverter, and transformer.

5.3) Rectifier circuit, output filter, and inductance

Describes the rectifier circuit, output filter, and levelling inductance.

5.4) Current transducer and power circuits

Explains current transducer and power circuits for control.

5.5) Control circuits (front panel)

Describes control circuits on the front panel.

5.6) H.F. transformer and discharge generation

Explains H.F. transformer and discharge generation for TIG.

5.7) Cooling unit power supply circuits

Details power supply circuits for the cooling unit WU15.

5.8) Auxiliary transformer

Explains the auxiliary transformer's role in providing power supplies.

DESCRIPTION OF DIAGNOSTIC INDICATIONS

6.1) Diagnostic indications external

Explains the external LEDs (GREEN, YELLOW) on the front panel for status.

6.2) Internal diagnostic indications

Details internal diagnostic LEDs (L1-L4) on board 15.14.254.

AVAILABLE SPARE PARTS

WARNINGS, PRECAUTIONS, GENERAL INFORMATION ON EXECUTING REPAIRS

Live parts precautions

Warns about high voltage and capacitors, advising waiting before access.

Moving parts precautions

Advises caution with moving parts like fans when machine is powered.

High temperature parts precautions

Warns about handling hot internal parts and radiators.

DIAGNOSTICS AND REPAIR INSTRUMENTS AND TOOLS

9.1) Diagnostics instruments and tools

Lists necessary instruments for Level 1 and Level 2 diagnostics.

DIAGNOSIS PROCEDURE

10.1) General information

Explains the general logic and approach to diagnosis.

10.2) Agreements

Defines conventions for measurements and pin identification.

10.3) Fasi diagnostiche (G 240)

Provides detailed diagnostic steps for the G 240 model.

G 240 TLH: Phase 1 and Stage 2

Diagnostic steps for G 240 TLH, Phase 1 and Stage 2.

G 240 TLH: Stage 3 and 4

Diagnostic steps for G 240 TLH, Stage 3 and 4.

G 240 TLH: Stage 5, 6, 7, 8

Diagnostic steps for G 240 TLH, Stages 5, 6, 7, 8.

Check procedure for power inverter

Procedure to check the power inverter.

Check procedure of secondary power diodes

Procedure to check secondary power diodes.

Check procedure for power supplies (G 240)

Procedure to check power supplies for G 240.

Check procedure for power supplies (G 240 TLH)

Procedure to check power supplies for G 240 TLH.

Check procedure for current control circuits (G 240)

Procedure to check current control circuits for G 240.

Check procedure for current control circuits (G 240 TLH)

Procedure to check current control circuits for G 240 TLH.

H.F. generation circuit checking procedure

Procedure to check the H.F. generation circuit.

PARTS DISMANTLING AND RE-INSTALLATION PROCEDURE

11.1) Upper cover

Instructions for removing and refitting the upper cover.

11.2) Plastic front panel

Steps for removing the plastic front panel.

11.3) Plastic rear panel

Instructions for removing the plastic rear panel.

11.4) Switch - Knob for switch

Procedure for removing the switch and knob.

11.5) Power supply cable

Steps to disconnect and remove the power supply cable.

11.7) Part 14.60.060

Procedure for removing the board 15.14.254 (kit 14.60.060).

11.8) Board 15.14.233

Instructions for removing and refitting board 15.14.233.

11.9) Board 15.14.240

Steps for dismantling and reinstalling board 15.14.240.

11.10) Rectifier circuit diode

Procedure for removing and replacing rectifier circuit diodes.

11.11) Fan

Instructions for fan removal and refitting.

11.12) Capacitor (connected to board 15.14.254)

Steps to remove the capacitor.

11.13) Varistor (on board 15.14.233)

Procedure for removing and replacing the varistor.

11.14) Diode bridges (on board 15.14.233)

Instructions for disassembling diode bridges.

11.15) Auxiliary transformer

Steps for removing the auxiliary transformer.

11.16) Fixed socket

Procedure for removing the fixed socket.

11.17) Front panels FP104 or FP106

Instructions for removing front panels.

11.18) Rear panels FP114 or FP113

Steps for removing rear panels.

11.19) Plastic base

Instructions for removing the plastic base.

11.20) Metal base

Procedure for removing the metal base.

11.21) TIG central socket (G 240 TLH)

Steps for removing the TIG central socket on TLH.

11.22) Solenoid valve - Nipple (G 240 TLH)

Instructions for removing the solenoid valve nipple on TLH.

11.23) H.F. generation board 15.14.192 (G 240 TLH)

Steps for removing the H.F. generation board on TLH.

OPERATING TESTS AND SETTINGS

G 240: Preliminary conditions

Lists preliminary conditions for operating tests on G 240.

12.1) Measurement and setting of minimum current (G 240)

Procedure for measuring and setting minimum current on G 240.

12.2) Measurement and setting of maximum current (G 240)

Procedure for measuring and setting maximum current on G 240.

G 240 TLH: Preliminary conditions

Lists preliminary conditions for operating tests on G 240 TLH.

12.1) Measurement of minimum current (G 240 TLH)

Procedure for measuring minimum current on G 240 TLH.

12.2) Measurement and calibration of maximum current (G 240 TLH)

Procedure for calibrating maximum current on G 240 TLH.

12.3) Measuring and calibrating maximum current with external reference (G 240 TLH)

Calibrating max current using external reference on G 240 TLH.

TELEPHONE ASSISTANCE REQUEST PROCEDURE

Selco Genesis 240 TLH Specifications

General

Input Voltage	230V
Input Frequency	50/60 Hz
Rated Input Current	16 A
Welding Current Range	5 - 240 A
Output Current Range	5 - 240 A
Protection Class	IP23
Welding Process	TIG, MMA
Duty Cycle	35% at 240 A