Selco Genesis 4000 AC/DC

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The device manual describes the Selco Genesis 4000 AC/DC and Genesis 5000 AC/DC welding machines. These are constant current inverter power sources designed for various welding processes including Manual Metal Arc (MMA), TIG DC (direct current), and TIG AC (alternating current) welding. They are fully digital multiprocessor systems, utilizing DSP for data processing and CAN-BUS communication, engineered to meet diverse welding requirements.

Function Description

The device features a front control panel with a 7-segment display and an LCD display. The 7-segment display shows general welding machine parameters during start-up, settings, current and voltage readings during welding, and alarm codes. The LCD display provides the same information but allows for instantaneous viewing of all operations. A main adjustment handle enables continuous regulation of the welding current and facilitates entry into the setup menu for parameter selection and adjustment. Dedicated buttons allow selection of various system functions, including welding process (MMA, TIG DC, TIG AC), welding mode (2 Step, 4 Step, Bilevel), current pulsation (Constant, Pulsed, Fast Pulse, AC/DC Mix), and graphic interface personalization (Easy, Advanced, Professional). The device also supports storage and management of up to 64 customizable welding programs.

The rear panel includes an On/Off switch, CAN-BUS signal cable inputs for remote controls (RC 100, RC 180, RC 200) and optional cable bundles, a gas fitting for TIG welding, and the power supply cable connection. The sockets panel features a gas fitting, a torch button connection for external CAN-BUS devices, and negative and positive power sockets for connecting earth cables and electrode torches.

Important Technical Specifications

The Genesis 4000 AC/DC and Genesis 5000 AC/DC operate on a 3x400Vac / 3x230Vac ±15% power supply (50/60Hz). They are equipped with a slow blow line fuse (25A/40A for 4000, 30A/40A for 5000) and feature a digital communication bus. Maximum input power for MMA welding is 18.4 kVA / 13.3 kVA (4000) and 24.6 kVA / 18.3 kVA (5000), with corresponding kW values. For TIG welding, maximum input power is 14.0 kVA / 13.8 kVA (4000) and 19.4 kVA / 19.8 kVA (5000). Both models have a power factor (PF) of 0.95 and an efficiency (μ) of 83%/81% (4000) or 85%/79% (5000). The welding current adjustment range (I2) is 3-400A / 3-320A for MMA and 3-400A / 3-400A for TIG (4000), or 3-500A / 3-400A for MMA and 3-500A / 3-500A for TIG (5000). Open circuit voltage (Uo) is 73Vdc, and peak voltage (Up) is 10.1kV. The protection rating is IP23S, and the insulation class is H. Dimensions are 690x290x510 mm, with weights of 35.4 kg (4000) and 37.3 kg (5000). The devices comply with EN 60974-1, EN 60974-3, and EN 60974-10 Class A standards. They are supplied with a 5m power supply cable (4x4 mm2 for 4000, 4x6 mm2 for 5000).

Usage Features

The device offers a comprehensive set of parameters for precise welding control. Key features include:

VRD (Voltage Reduction Device): Controls the open-circuit voltage for enhanced safety.
Hot Start (MMA): Adjustable parameter (0-500%) to facilitate arc ignition, preventing electrode sticking.
Arc Force (MMA): Adjustable parameter (0-500%) to provide dynamic arc response, reducing electrode sticking.
Dynamic Power Control (DPC): Allows selection of V/I characteristics (Constant Current, Falling Characteristic with adjustable slope, Constant Power) for different electrode types (Basic, Rutile, Cellulose, Aluminum, Steel, Cast Iron).
Arc Detachment Voltage: Sets the voltage at which the arc is forced to extinguish, useful for spot welding to minimize spatter and oxidation.
TIG DC/AC Welding: Supports both direct and alternating current TIG welding with various modes (2 Step, 4 Step, Bilevel, Pulsed, Fast Pulse, AC/DC Mix).
TIG AC Waveform and Balance: Allows selection of AC waveform and adjustment of AC balance (15-65%) for optimal cleaning and penetration.
Fuzzy Logic (TIG AC): Regulates power delivery during arc ignition based on electrode diameter (0.1-5.0mm) to maintain tip integrity.
Easy Rounding (TIG AC): Delivers more energy during arc ignition for uniform electrode rounding.
Mix AC/DC Time: Adjusts welding time in DC or AC current when MIX AC function is enabled.
Spot Welding: Enables timed spot welding operations.
Restart: Allows immediate arc extinction or restart of the welding cycle.
Easy Joining (TIG DC): Facilitates pulsed current arc ignition for quick and precise tack welding.
External Controls Management: Configures welding parameter control via remote devices (RC 100, RC 120 pedal, RC 180, RC 200, ST...DIGITIG torches).
Guard Limits: Sets warning and alarm limits for welding current, voltage, and automation movement to monitor the welding process and prevent issues.

Maintenance Features

Routine maintenance, as specified by the manufacturer, must be performed by qualified personnel. This includes:

Internal Cleaning: Regularly clean the power source interior using low-pressure compressed air and soft brbristle brushes.
Electrical Connections: Check all electrical connections and cables.
Component Temperature: For torch components, electrode holders, and earth cables, ensure they are not overheated.
Safety Gear: Always use regulation gloves, wrenches, and appropriate tools.
Covers and Doors: All access and service doors and covers must be closed and secured during operation.
Modifications: No unauthorized modifications are allowed.
Dust Accumulation: Prevent metallic dust from accumulating near cooling fins.
Power Disconnection: Always disconnect the power supply before any maintenance operation.