REPAIRS MANUAL
E N G L I S H
Genesis
502 GSM (TLH/PME)
Cod. 92.08.017 Edition: 01/00 SELCO s.r.l. Via Palladio, 19 35010 ONARA DI TOMBOLO (Padova) Italy Tel. 0499413111 Fax 0499413311
INDEX : 1) 2) 3) 4) 5)
GUARANTEE CONDITIONS . . . . . . . . . . . . . . . . . . .76 PURPOSE OF THE MANUAL . . . . . . . . . . . . . . . . . .77 MACHINE TECHNICAL SPECIFICATIONS . . . . . . . .77 DESCRIPTION OF MACHINE PARTS . . . . . . . . . . . .78 DESCRIPTION OF MACHINE OPERATION . . . . . . .83
1) GUARANTEE CONDITIONS. To specify the present warranty conditions , we remind that SELCO 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 equipment c) in products that have been modified or integrated with other products when such modification or integration can be the cause of the failure.
LAY-OUTS OF CARDS . . . . . . . . . . . . . . . . . . . . . . .115 6) DESCRIPTION OF DIAGNOSTIC INDICATIONS : . .132 - EXTERNAL - INTERNAL 7) AVAILABLE SPARE PARTS . . . . . . . . . . . . . . . . . . . .134 8) WARNINGS, PRECAUTIONS, GENERAL INFORMATION ON EXECUTING REPAIRS . . . . . . .137 9) DIAGNOSTIC AND REPAIR INSTRUMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 10) DIAGNOSIS PROCEDURE : . . . . . . . . . . . . . . . . . . .138 - LEVEL 1 - LEVEL 2 11) PARTS DISMANTLING AND RE-INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 12) OPERATING TESTS AND SETTINGS . . . . . . . . . . . .146 13) TELEPHONE ASSISTANCE REQUEST PROCEDURE . . . . . . . . . . . . . . . . . . . . .148
76
Guarantee conditions
2) PURPOSE OF THE MANUAL
3) MACHINE TECHNICAL SPECIFICATIONS .
The purpose of this manual is to provide authorised technical servicing centres the information required for repairing Genesis 502 GSM (TLH and PME) . To avoid serious damage to people and things, this manual must be used strictly by qualified technicians. What is involved in a repair job?: identifying the faulty part - as this part is included in the list of available spare parts - and replacing it according to the procedures described below. If an electronic card is faulty, repair entails replacing the card and not replacing the faulty electronic component on the card itself. We suggest two diagnosis procedures on two levels: at the first level, simple initial action instruments/tools are used, at the second level, more sophisticated instruments/tools are used. Level two obviously ensures a quicker, surer diagnosis.
TECHN. CHARACT. Power supply voltage (50/60Hz) Max. absorbed power (x=60%) Max. absorbed current Delayed fuses 500V Efficiency Power factor MMA/TIG welding current (x= 60%) (x=100%) MIG welding current (x= 60%) (x=100%) Adjustment range DC MMA DC TIG DC MIG No-load voltage Protection degree Insulation class Construction standards
Purpose of the manual - Machine technical specifications
GENESIS 502 GSM
GENESIS 502 PME
3x400V +10% -15%
3x400V +10% -15%
23.2kW
23.2kW
41.9A 40A 0.87 0.80
41.9A 40A 0.87 0.80
500A 400A
500A 400A
500A 400A
500A 400A
6A/20V-500A/40V 6A/10V-500A/30V 15A/15V-500A/39V
6A/20V-500A/40V
90V IP23 H EN60974-1 EN50199
90V IP23 H EN60974-1 EN50199
15A/15V-500A/39V
77
FIG. 1 - G 502 GSM (multi-function version) e)
c)
f)
d)
g)
m)
l)
o)
k)
h)
n)
a)
p) r)
b)
j)
i)
t)
w)
u)
s) q)
4) DESCRIPTION OF MACHINE PARTS. 4.1) Power source G 502 GSM consists of the following parts: (see fig. 1-2-3-4) : a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v)
78
input filter card (15.14.202) ON switch (I1) contactor (TEL1) pre-loading resistance (R1) rectifier bridge (P1, P2 and P3) voltage levelling capacitors (C1 , C2 and C3) power inverter IGBT driver card (15.14.218) power inverter control and protection circuits card (15.14.201) control logic card (15.14.149) resonance inductance (L1) power transformer (T1) secondary rectifying circuit and snubber card (15.14.223) welding current transducer (Hall effect sensor) (HALL) output filter (15.14.174) welding current levelling inductance (L2) fans auxiliary transformer (AUX1) front panel (FP91 - FP111 - FP62 - FP73) H.F. transformer (HF) H.F. discharge generation card (15.14.192) TIG gas solenoid-valve (ELV)
Parts t), u) and v) are not supplied with the PME (FP108 or FP136) version as the TIG H.F. function is not present. In the multi-function version (FP62 or FP73) and PME (FP108 or FP136), in addition to the preceding circuits, the following is also supplied: w) interface card with wire feeder (15.14.162) In the version with robot interface ( FP73), in addition to the preceding 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), an additional DC/AC conversion at high frequency effected by the inverter (g), transfer by isolating transformer (I) to the output circuits and, finally, a last AC/DC conversion by the output rectifier (m). An arc sparking circuit in TIG with high voltage pulse (t) is provided.
Description of machine parts
FIG. 2 - G 502 GSM (TLH version)
s)
FIG. 3 - G 502 GSM (multi-function version with robot interface)
x)
s)
Description of machine parts
79
FIG. 4 - G 502 PME (PME version)
s)
80
Description of machine parts
WF103 wire feeder
Description of machine parts
81
FIG. 5 - WF103 wire feeder a1)
c1)
d1)
e1)
f1)
b1)
4.2) The WF103 wire feeder consists of the following parts (see fig. 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 WF103 f1) MIG gas solenoid valve (EV) NOTE : The previous drawing also shows the optional card 82.08.087 and the optional connector J12 (complete with cables n. 19 - 20) for using the push-pull torch.
82
Description of machine parts
5) DESCRIPTION OF MACHINE OPERATION. 5.0) General methods explained
Unless otherwise specified, when a measurement is taken between a pair of terminals, e.g. a-aa, it is understood that the red probe (or the oscilloscope probe) is placed on the left terminal (on a in this example), whereas the black probe (or the ground lead of the oscilloscope) is placed on the right terminal (on aa in this example).
In the figures, when an arrow is shown between two measuring points, the tip indicates where to place the red probe (or the oscilloscope probe), whereas the black probe (or the oscilloscope ground wire) is placed at the other end. The connector terminals are indicated with the name of the connector 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:
FIG. 6
Description of machine operation
83
FIG. 7
c)
e)
d) a)
b)
5.1) Input filter card (15.14.202) (a) (see fig. 7) Supply voltage 3 x 400 Vac is applied to the terminals of card 15.14.202 (a) (see fig. 8) , which contains the mains over-voltages suppression circuit, consisting of three varistors (see note 1) and the radio-noise suppression circuit (see note 2) connected to ground. The PE terminal of the card, to which the yellow-green power cable is connected, is electrically connected to the machine's metal parts, both via a yellow-green cable and via a metal column. IMPORTANT ! : When the machine is connected to the mains, the filter card is powered, irrespective of the position of the power switch. We, therefore, advise you to unplug the power plug before accessing the machine's internal parts.
84
NOTE 1 : If the electrical component know as a varistor is placed between the two power supply phases, when an instantaneous voltage in excess of 460 V appears on its terminals, the varistor very rapidly becomes conductive, absorbing a current peak which is sufficient to limit the said over-voltage and it thus protects the other parts of the machine. This process has no destructive effect on the component if the energy generated by the voltage peak is low, as in the case of atmospheric lightning strikes. If, however, over-voltage is high and prolonged, the varistor cannot dissipate this high energy and blows. This happens if, for example, the machine is wrongly connected to 460 Vac mains voltage, or following over-voltage caused by non stabilised power units of inadequate capacity. NOTE 2 : The radio noise suppression circuit has two purposes: to keep the machine's radio frequency emissions within limits specified by standards and to ensure machines immunity against the same type of problems caused by any electronic devices connected to the same power supply source. The filter consists of a network of capacitors, some of which are grounded, and two toroidals inductors.
Description of machine operation
FIG. 8 (card 15.14.202)
Description of machine operation
85
FIG. 9
c)
e)
d) a)
b)
5.2) On switch (b) - contactor (c) - pre-loading resistor (d). (see
fig. 9)
The three power phases at output of card 15.14.202 (400 Vac between cables n° 1 , 2 , 3) are switched by contactor (c). Voltage obtained from the only two phases (400 Vac between cables n° 1 , 2), used to power the control circuits and the auxiliary devices, is switched by the power switch (b). When the power switch is ON, the contacts of contactor L1-T1 e L2-T2 are short-circuited respectively by cables n° 1 - 40 and by cables n° 2 -00 - 22 - the latter in series with the pre-loading resistors (d) (= two 100 Ohm in series). As immediately after the machine is powered-up the contacts of the contactor stay open for a certain time (a few seconds), the bank of levelling capacitors C1 and C2 is pre-loaded through the above circuit . The contactor coil is commanded by 230 Vac supplied by the auxiliary transformer (the coil is switched by the power switch contact and 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 the power contactor to close, and therefore, 0 V is measured at the ends of the contactor coil during pre-loading, and 230 Vac after pre-loading.
86
IMPORTANT ! : When accessing the internal parts of the machine, remember that opening the on switch does not mean that the risk of electrical shocks is avoided. We, therefore, advise you to unplug the power plug.
Description of machine operation
FIG. 10 e)
c)
f)
d)
g)
h)
a) r)
b)
j)
i)
q)
Description of machine operation
87
FIG. 11
c)
e)
d)
f)
g)
h)
a)
b)
5.3) rectifier bridge (e) - voltage levelling capacitors card (f). (see fig. 11)
When the contactor is closed, the 3-phase supply voltage is applied 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 to the bank of capacitors laid out in two groups of 2 capacitors in series with each other. When the machine is in open circuit status, the voltage rectified 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 has a 300 Hz ripple, (see fig. 13). The voltage on each capacitor is half the value of the rectified voltage (between + and -).
88
Description of machine operation
FIG. 12
FIG. 13
Description of machine operation
89
FIG. 14
f)
g)
h)
m)
l)
n)
o)
k)
p)
t)
5.4) power inverter (g) - driver card of IGBTs (h) - power inverter control card (i) - resonance inductance (k) - power transformer (l) - welding current transducer (Hall effect sensor) (n) . (see fig. 14)
IMPORTANT ! : If one of the IGBT modules fails, card 15.14.218 must also be replaced simultaneously.
The direct voltage at the terminals of the voltage levelling capacitors is applied to the power inverter. The inverter consists of two IGBT power modules, each housing two IGBTs as shown in the diagram in fig. 15. By using a multimeter set for the diode test, and referring to the previous figure, you can check all the connections of the four IGBTs, obtaining
The voltage between the Collector and Emitter of the power IGBTs connected between ~ and - is shown in fig. 15 (do not take this measurement on the IGBTs connected between + and ~). Important: the signal of the module on the top is different from the one on the bottom . Card 15.14.181, also houses the switch-off circuit consisting of two auxiliary IGBTs and two diodes cooled by a radiator. Fig. 15 shows how to check the connections of the switch-off IGBTs, by using a multimeter set for the diode test : C - E = OPEN E - 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 of small cables on the right (power source set to MMA and open circuit at output).
C - E = OPEN E - C = 0.4 and using a multimeter set to Ohm : B - E = 10 kOhm (however, even if this test is positive, the inverter may nevertheless by faulty). Card 15.14.218 generates the command signals to the power IGBTs; the signal shown in fig. 16 (power source set to MMA and without output load) is obtained between the four pairs of small cables on the left. The frequency of these signals varies according to the current supplied by the power source and is in the range from approximately 47 kHz at low load to 30 kHz at maximum load. IMPORTANT ! : While current is supplied at the output of the power source, we advise you to measure the command signals of the power IGBTs. IMPORTANT ! : The measuring instrument must not be grounded (see chapter 9).
90
Description of machine operation
The overall effect of a correctly operating switch-off circuit is to generate a voltage signal between the Collector and Emitter of the IGBTs of the top module, with soft slope-up and slope-down (not steep as in the case of the bottom module). The power inverter control card 15.14.201 regulate the welding current according 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 receved from the Hall sensor (signal from Hall sensor = 1 V in CN1/2 of card 15.14.201 means 125 A supplied ; ground = CN1/3 see fig. 18) . The signal received from the Hall sensor is amplified and transmitted to card 15.14.149. Moreover, card 15.14.201 provides the Hall sensor with the following 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-capacitive load and a power transformer. The capacitors are fitted on the card 15.14.205 , whereas inductance L1 is located at the front of the machine. Power transformer T1 transfers power to the output circuits. The current supplied on the above load can be measured on TP3 of card 15.14.201 indicated in fig. 18 ; (the signal at the indicated 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 shown below for the following cases: welding I 0A 50 A 250 A 500 A
Fig. Fig. Fig. Fig.
18A 18B 18C 18D
(NOTE : when examining the preceding wave shapes, remember that they may be affected by electromagnetic noise of varying intensity). Card 15.14.201 checks the level of the rectified voltage, at the terminals of the voltage levelling capacitors (inverter section input voltage) by sending to the control logic card (15.14.149) either an overvoltage alarm signal if the value exceeds approximately 670 Vdc, or an undervoltage alarm signal if the value is below 440 Vdc. The previous values correspond respectively to about 470 Vac and 310 Vac of mains power. A voltage value in excess of the permissible limits must continue for a few seconds to trip the alarm. The above mentioned signals can be obtained in TP2 (overvoltage alarm) and TP1 (undervoltage alarm) from card 15.14.201 (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)
Description of machine operation
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 powering 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 (cable n° 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 (cable n° 04) When changing over from TIG or MIG to MMA, the cooling unit is immediately turned OFF. If no welding is done for five minutes while TIG or MIG is selected, the commands to the cooling and fan units are cancelled. Furthermore, card 15.14.201 commands the coil of the power contactor a few seconds after the machine is powered up (230 Vac between the terminals of the contactor coil, i.e. between cables n° 4 and 9 at end of pre-loading time).
91
FIG. 15
FIG. 15A
92
FIG. 15B
Description of machine operation
FIG. 16 (Card 15.14.218)
FIG. 16A
FIG. 16B
FIG. 16C
FIG. 17 (Card 15.14.149)
Description of machine operation
93
FIG. 18 (Card 15.14.201) FIG. 18A
FIG. 18B
FIG. 18C
FIG. 18D
TP3 (current flowing in the primary winding of the power transformer) :
FIG. 19 e)
c)
f)
d)
g)
h)
a) r)
b)
j)
i)
q)
94
Description of machine operation
FIG. 20
j)
i)
t)
w)
u)
s)
5.5) Control logic card (j) (see fig. 20) The main purpose of the control logic card is to generate the current reference signal for the power inverter control card, by processing the information for the welding parameters acquired outside. This information is received from the following, according to system 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 keyboard. Transmission is effected digitally through the two optic fibres connected to the connectors of fig. 22 (blue terminal to blue connector; grey terminal to black connector) and to J20 (see fig. 21). If RC08/RC10 fails to receive or receives incorrectly, it displays the alarm message. This can occur also if the microswitches of card 15.14.149 are incorrectly configured (see fig. 23). (See NOTE 1) . Case B : Received data include those that can be set on the panel. Transmission is effected digitally via the flat cable connected to CN6 on15.14.149. If FP91/FP11/FP108/FP136 fails to receive or receives incorrectly, it displays the alarm message. This can occur also if the microswitches of card 15.14.149 are incorrectly configured (see fig. 23). Moreover, other information can be received from remote controls 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)
Description of machine operation
In the case of RC16, the received data is the welding current reference in MMA or TIG (with the external reference selected on RC10/RC08 or on front panel FP91 or FP111); in the case of RC12, the welding start signal is received in addition to the current reference. The current reference (analog signal in value range of 0 to 5 Vdc) and the start signal (relay contact OPEN =OFF, CLOSE = ON) are received via the flat cable connected to CN6 of card 15.14.149. The value of requested current and the information on the presence of the start signal are transmitted for display from 15.14.149 to RC08/RC10 or to front panel FP91 or FP111, as the case may be. The card also supplies 5 Vdc power for the potentiometers inside RC16 and RC12. This 5 Vdc can be measured directly on the connector of the front panel between points A and B. The data received via RC07 are the wire speed reference and the correction of welding voltage level in MIG (with the external reference selected on RC10/RC08). The data, acquired from the wire feeder, are transmitted firstly digitally via two optic fibres of the cable bundle and, later, via the connection, inside the machine, between the connector (J23 on the machine rear panel - see fig. 21) and card 15.14.162 (blue terminal to blue connector, grey terminal to black connector). Further, card 15.14.162 performs switching of the 42 Vac power for the wire feeder, through a relay. When operating in MIG, 42 Vac is measured between cables n° 43 (fuse-holder terminal) and n° 45 (connector CN2 of card 15.14.162; this voltage is measured at the same conditions also between terminals C and E of the connector if fuse F2 = 6.3 A is OK.
95
The main power supplies of the card are measured as follows with respect to TP2 (= ground) (see fig. 22) : TP5 = +15Vdc TP12 = -15Vdc TP1 = +5Vdc The current reference processed by card 15.14.149 is measured on the TP8 of the card itself (1V = 100A), with respect to TP2 (ground). The power release signal is measured between pin 8 of integrated circuit IC15 and TP2 (0= power cut out; 5 Vdc = power released). When the power is released the card commands, lighting of LED L3 on the front panel. The 15.14.149 card also measures welding voltage for the following purposes: in MMA : - hotstart function (current increase at first impact of electrode on piece) - arc-force function (increase of current at shortcircuit of electrode on piece) - anti-stick protection function (if the shortcircuit at the previous point continues) in TIG (lift) : - current limitation when electrode shortcircuited in TIG (h.f.) : - current increase following sparking in MIG : - adjustment of welding average voltage and, in general, display of arc voltage on RC or on the front panel. Therefore, with the power source set to MMA, voltage of approximately 80 Vdc should be measured between cables n° 72-73 of connector CN5. When the machine is configured to multi-function or PME, the card receives also voltage output by WF103 to take a more accurate measurement, taking into account the voltage drop on the cable bundle (electrical continuity between the Binzel MIG connector of the wire feeder and CN5/11 of card 15.14.159 = cable n° 46). Card 15.14.149 also measures welding current, obtaining the signal 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 maximum specified level for a few tenths of a second.
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 three overtemperature detection devices one on the radiator of the inverter and two of the output rectifier, 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 isolate the 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 very simple: expose one end to a flashing light (e.g. a lamp with its beam interrupted by waving a finger over the end of the optical fibre) and check the brightness variation at the other end. NOTE 2 : The signal coming from the pressure switch (through 4-pole connector J35 on rear panel FP71, see fig. 21) indicates the presence of pressure in the hydraulic circuit, but not if a liquid flow is also present (a flowmeter would be necessary to do this). Of the two contacts, the N.O. (normally open) contact is the one used and therefore : open contact = pressurised circuit closed contact = non pressurised circuit
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)
96
Description of machine operation
FIG. 21
f)
g)
m)
l)
o)
k)
h)
n)
p)
j)
i)
t)
w)
u) connection with the cable bundle
s)
FIG. 22 (Card 15.14.149)
Description of machine operation
97
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 kit for connection of WF103 (version TIG DC with RC08, RC10 or SW SELCO)
GENESIS 502 GSM with FP62 or FP73 with kit for connection of WF103 (code 74.04.003) (MULTI-FUNCTION version with RC08,RC10 or SW SELCO)
GENESIS 502 PME with FP136 (FP108)
98
Description of machine operation
FIG. 24
f)
g)
h)
m)
l)
n)
o)
k)
p)
5.6) secondary rectifying circuit and snubber card (m) - output filter (o) - welding current levelling inductance (p) (see fig. 24)
The secondary rectifying circuit, which serves to convert transformer output current into direct current, consists of two groups of three modules (see fig. 25). Each group, connected to a terminal on the power transformer, rectifies the corresponding current half-wave. The snubber card consists of a diode-capacitor-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 fitted to card 15.14.174 and capacitors connected directly between the + and - output terminals of the power source. The main purpose is to prevent the h.f. discharge from entering the power source and help starting of the electrical arc. The voltage feedback signal received by card 15.14.149 is also obtained from card. 15.14.174 via cables n° 72-73.
Description of machine operation
99
FIG. 25
100
Description of machine operation
FIG. 26
r)
j)
q)
5.7) Auxiliary transformer (r ) (see fig. 26) This is used to generate voltages supplying system's auxiliary circuits (fan, etc.) and the electronic cards, commencing from the input 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, it is 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 the wire feeder when commanded by the control logic) is protected by fuse F2 (6.3 A, 250V), accessible from the machine rear panel.
Description of machine operation
101
FIG. 27 f)
g)
m)
l)
o)
k)
h)
n)
p)
j)
i)
t)
w)
u)
s)
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 the H.F. transformer create a set of high voltage pulses (several thousand volts) to spark the TIG H.F. welding arc. These pulses, generated commencing with the 230 Vac present between CN2/1 - CN2/4 (cables n° 0 - 23) , begin when the card receives - in CN1 - the command supplied by card 15.14.149 and are repeated until the current is sparked and, in any event, for no longer than a maximum time of approximately 3 s. The command signal measured between CN1/1 - CN1/2 is of approximately 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.
102
Description of machine operation
FIG. 28 (Card 15.14.192)
Description of machine operation
103
FIG. 29 e)
c)
f)
d)
g)
h)
a) r)
b)
j)
q)
5.9) Fan (q) - TIG gas solenoid-valve (v) (see fig. 29) The two fans, powered on 230 Vac single-phase (when commanded by the control logic, see paragraph 5.4), thrusts air from the front to the rear of the machine. The solenoid-valve, powered on 24 Vac (when commanded by the control logic) also has a gas flow direction as shown by the arrow on the valve body.
104
Description of machine operation
FIG. 30
j)
i)
t)
w)
u)
s)
FIG. 31
s)
Description of machine operation
105
FIG. 32
x)
s)
FIG. 33
s)
106
Description of machine operation
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 no adjusting function). There is, however, an exception to the above: data received from RC12 or RC16 transit only through the panel and are acquired directly by the control logic card (15.14.149) which returns the data to the panel, for display purposes, in digital form by a 40-way flat cable. The settable parameters are listed in the following table (FP111):
Parameter
Pre-gas time Initial current Increase time tu Welding current I Back current Ib Pulse time tp Frequency tp & tb Back time tb Decrease time td Final current If Post-Gas time Hot-Start Arc-Force Bilevel I2 current Select remote control Select bilevel I min I max
um Note s % s A A s Hz s s A s % % A n° n° A A
It can be set from setup only Percentage on the welding current, setup only Pulsed and fast pulse Pulsed only In fastpulse only, repr. by leds Tpulse and Tback Pulsed only Combined with the only potentiometer provided knob MMA, settable from setup only MMA, settable from potentiometer Constant current only, setup only 0=RC12 1=RC16 only setup 0=2T 1=4T Remote control adjustment Remote control adjustment
min
max
6 6
max max
0.0 2 0.0 6 6 0.02 20 0.02 0.0 6 0.0 0 0 6
25.0 200 10.0 max max 2.00 500 2.00 10.0 max 25.0 100 100 max
predef.
0.0 50 0.0 100 6 0.24 100 0.24 0.0 8 handgrip 80 handgrip 50 1 1 min max
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 presence of 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 no adjusting function). The settable parameters are listed in the following table (FP108-FP136):
Parameter
Hot-Start Arc-Force Post-Gas time Initial increased percentage Crater filler percentage Select synergetic curve Soft Start percentage Inductance Burn Back time Wire speed Synergetic voltage offset Welding voltage in manual mode
um Note
% % s % % n° % % s m/min. V V
MMA, It can be set MMA, It can be set from potentiometer In MIG, only setup Only setup Only setup In MIG In MIG In MIG SHORT In MIG In MIG In sinergyc MIG
min 0 0 0 20 20 S01 10 12 0.0 1 -9.8 5
max 100 100 10 200 200 P30 100 100 1 22 +10 55.5
predef.
80 handgrip 2 100 80 S01 50 50 0.06 1 handgrip handgrip
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 presence of 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 RC12 or RC16 (connected to the connector on the left) transit only through the panel and are acquired or transmitted directly by the control 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 program of 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 connector at the right, to supply RC08/RC10. Description of machine operation
107
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 State
J8
Config. jumper 2-3
" J7
1-2 2-3
contact open when arc sparked contact closed when RC10 indicates alarm and LED L2 is lighted
"
1-2
J2
2-3
contact open when RC10 indicates alarm and LED L2 is lighted on panel LED L3 lighted on panel when contact closed
" J4
1-2 2-3
" J1
1-2 2-3
LED L3 lighted on panel when contact open Selected program number. See Note. " "
" J3
1-2 2-3
" "
"
1-2
"
Pin conn.
IN/OUT
Type
Jumper
R-S
OUT
" J-K
" OUT
"
"
Relay contact " Relay contact "
A-F
IN
" B-F
" IN
" C-F
" IN
" D-F
" IN
"
"
Relay contact " Relay contact " Relay contact " Relay contact "
contact closed when arc sparked
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 B-F A C A C A C A C
C-F A A C C A A C C
D-F A A A A C C C C
Program 1 2 3 4 5 6 7 8
C-F C C A A C C A A
D-F C C C C A A A A
Program 1 2 3 4 5 6 7 8
In the second case C = closed, A = open B-F C A C A C A C A ANALOG SIGNALS Pin conn. T-V U-V
108
Signal range 0 - 10/24 Vdc 0 - 10/24 Vdc
Effect
Setting potentiometer Min to MAX variation P1 of speed reference on RC10 Min to MAX variation P2 of voltage reference on RC10
Description of machine operation
WORK PIECE PRESENCE SIGNAL Pin conn.
IN/OUT
Type
Jumper
N-P
OUT
J9
"
"
Relay contact "
Config. jumper 2-3
"
1-2
State
when the contact is open, the piece search function is enabled
State contact closed when out + and - of the power source are short-circuited. See Note. contact open when out + and - of the power source are short-circuited. See Note.
Note: the function is enabled Pin conn.
IN/OUT
Type
Jumper
G-F
IN
J6
"
"
Relay contact "
Config. jumper 2-3
"
1-2
when the contact is closed, the piece search 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 case of FP73. The panel generates 24 Vdc which can be measured at the appropriate point in the figure 34, and 24 Vdc which can be checked 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 connector at the right, to supply RC08/RC10. Diagrams for remote commands RC07, RC12 and RC 16 are shown below.
Description of machine operation
109
FIG. 34 (Card 15.14.190)
FIG. 35 Electrical diagram RC07 Electrical diagram RC16
Electrical diagram RC12 PEDAL POTENTIOMETER CONNECTOR
110
Description of machine operation
FIG. 36 a1)
c1)
d1)
e1)
f1)
b1)
5.11) Gearmotor unit with encoder (a1) - motor control card (15.14.147) (b1) - Reed sensor card (15.14.173) (d1) - MIG gas solenoid-valve (f1) (see fig. 36)
Card 15.14.147 receives the command from MIG torch pushbutton (push-button ON = 0 V , push-button OFF = 35 Vdc between CN3/9 - CN3/10 of card 15.14.147; cables n° 3 - n.4). It transmits the command to the power source and receives from it the start signal and speed reference digitally through two optic fibres connected to J4 (fig. 37) and to the connectors in fig. 38 (blue terminal to blue connector; grey terminal to black connector). The cable bundle, also supplied with two optic fibres, effects connection between the wire feeder and power source. (For a functional check of the optic fibres, see note 1 at point 5.5). The card internally generates voltages 5 Vdc , +15 Vdc , -15 Vdc 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 comparing the speed reference with the encoder feedback signal. The encoder is powered by 15.14.147 (5 Vdc between cables n° 21 - n° 20 (= ground) and supplies variable frequency signal in linear 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, and about 35Vdc at 22m/min (without wire feeding), and is generated commencing with 42 Vac supplied by the power source via the cable bundle.
Description of machine operation
The card receives - via the serial line of front panel FP 60 - the speed reference and the arc voltage correction set by RC07 (on RC08/RC10, if the outside reference is selected) and transmits these data to the power source. The power source, in turn, transmits them to RC08/RC10 for display. 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 card 15.14.173 (the following are measured at the ends of the glass ampoule : +5 Vdc = wire feeder not supplying current 0 = wire feeder supplying current ) which is used for soft-start control (see NOTE). The card directly commands the MIG gas solenoid-valve (command 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 command synchronised with the start of the gearmotor unit (36 Vac between cables n° 13 - 15 when the gearmotor is operating and the push-pull torch is connected). NOTE : Soft-start operating mode can be clearly verified if you set it at 20-30% value and press the torch push-button a few seconds after the end of the previous welding operation, if any. With the power source in open circuit state (no welding), the soft-start value is maintained for five seconds, and speed then changes to the set value. 111
FIG. 37
connection with the cable bundle (rear part of WF103)
FIG. 38
FIG. 38A
112
FIG. 38B
Description of machine operation
FIG. 39
c1)
d1)
b1)
5.12) Front panel FP60 (15.14.148) (c1) (see fig. 39) Its function is to convert into digital form the speed reference and voltage correction received from RC07, and to galvanically isolate the digital signal by means of the opto-isolators and transmit it via serial line to card 15.14.147. (Remember that the value set with RC07 can be read on the display of RC08/RC10, if the outside reference is selected). The card generates 5 Vdc for powering its own internal circuits and the potentiometers of RC07 (5 Vdc between pins A-B of the connector). The gas test and wire feeder push-buttons are also located on the panel.
Description of machine operation
113
FIG. 40 a1)
e1)
f1)
5.13) Auxiliary transformer for WF103 (e1) (see fig. 40) It supplies power to the cards commencing from 42 Vac received from the power source via the cable bundle. It also supplies 36 Vac to 15.14.147 for powering the push-pull torch.
114
Description of machine operation
LAY-OUTS OF CARDS
Card 15.14.201 side A (Fig. 41)
116
Lay-outs of cards
Card 15.14.201 side B (Fig. 41)
Lay-outs of cards
117
Card 15.14.201 side C (Fig. 41)
118
Lay-outs of cards
Card 15.14.213 side A (Fig. 42)
Lay-outs of cards
119
Card 15.14.213 side B (Fig. 42)
120
Lay-outs of cards
Card 15.14.202 (Fig. 43)
Lay-outs of cards
121
Card 15.14.181 (Fig. 44)
122
Lay-outs of cards
Card 15.14.192 (Fig. 45)
Lay-outs of cards
123
Card 15.14.149 side A (Fig. 46)
124
Lay-outs of cards
Card 15.14.149 side B (Fig. 46)
Lay-outs of cards
125
Card 15.14.149 side C (Fig. 46)
126
Lay-outs of cards
Card 15.14.149 side D (Fig. 46)
Lay-outs of cards
127
Card 15.14.147 side A (Fig. 47)
128
Lay-outs of cards
Card 15.14.147 side B (Fig. 47)
Lay-outs of cards
129
Card 15.14.148 side A (Fig. 48)
130
Lay-outs of cards
Card 15.14.148 side B (Fig. 48)
Lay-outs of cards
131
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) with the following diagnostic functions : Position L1 L2 L3
Status under Meaning normal conditions ON Machine powered GREEN and master switch closed Protection device YELLOW OFF NOT active LIGHTED with Always lighted in RED voltage at output MMA Lighted in TIG between 1°T and 2°T (in 2T) or between 2°T and 3°T (in 4T) Color
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 closed and if the power circuits of card 15.14.149 are operating
Vice versa if the green LED is off then
either the machine is not connected correctly to the power mains or the master switch is open o or the circuits powering card 15.14.149 are not operating
YELLOW LED : This LED is OFF when the machine is operating normally. When it is on, it indicates that an alarm is tripped thus cutting off current supply from the machine. The alarm which may be tripped are as follows (for their meanings, consult the machine functional description) : Code (see note) (FP91/FP111/ FP108/FP136) 00 11 12 15 16 19 20 22
Alarm full description (RC08/RC10) Communications interrupted Coolant shortage Power module overtemperature Overvoltage Undervoltage Overcurrent Data memory error Communications error
then the green LED is on
132
Description of diagnostic indications
Therefore if 00 then
Vice versa if the red LED is OFF either the 40-way flat cable connection to card 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
- in MIG : or the power source is not supplying power to the cooling unit or the pump has failed or water cooling level is too low
Therefore if 12 then
or the machine has exceed the work cycle limits or the fan has failed or air flow is obstructed from the outside or the thermal devices are faulty
Therefore if 15 or 16 then
then
either the power supply has exceeded the permissible limits or the contactor is not closing or the rectifier bridge has failed or card 15.14.201 has failed
and and and
either the torch push-button is not closing the contact or there is no electrical continuity in the cables coming from the torch push-button or 24 Vac are not present between CN4A/1 and CN4A/2 on pc-board 15.14.149 or card 15.14.159 has failed
if the torch push-button was pressed if if WF103 transmits the command to the optic fibre cables of the cable bundle if if the optic fibres of the cable bundle and inside the power source are not interrupted if card 15.14.149 is functioning then the Red LED is lighted between 1° T and 2° T in MIG 2T or between 2°T and 3°T in MIG 4T .
Viceversa if the red LED is OFF then
either the torch push-button is not closing the contact or there is no electrical continuity in the cables coming from the torch push-button or WF103 fan has failed or the optic fibres of the cable bundle and inside the power source are interrupted or card 15.14.149 has failed
Therefore if 19 (01 in case of FP108) then
either overly high welding parameters were selected or 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 15.14.149 are not configured correctly or 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 output. Therefore - the LED is always lighted in MMA. - in TIG : if the torch push-button was pressed and if 24 Vac are present between CN4A/1 and CN4A/2 on pc-board 15.14.149 (the torch push-button uncoupling 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° T in TIG 2T or between 2°T and 3°T in TIG 4T .
Description of diagnostic indications
133
TAB. 01
SPARE PARTS GENESIS 502 GSM
001 002 003 007 009 012 013 014 016 017 018 020 021 022 025 027 029 033 034 035 036 038 040 041 042 043 044 045
134
Socket Delayed fuse 6x30 6.3A 250V Delayed fuse 6x30 4A 250V Fuse carrier Solenoid valve Wirings Rear plastic panel Assembled rear panel Fan PAPST7450 Handle support Handle Upper cover H.F. card Remote control switch Resonant filter 500A Resonant logic card 30µF condenser 600MKF Diode bridge Antivibration foot Lower cover Filter out card H.F. transformer Resonant inductor Leveling inductor Switch Inverter transformer Microprocessor card Toroidal transformer Capacitor
08.26.009 08.25.220 08.25.215 08.25.250 09.05.001 49.02.745 01.04.251 01.05.216 07.10.010 20.04.002 01.15.012 03.07.034 15.14.192 09.02.010 15.14.202 15.14.201 13.03.020 14.10.152 21.04.005 01.02.055 15.14.174 05.03.015 05.04.212 05.04.213 09.01.008 05.02.012 15.14.149 05.11.565 12.06.110
046 047 048 049 051 052 053 054 055 057 061 062
Secondary unit Hinode sensor Front plastic panel Assembled front panel Centralized adaptor Fixed socket Knob Plug Front control panel FP62 Secondary filter unit Primary inverter group Diode
14.60.055 11.19.003 01.04.253 01.04.252 19.06.005 10.13.020 09.11.009 10.01.151 74.04.005 15.14.223 14.60.054 14.05.076
7) AVAILABLE SPARE PARTS : power source . (see TAB. 01)
NOTES : In the exploded view drawing, spare parts with numbers 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 be provided separately. For power components, also order 16.03.102 (thermal paste).
Available spare parts
TAB. 02
SPARE PARTS WF103 WIRE FEEDER
002 005 006 007 008 010 011 012 013 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 033 035 036
Solenoid valve Plug for special connector Fixed plug, 70 mm2 Connection, 3/8, bevelled, with rubber holder Ring nut for connection 3/8 Panel, plastic, rear Rear panel Panel, side, right Slide closure Swivelling wheel Lower cover Rin nut Reel for coil Handle support Handle Upper cover Motor card Reed sensor card Panel, side, left Auxiliary transformer Gearmotor, 120W, 4 rollers with encoder Tip Tip, gas, axial Pipe, 91 mm Panel, front Panel, plastic, front Control panel Fast coupling Flange for adapter
Available spare parts
09.05.001 10.01.150 10.13.054 19.50.022 19.50.013 02.02.018 02.02.020 02.04.065 20.04.036 04.06.003 02.04.067 20.02.006 20.02.003 20.04.002 01.15.002 02.04.068 15.14.147 15.14.173 02.04.066 05.11.056
AVAILABLE SPARE PARTS : WF 103 wire feeder . (see TAB. 02)
NOTE 1 : The current version of pieces 015 , 016 and 022 has a 10 mm diameter pin, whereas the diameter was 8 mm on the previous version. In the second case, all three pieces must be replaced.
07.01.013 19.01.015 19.01.002 19.01.021 02.02.021 02.02.019 15.22.033 19.50.043 19.01.031 135
TAB. 03
SPARE PARTS REDUCTION GEAR, 4 ROLLERS, 120W WITH ENCODER
001 004 005 009 015 016 017 018 019 020 021 022 023 024 026 028
136
Reduction gear, complete Protection grid Brush Pressure unit, complete Tightner cast piece, right Tightner cast piece, left Wire-tightner gear Bush for wire-tightner gear Upper roller Roller washer Special key, 4x5 Clast pece Middle wire threader Rear wire threader Rear wire threader for aluminium Middle gear Lower roller, 0.6-0.8 Lower roller, 1.0-1.2 Lower roller, 1.6 with core Lower roller for aluminium, 12-1.6 Lower roller for aluminium, 0.8-1.0
07.01 013 07.01.182 07.01.176 07.01.225 07.01.167 07.01.168 07.01.117 07.01.219 07.01.140 07.01.220 07.01.208 07.01.186.01 07.01.161 07.01.159 07.01.160 07.01.290 07.01.227 07.01.130 07.01.131 07.01.132 07.01.135
AVAILABLE SPARE PARTS : WF 103 wire feeder . (see TAB. 03)
NOTE 2 : In the first versions of the wire feeder, piece 022 used to be fitted on the gearmotor without an aluminium plate (now supplied). In this case, to replace the piece, code 01.14.208 (= aluminium plate) must be ordered.
Available spare parts
8) WARNINGS, PRECAUTIONS, GENERAL INFORMATION ON EXECUTING REPAIRS
9) DIAGNOSTICS AND REPAIR INSTRUMENTS AND TOOLS.
Repairs may be executed by qualified personnel only.
9.1) Diagnostics instruments and tools
Before attempting any repairs, we advise you to read and understand the information in this manual, especially in regard to safety recommendations. Do not carry out any repair unless another person is present who can provide help in case of an accident. To repair equipment, access is necessary to the internal parts of the machine, and to obtain this, some protective panels have to be removed. Therefore, some extra precautions are necessary, over and above those applying to normal use of the machine for welding, 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 the machine, remember that turning off the switch will not prevent the danger of electric shocks. We therefore advise you to remove the plug and wait for about a minute before attempting any job. Further, as capacitors charged with high voltage may be present, wait about a minute before working on the internal parts. IMPORTANT!: When taking measurements, remember that the measuring instruments themselves can become live and, therefore, do not touch their metal parts. IMPORTANT!: when the TIG mode is selected, the machine 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 not expressly included in the diagnostic procedure, you are advised to disconnect the connector CN2 from board 15.14.192. - Moving parts: IMPORTANT!: Keep your hands well away from the fan when the machine is connected to the power supply. Make sure that the power plug is removed and that the fan is idle before replacing it.
9.1.1) Level 1 You will need the following: - a multimeter with the following scales: Ohm : from 0 to a few Mohm Diode test Direct voltages (Vdc): from mVdc to 1000 Vdc Alternate voltages (Vac): from 10 Vac to 700 Vac NOTE : We recommend you to use an instrument with an automatic scale, because, if the machine faulty, in theory, the level 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 on low capacities, rapid measuring is necessary to prevent the shunt overheating.
9.1.2) Level 2 In addition to the instruments and tools recommended at the previous 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, whether direct or through the metal frame of the oscilloscope must be eliminated. However, we advise you to make a ground connection for the oscilloscope through an in-series capacitor-resistor circuit, where C = 10 nF 1600 V, R = 220Kohm 1W.
- Parts at high temperature: IMPORTANT!: When you have to handle internal parts of the machine, remember that some could be at high temperature. In particular, do not touch cooling radiators.
Warnings, precautions, general information - Diagnostics and repair instruments and tools
137
TAB. 04 Load n. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10)
SELCO normalised loads Resistance (Ohm) Power (KW) 8.8 0.22 8.8 0.22 4.4 0.44 1.76 1.1 0.88 2.2 0.44 4.4 0.44 4.4 0.22 8.8 0.22 8.8 0.15 13.1
NOTE : When designing an electrical panel containing loads for testing welding equipments, there must be a facility for inputting several loads (as listed in the table) in parallel by means of switches. In the remainder of this manual, we shall use the symbol + for inputting two loads in parallel (e.g. 3 + 8 means inputting normalised loads 3 and 8 in parallel).
9.2) Static load If the static loading facility is available, it considerably simplifies the output current check. If this is not feasible, the same tests can be run with the TIG welding technique, but this is more difficult. IMPORTANT!: with static load, in order to avoid damage, disconnect the H.F. generation circuit following the directions given in chapter 8 (Warnings, precautions
). IMPORTANT!: on static load, in order to prevent tripping either the arc-force function, overheating protection, or saturation at generator output, load value must be adapted according to the supplied current. For G 502 GSM , with reference to the SELCO normalised loads (see TAB. 04), the following loads are required , depending on the delivered current : Current (A) 50 150 260 350 500
Load n. 4+5 4+5+8 4+5+6+8 4+5+6+10 6+7+8+9
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 range 1 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.
138
- a pair of pincers and nippers suitable for electronic components. - a bigger pair of nippers for cutting small gauge steel sheet. - a pair of pincers suitable for tightening the gas pipe end rings. - long jawed pincers (to remove the tube of the Binzel adapter) - 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 notes In view of the machine's complexity, before carrying out a diagnosis, knowledge and understanding is required of the machine functions as already described. Therefore, in regard to the diagnosis procedure, consult the information in the paragraph describing the functions of the machine. In this section, we shall just provide some guide-lines to help you make the best use of what we said up to this point, and to provide a useful information exchange tool during contacts with Selco's Servicing Department. 10.2) Diagnosis In the following table, L = level (= 1 or 2)
Diagnosis procedure
CHECKS G 502 GSM Power inverter check Check of rectifier bridge connections
Correct result
K-A = 0.4 A-K=OPEN Check of condition of contacts of contactor and OK e pre-loading resistor 200 Ohm Check of diode connections of the secondary K-A = 0.4 rectifying circuit A-K=OPEN Visual check of 15.14.218 and power modules. OK Check of power IGBT connections C - E = OPEN* * tester set for diode testing E - C = 0.4* ** tester set to Ohm B - E = 10 KOhm** Check of connections of switch-off circuit components C - E = OPEN* ** tester set to Ohm E - C = 0.4* B - E = 22 Ohm** Measurement of open circuit voltage at power source 80 V output (in MMA) Measurement of output cables of card 15.14.218 fig. 16 (open circuit in MMA) Measurement of C - E voltage of the power IGBTs fig. 15 connected to - (open circuit in MMA) Measurement of current supplied by the inverter (in MMA) fig. 18 Current adjustment check Measurement of current output by the power source I measured = (in MMA at static load or in TIG HF or LIFT) I set Current read on FP or RC I read = I measured Voltage read on FP or RC V read = V measured Measurement of Hall sensor power +15Vdc -15Vdc Measurement of welding current reference and 1V=100A feedback signals 1V=125A Function check in TIG H.F. (not for PME) Check if LED L3 of FP is on OK Torch check (replacement test) OK Check of torch fitting condition OK Check of CN4A/3-CN4A/4, card 15.14.149 24 / 0Vdc push-button pressed /released Check of presence of command signal in IC1 of card 1.5Vdc 15.14.192 Check of thyristor of card 15.14.192 fig. 28 Function check of WF103 Check if LED L3 of FP is on OK Voltage check at auxiliary transformer input 42 Vac Voltage check at motor terminals (without wire of 17.5Vdc 11m/1' welding ) 35Vdc 22 m/1' Encoder power supply check +5 Vdc (frequency) Check of encoder feedback signal fig. 38
Paragraph
Effective result L
5.3
1
5.2
1
5.6
1
--5.4
1 1
5.4
1
5.4
1
5.4
2
5.4
2
5.4
2 1 1 1
5.4
1
5.4
1/2
5.5 e 6.1 --5.5
1 1 1 1
5.8
1
5.8
2
5.5 e 6.1 5.13 5.11
1 1 1
5.11 5.11
1 1/2
If the information in this manual and the procedure described here were insufficient to identify the faulty part, first write the effectively checked 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]
11) PARTS DISMANTLING AND RE-INSTALLATION PROCEDURE : power source . (see fig. 50) 11.0) General notes : Dismantling and reassembly operations
are described here only for special parts or parts calling for special attention. To identify the parts, refer to the exploded view drawing and the relevant 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 casing and must be detached to free the casing completely. To refit, carry out these jobs in reverse order. IMPORTANT ! : Don't forget to fix the yellow-green cable to the cover before refitting the cover definitively.
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 located parallel 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 To refit, carry out these jobs in reverse order.
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 card 15.14.202 (022). To refit, carry out these jobs in reverse order.
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 completety. To refit, carry out these jobs in reverse order. IMPORTANT ! : Don't forget to fix the yellow-green cable to the cover before refitting the cover definitively.
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 inductance 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 the intermediate 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 underneath. - Disconnect the connectors CN1 , CN2 , CN4 of pc-board 15.14.201 (025) and pass them through the hole of the intermediate metal plate. - Remove the two screws fixing the inverter block to the intermediate metal plate. - Remove the two screws fixing the inverter block to the lower metal plate. - Take out the inverter block (061) To refit, carry out these jobs in reverse order. IMPORTANT ! : When assembling, take great care no to reverse cables n. 5 (= +) and n. 6 (= -) (see fig. 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 layer of thermal paste (code 16.03.102) on the surface of the power component; - fix the power component on the radiator by means of the screws. IMPORTANT! To insert the component correctly as indicated in fig. 52, the component terminals must be correctly identified using a tester set to diode testing. NOTE : the torque wrench is not necessary for reassembling the diodes. When fixing to the copper bars, however, you should take the precaution of first applying all the screws and tightening them afterwards.
11.9) Fan (014) The fan can be disassembled only after removing the rear plastic 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. To refit, carry out these jobs in reverse order.
140
Parts dismantling and re-installation procedure
11.10) Varistor (on board 15.14.202) (022)
11.16) Solenoid valve (007) - Nipple (005)
Begin to dismantle only after checking the condition of the tracks, of the other electronic components, and of the securing holes for the part.
The probe can be dismantled only after removing the rear metal panel (013) .
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 a uniform but not excessive layer of thermal paste (code 16.03.102) on the surface of the power component. Secure the power component on the radiator, with the screws. IMPORTANT ! : To connect the part correctly, check the 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. To refit, carry out these jobs in reverse order.
- Unscrew the nipple - Unscrew the two screws securing the solenoid valve supporting 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 To refit, carry out these jobs in reverse order. IMPORTANT! When mounting the front nipple, use only LOCTITE 577 joint sealing compound or ordinary TEFLON sealing tape.
11.17) Control logic card 15.14.149 (and 15.14.162) (036) Replacement is very simple. IMPORTANT ! : When assembling, remember to fit the optic fibre connectors correctly Blue terminal Grey terminal
to blue card connector to black card connector
11.13) Fixed socket (052) For the + socket, we advise you to first remove the Hall effect sensor (047) . IMPORTANT ! : When assembling, check if the three 5 nF capacitors in triangle lay-out (between +, - and ground) are connected correctly and, in particular, make sure there are no short-circuits between the capacitor 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.
To refit, carry out these jobs in reverse order.
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. To refit, carry out these jobs in reverse order.
Parts dismantling and re-installation procedure
141
Fig. 50
142
Parts dismantling and re-installation procedure
FIG. 51
FIG. 52
Parts dismantling and re-installation procedure
143
PARTS DISMANTLING AND RE-INSTALLATION PROCEDURE : WF 103 wire feeder . (see fig. 53)
11.24) Gearmotor unit (026)
11.18) Rotating wheel (015)
Do not attempt dismantling unless you have removed the Binzel adapter (036) flange.
- Remove the lower cover (016) by unscrewing the four securing screws at the corners of the plate and the other four around the central pin. - Unscrew the nut securing the wheel to the cover.
-
To refit, carry out these jobs in reverse order.
11.19) Flange for Binzel adapter (036) - Remove the three screw securing the flange for the Binzel adapter (036) - Remove the two hexagon head screws at the side of the Binzel adapter(036) flange To refit, carry out these jobs in reverse order.
11.20) FP60 Control panel (033) Do not attempt dismantling unless you have removed the Binzel adapter (036) flange.
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 elements are present on the four securing holes in the gearmotor support plate. Further, make sure no part of the gearmotor, after it is installed, comes into contact with the wire feeder frame. IMPORTANT ! : Correct fitting direction of the encoder J10 connector: cable n. 20 toward the door. IMPORTANT ! : If, following installation of the gearmotor unit, the wire is pushed in opposite to correct direction, just change over cables n. 22 and n. 23.
11.25) Motor control card 15.14.147 (022)
- 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 disconnect connectors CN1 and CN7.
Replacement is very simple.
To refit, carry out these jobs in reverse order.
Blue terminal Grey terminal
11.21) Plastic front panel (031)
IMPORTANT ! : When assembling, remember to fit the optic fibre connectors correctly to connector of blue card to connector of black card
Do not attempt dismantling unless you have removed the FP60 control panel (033).
11.22) Binzel adapter (028) - tip (027) Do not attempt dismantling unless you have removed the Binzel adapter (036) flange. -
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
To refit, carry out these jobs in reverse order. IMPORTANT ! : When assembling, check if the Binzel adapter (028) projects from the front panel at least as much as the adapter flange (036).
11.23) 91mm tube (029) - Place a screwdriver at roller output and push it toward the outside of the tip - Remove it from outside of the adapter, using long jawed pincers.
144
Parts dismantling and re-installation procedure
Fig. 53
Parts dismantling and re-installation procedure
145
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 the same 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 automatically 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.
146
Operating tests and settings
Card 15.14.201 (Fig. 54)
Operating tests and settings
147
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 diagnostic form.
148
Telephone assistance request procedure
