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REPAIRS MANUAL

Genesis 200 CLS

Cod. 92.08.061
Edition: 1.0
Revision: 26/11/07

selco s.r.l.
Via Palladio, 19
I - 35019 ONARA DI TOMBOLO (PD)
TEL. +39 049 9413111
FAX. +39 049 9413311
email: service.dept@selcoweld.com

How to contact Selco Service Department.:

SELCO s.r.l
Service Department
c/o SELCO 2
Via Macello, 61
I - 35010 CITTADELLA (Padova) Italy
Tel. +39 049 9413111
Fax. +39 049 9413311
email: service.dept@selcoweld.com

All translation, reproduction and adaptation rights, total or partial

and by any means (including photostat copies, films and microfil-
ms), are reserved and forbidden without the written authorisation of
Selco S.r.l.

INDEX:
1) PURSPOSE OF THE MANUAL........................................................................................................PAG. 3
2) WARNINGS, PRECAUTIONS AND GENERAL NOTICES FOR PERFORMING REPAIRS................. PAG. 4
3) INSTRUMENTS AND CONVENTIONS FOR PERFORMING DIAGNOSIS AND REPAIR................ pAG. 5
4) USE AND ROUTINE MAINTENANCE OF POWER SOURCES AND ACCESSORIES
AND TECHNICAL DATES.................................................................................................................. PAG. 7
5) MACHINE DESCRIPTION.............................................................................................................. pag. 11
6) DESCRIPTION OF GENERATOR FUNCTIONING (BLOCK DIAGRAM)......................................... pag. 16
7) WIRING AND CONNECTION DIAGRAM...................................................................................... pag. 22
8) DESCRIPTION OF DIAGNOSTIC INDICATIONS.......................................................................... pag. 24
9) SET-UP parameters.................................................................................................................... pag. 27
10) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS, CURRENT
CALIBRATION.................................................................................................................................... pag. 29
11) TROUBLESHOOTING................................................................................................................. PAG. 43
12) Spare parts list....................................................................................................................... PAG. 52
13) NOMINAL DATA.......................................................................................................................... PAG. 54


1) PURSPOSE OF THE MANUAL
This manual is designed to provide authorised service centres with
the basic information necessary for performing repairs on the models
Genesis 200 CLS.
In order to avoid serious injury to persons or damage to things, this
manual must be used only by qualified technicians.
Selco S.r.l. accepts no liability for any injury to persons or damage
to things that may occur during performance of repairs, even after
reading or practical application of this manual.
For a detailed description of the operation, use and ordinary main-
tenance of the machine, please refer to the “Instructions for use and
maintenance manual” which must always accompany the machine.
The purchaser must follow the directions contained in the above
manual. Failure to do so will exempt Selco from all liability.
The operations described in this manual require the use of a dig-
ital multimeter, an DC ammeter clamp and a basic knowledge of
how the machine works. Basic electrotechnical knowledge is also
required.

Repair consists in identification of the faulty part, included in

the list of available spare parts, and replacement of it.

In the event of failure of an electronic board, repair

entails replacement of the board and not replace-
ment of the faulty electronic component on the
board.

Do not carry out modifications or maintenance not scheduled in

this manual.

If the problem cannot be solved by following the instructions pro-

vided in this manual, contact the Selco Service Department or send
the machine to Selco for repair.


2) WARNINGS, PRECAUTIONS AND GENERAL NO-
TICES FOR PERFORMING REPAIRS
Repairs must be performed by qualified personnel only.
Before performing the repair, you should read and assimilate the
contents of this manual, in particular the safety precautions.
Avoid performing repairs without the presence of another person
able to provide help in the event of an accident.
The repair of a machine requires access to its internal parts and con-
sequently removal of some of the protective panels. Additional pre-
cautions are therefore necessary with respect to use of the machine
for welding in order to prevent possible injury or damage caused by
contact with

- live parts
- moving parts
- parts at high temperature

CAUTION

LIVE PARTS
When handling internal parts of the machine, remember that open-
ing of the switch does not prevent the risk of electric shocks: the
machine must be unplugged from the power supply.
Wait approx. one minute before carrying out work on the internal
parts as the capacitors may be loaded at high voltage.

CAUTION

LIVE PARTS OF THE TOOLS

When taking measurements, remember that the measuring instru-
ments can be live and you should therefore avoid touching their
metal parts.

CAUTION

MOVING PARTS
Keep your hands well away from the fan when the machine is con-
nected to the power supply. Ensure that the machine is unplugged
and that the fan is at a standstill before replacing it.

CAUTION

PARTS AT HIGH TEMPERATURE

When handling internal parts of the machine, remember that some of
them may be very hot. In particular avoid contact with heat sinks.


3) INSTRUMENTS AND CONVENTIONS FOR 3.3 Conventions
PERFORMING DIAGNOSIS AND REPAIR By convention, when a measurement has to be taken between two
3.1 Instruments for basic diagnosis
The following are required:
- a multimeter with the following scales:
Ohm: from 0 ohm to a few Mohm
Diode testing
Direct voltage (Vdc): from mVdc to 1000 Vdc
Alternating voltage (Vac): from 10 Vac to 700Vac
NOTE: You are advised to use an instrument with automatic scale
since it is not theoretically possible to predict the electri-
cal quantity to be measured when the machine has broken
down.
- an DC ammeter clamp at least in class 2.5 with e.o.s. 1000A
pk.
- alternatively to the ammeter clamp, a shunt can be used with
value 120 mV @ 500 A.
points, for example a b, the arrow point indicates where to
apply the red tip of the multimeter (a),while the black tip is applied
at the other end (b).
When a double arrow appears between two measuring points (e.g.:
c d), the voltage to be measured is alternating (normally at
50 Hz), therefore it does not matter in which order the multimeter
terminals are applied.
In drawings and tables, when a voltage measurement appears refer-
ring to terminals of components such as DIODES, BJT, MOSFET and
IGBT, the multimeter is used in “diode test” mode (these measure-
ments are always taken with the machine switched off and normally
give values in the range +0.10 … +0.90Vdc). In this case the follow-
ing symbol is affixed beside the value to be measured:
Junction measurement (multimeter in “diode test”
mode)
The following symbols will be used in the same way:
AC or DC voltage measurement (multimeter in voltme-
ter mode).
Resistance measurement (multimeter in ohmmeter
mode).

NOTES:
* Remember that other types of shunts can also be used, but ac-
curacy is reduced with higher capacities, whereas with lower ca-
pacities the measurement must be taken quickly to avoid over-
heating of the shunt
Current measurement (ammeter clamp or shunt + mul-
timeter in millivoltmeter mode).
Frequency measurement (multimeter in frequencymeter
mode).

* Once fitted, the shunt is at welding potential

The measuring conditions (power source on/off, MMA/TIG operat-
* The ammeter clamp is preferable as it is more practical ing mode, erc.) are always clearly indicated beside the values to be
measured.

The connector terminals are indicated by the name of the connec-

tor followed by a slash and the number of the terminal; for example
3.2 Repair tools
CN1/2 indicates terminal 2 of connector CN1.
- Complete set of fork spanners
- Complete set of pipe spanners for hexagonal nuts
Unless otherwise specified, all the measurements must be performed
- Complete set of blade screwdrivers
with the boards fitted, together with their connections.
- Complete set of Phillips screwdrivers
- Complete set of Allen keys
- Crimper for insulated wire terminals (blue, red and yellow) Remember that the first of the tests to be performed
- Pliers for AMP contacts is the VISUAL CHECK!
- Tweezers and cutting nippers - type commonly used for elec-
tronic components
- Tongs (dimensions suitable for closing gas pipe clamps) The visual check reduces troubleshooting times and directs any
- Welder for electronic components, minimum power 50 W subsequent tests towards the damaged part!
- Portable electric drill


3.4 Static load
Use of grid load can speed up fault tracing and machine testing.
Just remember that a fixed power resistor applied to machine’s out-
put is somewhat equivalent to a welding arc, but only inside of a
narrow output voltage range, whose center value can be determined
by the formula:

STICK WELDING:
VOUT = 20 + 0.04 x IOUT

Es.: 22Vdc @ 50A

24Vdc @ 100A
28Vdc @ 200A etc.

TIG WELDING:
VOUT = 10 + 0.04 x IOUT

Es.: 12Vdc @ 50A

14Vdc @ 100A
18Vdc @ 200A etc.

If output voltage goes too much above or below the rated value, the
generator could either saturate or go into arc force or other special
features could be performed (such as anti-flashing): in both cases
real output current could be much different from expected value
and the generator could even show an intermittent output power.
Grid load resistor’s rated power is also important, ‘cos a 24Vdc @
100A grid load produces 2400W to be dissipated by air cooling.

So, when using grid load, pay attention to both out-

put current & output voltage and use correct resist-
ance value & power!


4) USE AND ROUTINE MAINTENANCE OF POWER SOURCES AND ACCESSORIES, TECHNICAL DATES
Use and routine maintenance (excerpt from the “Instructions for use” manual provided with each power source).

CAUTION
4.1 WARNING
Before performing any operation on the machine,
make sure that you have thoroughly read and under-
stood the contents of this booklet.
Do not perform modifications or maintenance opera-
tions which are not prescribed.
The manufacturer cannot be held responsible for damages to
persons or property caused by misuse or non-application of the
contents of this booklet by the user.
Please consult qualified personnel if you have any
doubts or difficulties in using the equipment.
4.1.1 Work environment
Wear protective clothing to protect your skin from the
arc rays, sparks or incandescent metal.
Clothes must cover the whole body and must be:
- intact and in good conditions
- fireproof
- insulating and dry
- well-fitting and without cuffs or turn-ups
Always use regulation shoes that are strong and ensure
insulation from water.
Always use regulation gloves ensuring electrical and
thermal insulation.

Position a fire-retardant shield to protect the surround-

• All equipment shall be used exclusively for the operations for
which it was designed, in the ways and ranges stated on the rat-
ing plate and/or in this booklet, according to the national and
international directives regarding safety. Other uses than the one
expressly declared by the manufacturer shall be considered total-
ly inappropriate and dangerous and in this case the manufacturer
disclaims all responsibility.
• This equipment shall be used for professional applications only, in
industrial environments.
The manufacturer shall not be held responsible for any damages
caused by the use of the equipment in domestic environments.
• The equipment must be used in environments with a tempera-
ture between -10°C and +40°C (between +14°F and +104°F).
The equipment must be transported and stored in environments
with a temperature between -25°C and +55°C (between -13°F
and 131°F).
• The equipment must be used in environments free from dust,
acid, gas or any other corrosive substances.
• The equipment shall not be used in environments with a relative
humidity higher than 50% at 40°C (104°F).
The equipment shall not be used in environments with a relative
humidity higher than 90% at 20°C (68°F).
• The system must not be used at an higher altitude than 2,000
metres (6,500 feet) above sea level.
Do not use this machine to defrost pipes.
Do not use this equipment to charge batteries and/or
accumulators.
Do not use this equipment to jump-start engines.
ing area from rays, sparks and incandescent slags.
Advise any person in the area not to stare at the arc
or at the incandescent metal and to get an adequate
protection.
Wear masks with side face guards and a suitable pro-
tection filter (at least NR10 or above) for the eyes.
Always wear safety goggles with side guards, especially
during the manual or mechanical removal of welding
slag.
Do not wear contact lenses!
Use headphones if dangerous noise levels are reached
during the welding.
lf the noise level exceeds the limits prescribed by law,
delimit the work area and make sure that anyone getting
near it is protected with headphones or earphones.
While loading and feeding the wire, keep your head
away from the MIG/MAG torch. The wire that is com-
ing out can seriously damage your hands, face and
eyes.
Avoid touching items that have just been welded: the
heat could cause serious burning or scorching

• Follow all the precautions described above also in all operations

4.1.2 User's and other persons' protection
carried out after welding since slag may detach from the items
The welding process is a noxious source of radiation,
while they are cooling off.
noise, heat and gas emissions.


 Keep a first aid kit ready for use.
Do not underestimate any burning or injury.
Before leaving work, make the area safe, in order to
avoid accidental damage to people or property.
• Do not weld in places where explosive powders, gases or vapours
are present.
• When you finish welding, check that the live circuit cannot acci-
dentally come in contact with any parts connected to the earth
circuit.
• Position a fire-fighting device or material near the work area.

4.1.5 Prevention when using gas cylinders

4.1.3 Protection against fumes and gases
• Fumes, gases and powders produced during the welding process
can be noxious for your health.
Under certain circumstances, the fumes caused by welding can
cause cancer or harm the foetus of pregnant women.
• Inert gas cylinders contain pressurized gas and can explode if the
minimum safe conditions for transport, storage and use are not
ensured.
• Cylinders must be secured in a vertical position to a wall or other
supporting structure, with suitable means so that they cannot fall
or accidentally hit anything else.

• Keep your head away from any welding gas and fumes.
• Provide proper ventilation, either natural or forced, in the work area.
• In case of poor ventilation, use masks and breathing apparatus.
• In case of welding in extremely small places the work should be
supervised by a colleague standing nearby outside.
• Do not use oxygen for ventilation.
• Ensure that the fumes extractor is working by regularly checking
the quantity of harmful exhaust gases versus the values stated in
the safety regulations.
• The quantity and the danger level of the fumes depends on the
parent metal used, the filler metal and on any substances used to
clean and degrease the pieces to be welded. Follow the manu-
facturer's instructions together with the instructions given in the
technical sheets.
• Screw the cap on to protect the valve during transport, commis-
sioning and at the end of any welding operation.
• Do not expose cylinders to direct sunlight, sudden changes of
temperature, too high or extreme temperatures. Do not expose
cylinders to temperatures too low or too high.
• Keep cylinders away from naked flames, electric arcs, torches or
electrode guns and incandescent material sprayed by welding.
• Keep cylinders away from welding circuits and electrical circuits
in general.
• Keep your head away from the gas outlet when opening the cyl-
inder valve.
• Always close the cylinder valve at the end of the welding opera-
tions.
• Never perform welding operations on a pressurized gas cylinder.

• Do not perform welding operations near degreasing or painting • A compressed air cylinder must never be directly coupled to the
stations. machine pressure reducer. Pressure might exceed the capacity of
Position gas cylinders outdoors or in places with good ventila- the reducer which could consequently explode.
tion.

4.1.4 Fire/explosion prevention

• The welding process may cause fires and/or explosions.

• Clear the work area and the surrounding area from any flamma-
ble or combustible materials or objects.
Flammable materials must be at least 11 metres (35 feet) from the
welding area or they must be suitably protected.
Sparks and incandescent particles might easily be sprayed quite
far and reach the surrounding areas even through minute open-
ings. Pay particular attention to keep people and property safe.
• Do not perform welding operations on or near containers under
pressure.
• Do not perform welding or cutting operations on closed contain-
ers or pipes.
Pay particular attention during welding operations on pipes or
containers even if these are open, empty and have been cleaned
thoroughly. Any residue of gas, fuel, oil or similar materials might
cause an explosion.

 4.1.6 Protection from electrical shock

• Electric shocks can kill you.

• Avoid touching live parts both inside and outside the welding
system while this is active (torches, guns, earth cables, electrodes,
wires, rollers and spools are electrically connected to the welding
circuit).
• Ensure the system and the welder are insulated electrically by
using dry bases and floors that are sufficiently insulated from the
earth.
• Ensure the system is connected correctly to a socket and a power
source equipped with an earth conductor.
• Do not touch two torches or two electrode holders at the same
time.
lf you feel an electric shock, interrupt the welding operations
immediately.


4.2 ELECTROMAGNETIC COMPATIBILITY (EMC)

CAUTION
4.2.1 Electromagnetic fields & interferences
• The welding current passing through the internal and external
system cables creates an electromagnetic field in the proximity of
the welding cables and the equipment itself.
• Electromagnetic fields can affect the health of people who
are exposed to them for a long time (the exact effects are still
unknown).
Electromagnetic fields can interfere with some equipment like
pacemakers or hearing aids.
Persons fitted with pacemakers must consult their doc-
tor before undertaking arc welding or plasma cutting
operations.
Installation, use and area examination
This equipment is manufactured in compliance with the require-
ments of the EN60974-10 harmonized standard and is identified as
"CLASS A" equipment.
This unit must be used for professional applications only, in indus-
trial environments.
The manufacturer will accept no responsability for any damages
caused by use in domestic environments.
- The cables must be kept as short as possible, positioned as close
as possible to each other and laid at or approximately at ground
level.
- Position the equipment at some distance from the welding area.
- The cables must be kept away from any other cables.
Earthing connection
The earth connection of all the metal components in the welding
equipment and in the close aerea must be taken in consideration.
The earthing connection must be made according to the local regu-
lations.
Earthing the workpiece
When the workpiece is not earthed for electrical safety reasons
or due to its size and position, the earthing of the workpiece may
reduce the emissions. It is important to remember that the earthing
of the workpiece should neither increase the risk of accidents for the
user nor damage other electric equipment.
The earthing must be made according to the local regulations.
Shielding
The selective shielding of other cables and equipment present in the
surrounding area may reduce the problems due to electromagnetic
interference. The shielding of the entire welding equipment can be
taken in considered for special applications.

The user must be an expert in the activity and as such is 4.2.2 Risk Analysis
responsible for installation and use of the equipment
Risks posed by the machine Solutions adopted to pervent
according to the manufacturer's instructions.
them
lf any electromagnetic interference is noticed, the user
must solve the problem, if necessary with the manufac- Risk of wrong installation A manual with the instructions
turer's technical assistance. for use has been produced for
In any case electromagnetic interference problems must this purpose
be reduced until they are not a nuisance any longer. Electrical risks Application of the EN 60974-1
Standard
Risks connected with electro- Application of the EN 50199
Before installing this apparatus, the user must evaluate magnetic disturbances produ- Standard
the potential electromagnetic problems that may arise ced by the welding power sour-
in the surrounding area, considering in particular the ce and induced on the welding
health conditions of the persons in the vicinity, for exam- power source.
ple of persons fitted with pacemakers or hearing aids.

Mains power supply

In case of interference, it may be necessary to take further precau-
tions like the filtering of the mains power supply.
lt is also necessary to consider the possibility of shielding the power
supply cable.

Welding cables
To minimise the effects of electromagnetic fields follow the following
instructions:
- Where possible, collect and secure the earth and power cables
together.
- Never coil the welding cables around your body.
- Do not place your body in between the earth and power cables
(keep both on the same side).
10
5) MACHINE DESCRIPTION
The GENESIS 200 CLS are power source that can perform the fol-
lowing types of welding with excellent results:
- MMA;
- TIG (with reduction in the current on short-circuiting);
The generator is equipped with:
- Positive (+) and negative (-) socket.
- Front panel.
- Rear control panel.
5.1 CONTROLS
5.1.1 Front control panel FP134
* L1 : Voltage warning light green led.
It turns on with the start switch ( "I1" in position "I" and indicates that
the plant is on and there is voltage.
* L2 : Safety device warning light yellow led.
Indicates the triggering of the thermal cutout or of the cutout for
incorrect supply voltage. With "L2" on, the number 10 flashes on
"D1", the generator remains connected to the mains, but does not
supply power at the output.
If other alarm codes appear on "D1", contact your authorised SELCO
dealer.
If over-heating occurs, "L2" stays on until the fault has been removed
and in any case until the inner temperatures are not within the nor-
mal values; in this case it is necessary to leave the power source on
to exploit the operating ventilator and reduce the time when it is not
active. Push any key button to start again.
* L3 : Voltage output warning light (work) red led.
Indicates the presence of output voltage.
* Display "D1"
Shows the welding current or the value of the welding parameter
chosen with "S5" on the drawing "G1".
It is used for providing alarm messages, setting the set-up parameters
and displaying the real welding voltage and current readings.
* E1 : Encoder for setting of the welding current, welding
parameters and setup values
Allows you to continuously adjust the current both in TIG and in
MMA welding, from 5 to 160A. This current stays unchanged when
the supply and welding conditions vary within the allowed ranges.
In MMA welding, the presence of HOT-START and ARC-FORCE
means that the average output current may be higher than that set.
Allows you to change the value, shown on "D1", of the parameter
selected with "S5" on the drawing "G1".
Allows you to specify the required setup line and to vary the value.
* S1: Current adjusting system push button
Selectes the welding current adjuststing system:
- from front panel "inside"
- from remote control "outside"
The coming on of the led beside the symbol confirms the selec-
tion.
* J1: 7 pins connector
For the connection of the remote controls RC16 and RC12.
* S2: Welding selection push button
Selects the process and the relative welding mode.
The coming on of the led beside the symbol confirms the selection.
Processes:
- electrode
- TIG with LIFT-ARC start
* S3: Standard (STD) electrode or cellulose (CEL) electrode selection
key.
If the "STD" mode is selected, the Arc-Force, Hot-Start and dynamics
values stored by the operator will be used (Selco stores the optimum
values for basic electrodes by default) which can be modified during
SETUP (see "S5": SETUP/parameters key).
It is possible to switch from "CEL" to "STD" by simply pressing "S3"
and vary Hot-Start and Arc-Force as required via "S5" and "E1".
Ignition of the led near the symbol confirms the selection.
* S4: Readings key
The reading of the real welding current appears on "D1" during and
at the end of welding. "S4" permits display of the real welding volt-
age and allows you to switch from one value to another. Ignition of
the LED near the symbol confirms the selection.
11
S5: SETUP/parameter push button * If it is necessary to modify the values of the welding parameters of
Ensures access to the SETUP and to the welding parameter values. the diagram "G1":
If pressed on starting, while on "D1" the software version is displayed, - Wait four seconds after the leds on the panel have gone out, the
it allows you to access the parameters:

led "I" (welding current) will remain on in the diagram.
0 Save and exit - Press the "S5" push button; every time the push button is pressed,
6 Min. current value with remote control one of the leds in the diagram (7) comes on (in clockwise
(6A÷I max, predef. 6A) sequence) and the value of the relevant parameter appears on the
7 Max. current value with remote control display "D1" stop at the desired parameter.
(6A÷I max, predef. I max)
9 Reset of all parameters Hot-Start % - MMA, adjustable from front panel
13 Electrode type selection, others not used min. 0 - max. 100 - predef. 80

Arc-Force % - MMA, adjustable from front panel
If the button is pressed at the end of the start-up procedure for the
min. 0 - max. 100 - predef. 30
welding machine, the welding parameters shown on the drawing "G1"
are selected with the value shown on "D1" and variable with "E1". Imax. external A - Adjustable from front panel and setup mode
min. 6 - max. 200 - predef. 200
To store the most suitable welding dynamics for the job you are
doing in "STD", enter SETUP at parameter 13. I min external A - Adjustable only from the setup mode
Press "S5" to confirm. min. 6 - max. 200 - predef. 6

Choose the type of electrode via "E1".
- Rotate the potentiometer " E1 " and modify the parameter value.
- Press the SETUP/parameter push button (6) again to pass to another
0 Basic
parameter, or wait five seconds (the led " I " in the diagram (7)
1 Rutilic
comes on again automatically).
2 Cellulose
3 Steel
The machine is always ready to weld and its state
4 Aluminium
is defined by ail the leds that are on the panel.
5 Cast iron

Press "S5" to confirm.

Exit SETUP (return to 0 via "E1" and press "S5" to exit).
5.1.2 Rear control panel
The dynamics for the selected electrode will be stored until the next
* I1: Off/On switch
modification in "STD".
Turns on the electric power to the welder.
Arc-Force and Hot-Start can be varied as required.
It has two positions, "O" off, and "I" on.

Operation:
The machine stores the last welding step and With the I1 switch in the "I" on position, the welder
presents it again when restarted. is operational, and gives a voltage between the posi-
tive (+) and negative (-) clamps.

* Position the start switch "I1" on "I"; the coming on of the voltage
warning light "L1" (green led) confirms that the plant is under volt-
age.
* The display "D1" shows the figure 200 and all the LED's light up
(as a check) for 3 seconds. Then the LED's go off on the front and
for 4 seconds "D1" shows the software version for the welder (e.g.
1.0); during this time, you can:
- enter the SETUP mode by pressing the key "S5";
- or continue welding (or change the parameters).
The welder is connected to the mains supply even
if the I1 switch is in the "O" position, and therefore
there are electrically live parts inside it.
Carefully follow the instructions given in this man-
ual.
*1 : Supply cable.

* If selected, the SETUP mode is confirmed by a center "0" on the

display "D1".
- Rotate the potentiometer "E1", the display "D1" shows the numbers
corresponding to the parameters in sequence; stop at the desired
parameter and push the "S5"

With parameter (9) all the modifications made in

the SETUP mode are cancelled and the standard
values set by SELCO are restored.

- The number on the display "D1" is replaced by the value of the

parameter that can be modified through the potentiometer "E1"

12
5.2 TECHNICAL DATA 5.3.2 Electric connection to the supply mains
GENESIS 200 CLS The equipment is provided with a single electric connec-tion with a
5m cable positioned in the rear part of the po-wer source.
Power supply voltage (50/60 Hz) 3x400V±10% Size table of the power source input cables and fuses:
Max. absorbed power (x=40%) 6.6kW
Max. absorbed current (x=40%) 10.1A GENESIS 200 CLS
Absorbed current (x=100%) 6.6A Rated voltage 400V ± 10%
Voltage range 360 - 440V
Efficiency (x=40%) 0.85
Delayed fuses * 16A 500V
Power factor (x=40%) 0.94 Power supply cable 4x2.5mm2
Cos (x=40%) 0.99
*: In general, delayed fuses 10A 500V are suitable
Welding current (x=40%) 200A
(x=60%) 160A The electrical system must be made by skilled techni-
(x=100%) 140A cians with the specific professional and technical quali-
Adjustment range 6-200A fications and in compliance with the regulations in force
Open-circuit voltage (limited) 97V in the country where the equipment is installed.

Protection rating IP23 The welding power source supply cable is pro-
lnsulation class H vided with a yellow/green wire that must ALWAYS be
earthed. This yellow/green wire must NEVER be used
Construction standards EN60974-1/EN50199
with other voltage conductors.
Dimensions (lxdxh) 179x430x290mm
Weight 16Kg * Verity the existence of the earthing in the used plant and the
good condition of the socket/s.
Above data are referred to environment al 40°C. * lnstall only plugs that are homologated according to the safety
regulations.
5.3 Transport - Unloading
Never underestimate the weight of the equip- 5.4 CONNECTING THE EQUIPMENT COMPONENTS
ment, see (TECHNICAL DATA).
Keep to the safety regulations contalned in section
Never make the cargo pass or leave it suspended 4.1 CAUTION.
over people or things.
Connect the componente carefully, in order to avoid
Neither let the equipment or the single unit fall, power losses.
nor put it down with force.

5.4.1 Connection for MMA welding

* Connect (4) the earth clamp (2) to the negative socket (-) (6) of the
Once it has been removed from the packing, the power source is power source.
supplied with an extendible belt which can be used to move it in * Connect (1) the electrode holder (5) to the positive socket (+) (3) of
the hand or on the shoulder. the power source.

The connection described above ensures welding

5.3.1 Installation - General rules with straight polarity. To weld with reverse polarity,
Choose an adequate installation area by following the criteria pro-
reverse the connection.
vided in Section "4.1 CAUTION".
Do not position the power source and the equipment on surfaces
with inclination exceeding 15° with respect to the horizontal plane.
Protect the installation from heavy rain and sun. The ma-chine pro-
tection degree (IP23) is effective against water that falls down in a
direction forming an angle up to 60° with the vertical line.

13
5.4.2 Connection for TIG welding 5.5.2 Possible faults in the TIG welding
* Connect (4) the earth clamp to the positive socket (+) (3) of the
Fault Cause
power source.
* Connect the TIG torch coupling (1) to the torch socket (6) of the Oxidations 1) lnsufficient gas.
power source. 2) No protection on the reverse.
* Connect separately the connector on the gas (7) pipe to the gas Tungsten inclusions 1) lncorrect electrode sharpening.
supply. 2) Electrode too small.
3) Operating failure (contact of the
tip with the workpiece).
The protection gas flow is adjusted using the tap
Porosity 1) Dirt on the edges.
normally located on the torch (8).
2) Dirt on the filler material.
3) High advancement speed.
4) Current intensity too low.
Hot cracks 1) Unsuitable filler material.
2) High heat supply.
3) Dirty materials.

5.5.3 Possible electrical failures

Failure Cause
Machine fails to come on 1) No current in the power
(Green LED off) socket.
2) Faulty supply plug or cable.
3) Internal fuse blown.
Power output incorrect 1) MMA/TIG selector switch in
(Green LED on) incorrect position or faulty.
5.5 PROBLEMS - CAUSES 2) Faulty current control poten-
tiometer.
5.5.1 Possible fault in the MMA welding Absence of output current 1) Mains power voltage out of
Fault Cause (Yellow led on and figure 10 range.
blinking on D1) 2) Equipment overheated (yel-
Excessive spatter 1) Long arc.
low LED on).
2) High current.
With welder on, wait for it to
Craters 1) Fast movement of the electro- cool.
de away from piece.
Inclusions 1) Poor cleanliness or distribu- If you have any doubts or problems, do not hesitate to consult
tion of the passes. your nearest Selco technical service centre.
2) Defective movement of the
electrode.
Insufficient penetration 1) High progression speed.
2) Welding current too low.
3) Narrow chamfering.
4) Deseaming failure on top.
Sticking 1) Arco troppo corto.
2) Corrente troppo bassa.
Blow-hole and porosity 1) Umidità nell’elettrodo.
2) Arco lungo.
Cracks 1) Correnti troppo elevate.
2) Materiali sporchi.
3) Idrogeno in saldatura (pre-
sente sul rivestimento del-
l’elettrodo).

14
5.6 ROUTINE MAINTENANCE
Prevent metal powder from accumulating near the aeration fins and
over them.

Disconnect the power supply before every opera-

tion!

Carry out the following periodic controls on the power source:

* Clean the power source inside by means of low-pressure com-
pressed air and soft bristel brushes.
* Check the electric connections and all the connection cables.
For the use and maintenance of the pressure reducers, consult the
specific manuals.

For the maintenance or replacement of torch compo-

nente TIG, electrode holder and/or earth cables:

* Disconnect the power supply before every operation.

* Check the temperature of the componente and make sure
that they are not overheated.
* Always use gloves in compliance with the safety standards.
* Use suitable spanners and tools

TIG torches
Type SR 26V
Available lengths 4m
8m
Current 100% d.c. 240A
a.c. 200A
Electrode diameter 0.5 - 4 mm
Type of cooling Aria
Type of connector BSB 35-50

Tighten the componente with care, in order to avoid:

- Heating;
- False contacts.
- Gas leaks.
- Mechanical damage.
Make sure that there is no dirt or metallic powder in the cooling pipes,
in the contact joints and near the electrode.

15
6) DESCRIPTION OF GENERATOR FUNCTIONING (BLOCK DIAGRAM)

Block diagram of Genesis 200 CLS

a) Master switch.
b) Varistors.
c) EMI input filter board.
d) Input rectifier.
e) DC LINK capacitor.
f) Zero Voltage and Zero Current Switching full bridge inverter.
g) Power transformer.
h) Output rectifier.
i) Output inductor.
j) Output current sensor.
k) Auxiliary transformer.
l) Power supply stage.
m) Control and driver logic of the inverter.
n) Front Panel.
o) Output filter.

16
6.1) Input filter WARNING
The 400Vac - 50/60Hz three-phase supply voltage is supplied to the
input filter board 15.14.233.

Between phases there is a varistor, which is an electronic component

which, when a voltage of around 500V appears on its terminals,
becomes conductive extremely rapidly, absorbing a current peak so When accessing parts inside the machine, remember that open-
as to limit this overvoltage and so protect the other parts of the ma- ing the circuit breaker does not prevent the dnager of electric
chine. shocks.
Therefore:
This process is not destructive for the component if the energy IT IS ADVISABLE TO PULL OUT THE POWER PLUG.
brought into play by the voltage peak is modest as in the case of
atmospheric lightning. If, however, the overvoltage is high and the
persistence time exceeds certain limits, the varistor is not capable of
supporting this energy and burns out.

This happens, for example, as a result of overvoltages on the electric

line or overvoltages caused by generating sets which are unstabilised
and have insufficient output.

The filter circuit is made using passive components such as a toroidal

inductor and some capacitors, some of them earthed. The filter has
the dual role of containing the machine’s radiofrequency emissions
within the limits specified by legislation and of rendering it immune
to interference from the supply sources.

17
6.2) Rectifier bridge and DC link
The rectifier bridge has the job of making the first power conversion
and in particular of making an AC/DC conversion.

The sinusoidal input voltage is rectified by a Graetz bridge rectifier

which feeds a bank of smoothing capacitors.

Thus, the capacitor bank forms a DC LINK or a connection between

the rectifier stage and the inverter stage on which a constant voltage
difference is present.

The value of the DC LINK voltage can be easily calculated by the

following equation:

VBUS = x Vac = 1.41x400=+565Vdc

Therefore, a continuous voltage of +565V is present on the bus.

The DC voltage thus obtained will be the input voltage for the fol-
lowing inverter stage.

18
6.3) inverter STAGE
The inverter stage is the second in processing the output. This stage
carries out the DC/AC conversion to obtain alternating frequency at
a frequency, about 40kHz (when you have open circuit voltage).

The alternating voltage is applied to the transformer primary. Since

the dimensions of the transformer are inversely proportional to the
frequency of the voltage applied, high frequency commutation
means that small transformers can be produced with lower mag-
netic losses compared to transformers with network frequency of
50/60Hz.

In addition to adjusting the voltage and current levels, the transform-

er is also used to achieve galvanic isolation between the user and the
electrical network, as required by current legislation.

The inverter produced by Selco for the Genesis 200CLS machines

is a Zero Voltage and Zero Current Switching full-bridge resonant
inverter. The commutations of the electronic switches are therefore
made for one leg when the voltage is nil and for the other when the
current is nil, thus reducing losses due to commutation and increas-
ing the efficiency of the system. The power output is regulated using
Phase Shifting.

19
6.4) OUTPUT STAGE
The AC voltage and current generated by the inverter stage and sup-
plied to the secondary are fed to a rectifier which carries out the final
AC/DC power conversion.
The power is now available for the welding process and is filtered in
order to give a voltage and/or current value as close as possible to the
ideal wave forms required by the welding process.

20
6.5) AUXILIARY POWER SUPPLY AND AUXILIARY
SWITCHING UNIT
An auxiliary transformer is supplied by 400Vac 50/60Hz voltage that
is drawed from input power supply to obtain the 230Vac and 24Vac
isolated voltage.
The 230Vac voltage feeds the fan motor and it is the input voltage of
switching power supply on mainboard 15.14.254.
At the output of switching power supply there are some linear stages
that generate the DC voltages +17Vdc, +15Vdc, +5Vdc, -10Vdc
and -15Vdc.
The front panel board is supplied with a DC voltages by switching
power supply and with the 24Vac generates by auxiliary transfor-
mer.
With linear stages are obtained the DC voltages +15Vdc, +5Vdc
and -15Vdc.

21
7) WIRING AND CONNECTION DIAGRAM

22
Filo/ Descrizione Description
Wire
2 230Vac alimentazione ventilatore 230Vac Fan power supply
4 Termico T1 T1 thermal protection
7 0_230Vac alimentazione ventilatore 0_230Vac Fan power supply
9 Termico T1 T1 thermal protection
11 Tensione di alimentazione 400Vac (fase U) 400Vac supply voltage (phase U)
12 Tensione di alimentazione 400Vac (fase V) 400Vac supply voltage (phase V)
13 Tensione di alimentazione 400Vac (fase W) 400Vac supply voltage (phase W)
14 NON UTILIZZATO NOT USED
15 +17Vdc +17Vdc
16 Termico T1 T1 thermal protection
17 0_230Vac 0_230Vac
18 230Vac 230Vac
19 Termico T1 T1 thermal protection
22 +VBUS +VBUS
23 -VBUS -VBUS
34 +15Vdc_HALL +15Vdc_HALL
35 OUT_HALL OUT_HALL
36 GND_HALL GND_HALL
37 -15Vdc_HALL -15Vdc_HALL
38 GND (0_VOUT) GND (0_VOUT)
39 +VOUT +VOUT
40 Termico T1 T1 thermal protection
41 Termico T1 T1 thermal protection
42 R1 clamp R1 clamp
43 R1 clamp R1 clamp
44 R2 clamp R2 clamp
45 R2 clamp R2 clamp
46 Termico T2 T2 thermal protection
47 Termico T2 T2 thermal protection
50 400Vac 400Vac
52 0_400Vac 0_400Vac
53 230Vac 230Vac
54 24Vac 24Vac

23
8) DESCRIPTION OF DIAGNOSTIC INDICATIONS
For the meaning and use of the various controls, please refer to the respective user manuals; only the diagnostic indications are described
in this section.

8.1) Genesis 200CLS external indication

ALIMENTAZIONE ALLARME POTENZA IN USCITA

(POWER SUPPLY) (ALARM) (OUTPUT POWER ENABLE)

MMA

INTERNO TIG LIFT ARC

(INTERNAL)
STD
ESTERNO
(EXTERNAL)
CEL

MISURA DI
TENSIONE

MISURA DI
CORRENTE

DISPLAY D1
(D1 DISPLAY)

POWER SUPPLY LED (GREEN)

Indicates the on/off status of the machine. Always illuminated if the panel, and therefore the machine, is correctly supplied.

THERMAL PROTECTION (YELLOW)

Indicates the equipment alarm status. Never illuminated unless a problem is present. The type of alarm is indicated by a code on the display
itself (see following table).

Alarm code Type of alarm

10 Mains alarm: no phases, undervoltage or overvoltage.
20 Memory fault.
21 Parameters could not be stored.
24 Remote control could not be adjust
25 Memory fault.
26 Incorrect cheksum of parameters.

OUTPUT POWER ENABLE (RED)

Indicates the presence of voltage in output of the machine.

24
DISPLAY
When switched on the generator performs an “AUTOTEST” during which the display indicates the size of the generator “200” and immedia-
tely afterwards, the display briefly indicates the software version installed (e.g. u01).
The display indicates the welding parameters requested by the operator (using the various buttons) and immediately afterwards the stiking
of the arc is displayed, showing the true value of the voltage or current supplied.

INTERNAL
Current system adjustment from front panel.

EXTERNAL
Current system adjustment from remote control.

MMA
MMA welding mode.

TIG LIFT ARC

TIG LIFT ARC welding mode.

STD
If the "STD" mode is selected, the Arc-Force, Hot-Start and dynamics values stored by the operator will be used (Selco stores the optimum
values for basic electrodes by default) which can be modified during SETUP.

CEL
If “CEL” mode is selected, the Arc-Force and Hot-Start can be free modified.

VOLTAGE MEASURE
Permits to see on the display the real value of welding voltage.

CURRENT MEASURE
Permits to see on the display the real value of welding current.

25
8.2) Genesis200CLS internal indication

L4 L1 L2 L3

L1 - Power supply LED (GREEN) L3 - Alarm LED (RED)

Indicates the presence of +17Vdc voltage supply.
L2 - Power supply LED (GREEN)
Indicates the presence of -10Vdc voltage supply.
26
Indicates the alarm status of the machine: overvoltage or undervo-
late.
L4 - Power supply LED (GREEN)
Indicates the presence of -10Vdc voltage supply.
9) SET-UP parameters
For the Genesis 200CLS generators, microprocessor board 15.14.236 is present. The settings on the front panel are incremented by those
present within the SET-UP, which is accessed in the following manner:
- Switch on the machine.
- The machine performs an “AUTOTEST” during which only the green power supply LED remains illuminated, “200” is shown on the di-
splay followed by the software version (e.g.: u01), and the machine is then ready according to the last welding conditions set.
- Select the type of process (MMA or TIG LIF-ARC) using the “PROCESS” button.
- Press the “S5” button for at least 3 seconds.
- The display shows a “0”.
- By turning the current encoder (knob on the panel), it is possible to set figures from “0” to “99” and by pressing the “PARAMETERS”
button it is possible to see the value of the associated parameter, as indicated in the following tables:

N° Parameter Description Range Default

0 Save changes and exit SET-UP --- ---
6 Minimum current in TIG EXT 6-200A 6A
7 Maximum current in TIG EXT 6-200A 200A
9 Reset --- ---
13 Select the electrode type 0 = Basic 0
only in the cellu- 1 = Rutilic
lose mode 2 = Cellulose
3 = Steel
4 = Aluminium
5 = Cast iron

For every electode type the Arc-Force, the Hot-Start and the voltage threshold to enter in Arc-Force and to open the arc are variable.
In the table below there are the threshold and the standard value of Hot-Start and Arc-Force.

Num. Material Hot-Start Arc-Force V Arc-Force V welding end

0 Basic 80% 30% 8V 57V
1 Rutilic 80% 30% 8V 57V
2 Cellulose 150% 350% 10V 70V
3 Steel 100% 30% 14V 57V
4 Aluminium 120% 100% 8V 70V
5 Cast iron 100% 70% 12V 57V

27
28
10) DESCRIPTION, TESTING AND REPLACEMENT OF THE ELECTRONIC BOARDS, CURRENT CALI-
BRATION
The normal working conditions of the boards making up the generator are illustrated in the following sections and the standard values are
given for the electrical parameters found at the main points of the boards themselves.
All the measurements indicated can be made with a digital multimeter.

It should be remembered that the first test to be performed is a VISUAL CHECK !

The visual check reduces the fault-finding times and guides any subsequent action towards the damaged part !

In general, the points to be visually checked are:

- Input filter area

- Electrolytic smoothing capacitors

- Any traces of smoke found inside the casing

- Power and signal connections

- Overall state of the boards.

WARNING

When the machine is connected to the mains, the main circuit-breaker is live, independently of its position (open or closed) !
Therefore, it is advisable to pull out the power plug before touching anything inside the generator !
It is also necessary, because of the possible presence of capacitors charged to a high voltage, to wait for about one minute before
being able to work on the internal parts !

29
10.1) input filter board 15.14.233

descriPTION
This board contains three varistors for protection against supply overvoltages, the EMC filter circuitry and the three-phase rectifier bridge.

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

board

PZ_W PZ_V PZ_U CN1 CN3

PZ- PZ+ PR F2 CN4

30
 Functional part Generator/ Component Test point Value Type of Note
Mode measure
Supplies voltage ON --- PZ_W PZ_U 400Vac + 15%
PZ_W PZ_V 400Vac + 15%
PZ_V PZ_U 400Vac + 15%

DC LINK ON --- PZ+ PZ- +565Vdc

Auxiliary transformer ON --- CN3/10 CN3/4 400Vac

supply voltage

Motor supply voltage ON --- CN1/4 CN1/12 230Vac

Input voltage of ON --- CN4/6 CN4/5 230Vac

switching feeder
T1 thermal protection OFF --- CN1/7 CN1/15 0ohm
CN4/4 CN4/8 0ohm
Motor supply and OFF F2 F2/1 F2/2 0ohm
switching feeder fuse
Rectifier bridge OFF PR PR1 PR+ +0.5Vdc
PR2 PR+ +0.5Vdc
PR3 PR+ +0.5Vdc
PR- PR1 +0.5Vdc
PR- PR2 +0.5Vdc
PR- PR3 +0.5Vdc

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

Rectifier bridge

PR1 PR2

PR+ PR-

PR3

31
10.2) MAINBOARD 15.14.254

DESCRIPTION
This board contains:
- Auxiliary switching supply
- Output inverter
- Control logic

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

board
F1 L4 L1 L2 L3 -VBUS +VBUS

CN2

D26

D25 IG1

P2 IG2

D39
D38

D63

D62 IG4

IG3

IG5 IG6

32
 TP1 TP2 TP3 TP4

TP8
TP13
TP10

33
 Functional part Generator/ Component Test point Value Type of Note
Mode measure
Power inverter OFF IG1 S D +0.4Vdc
D S Open circuit
G S 22ohm

IG2 S D +0.4Vdc
D S Open circuit
G S 22ohm

IG3 S D +0.4Vdc
D S Open circuit
G S 10kohm

IG4 S D +0.4Vdc
D S Open circuit
G S 10kohm

IG5 S D +0.4Vdc
D S Open circuit
G S 10kohm

IG6 S D +0.4Vdc
D S Open circuit
G S 10kohm

D38 A K +0.4Vdc
D39 A K +0.4Vdc
D62 A K +0.4Vdc
D63 A K +0.4Vdc

Switching feeder fuse OFF F1 F1/1 F1/2 0ohm

Thermal protection OFF T2 CN4/1 CN4/2 0ohm

DC LINK ON --- +VBUS -VBUS +565Vdc

Switching feeder sup- ON --- CN1/2 CN1/3 230Vac

ply voltage
Supplies voltage ON L1=ON TP8 TP3 +17Vdc

L4=ON TP10 TP3 +5Vdc

L2=ON TP13 TP3 -10Vdc

HALL sensor voltage ON --- CN2/7 CN2/9 +15Vdc
supply CN2/10 CN2/9 -15Vdc

Output HALL sensor ON --- CN2/8 CN2/9 0Vdc @ 0A

2Vdc @ 100A
4Vdc @ 200A

Open circuit voltage ON/MMA --- CN2/1 CN2/11 +97Vdc

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

34
CONFIGURING THE SOLDER BALLS
K4 K3 K2 K1

K5

K = CLOSED
K1 = CLOSED
K2 = OPENED
K3 = OPENED
K4 = CLOSED
K5 = OPENED

35
10.4) SECONDARY POWER STAGE

DESCRIPTION
Secondary rectifier stage. This rectifiers the alternate voltage/current supply by secondary side of the power transformer to produce a DC
voltage/current for welding process.

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

A1

A2

36
 Functional part Generator/ Component Test point Value Type of Note
Mode measure
Secondary diodes OFF --- A1 K +0.3Vdc
A2 K +0.3Vdc

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

Secondary diodes

37
10.5) SECONDARY ClAMP BOARD 15.14.282

descriPTION
Secondary diodes board. This board protects the secondary diodes from impulse overvoltages.

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

board

D1

D2

Functional part Generator/ Component Test point Value Type of Note

Mode measure
Diodes OFF D1 A K +0.4Vdc

D2 A K +0.4Vdc

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

38
10.6) OUTPUT FILTER BOARD 15.14.238

descriPTION
This board contains a series of filters for EMC.

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

board
CN1

PZ1 PZ2

Functional part Generator/ Component Test point Value Type of Note

Mode measure
Open circuit voltage ON/MMA --- PZ1 PZ2 +97Vdc* Open
CN1/1 CN1/4 +97Vdc* circuit
voltage
IOUT=0

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

39
10.7) FRONT PANEL BOARD 15.14.236

DESCRIPTION
Microprocessor board to set-up parameters, display parameters and interection with the user.

INSTRUMENTS REQUIRED
- Multimeter
- Set of screwdrivers

BOARD

L3 L4 L5

TP1 TP3 F1

40
 Functional part Generator/ Component Test point Value Type of Note
Mode measure
Supplies voltage ON --- CN2/1 CN2/2 24Vac
TP1 TP3 +5Vdc

LED status ON L3=ON Machine ON

L4=OFF Alarm

L5=ON Output power

Fuse OFF F1 F1/1 F1/2 0ohm

Note:
* Unless specified otherwise, all measurements may vary by + 10%.

41
10.8) PROCEDURE FOR CALIBRATING THE OUTPUT CURRENT

MAXIMUM CURRENT CALIBRATION

1) Set the generator in TIG LIFT mode.
2) Attach the amp clamp meter to the negative cable.
3) Select parameter number 50 from set-up.
4) Insert the unblock code 666.
5) Start welding. The machine provides the maximum output current.
6) Calibrate the trimmer P2 on the mainboard 15.14.254 to bring the current to the output value measure with an amp clamp meter at 200A.

42
 11 - TROUBLESHOOTING
This section of the repair manual gives assistance with locating and repairing possible malfunctions in the welding machine.
This can be done by following this simple procedure:

1) LOCATE THE PROBLEM: The FAULT column in the various tables describes possible malfunctions of the welding machine. The first step
is to identify the description which is closest to the problem you have. The problems are grouped into four sections:

11.1 Power supply unit failed.
11.2 Fan.
11.3 Thermal alarm.
11.4 Incorrect open circuit voltage.

2) POSSIBLE PROBLEM: The second column in the tables, POSSIBLE PROBLEM, lists the possible faults which may cause the problem
described.

3) SUGGESTIONS: The suggestions column gives tests or directs you to tests described in section 10 of this repair manual for checking the
components which may be causing the machine to malfunction.

43
 11.1 - POWER SUPPLY UNIT FAILED

OPERATION FLOW SIGNAL

The welding machine is connected to the 400Vac 50/60Hz three-phase network. When the input three-pole switch is closed, the three
input phases are connected to the filter board 15.14.233. Between one phase and the next there is a varistor, which is a device protecting
the downstream electronics from overvoltages. If there is very high overvoltage or overvoltage for a long time, the varistors explode.
The three-phase supply is filtered for purposes of EMI compatibility and is rectified by the three-phase input rectifier bridge.
The DC voltage obtained is +565Vdc.

BLOCK DIAGRAM

44
Fault
The machine does not switch on
No voltage on the DC LINK
Missing DC voltage
Possibile problem
1. Faulty supply cable or three-pole switch
2. Exploded varistors
3. Input filter fault
1. No +565Vdc voltage after rectification
1. Mainboard 15.14.254 faulty
Suggestions
If the generator is connected to the 400Vac
three-phase network, but there is no volt-
age between terminals 11 12,
11 13 and 12 13 , check the
three-pole switch and the supply cable.
If on opening the cover it is found that one
or more varistors have exploded, replace the
filter board 15.14.233 and any other part
damaged by the overvoltage.
Between terminals 11 12,
11 13 and 12 13 there is
400Vac voltage, but this voltage there isn’t
between input terminal of rectifier bridge.
Replace the input filter board 15.14.290.
Check the power supply to the welding ma-
chine and the three-phase rectifier bridge
using the procedure shown on page 30.
Chek that the LED diodes L1, L2 on main-
boar 15.14.254 are ON.
The LEDs indicate the presence of DC volt-
age that are provided by switching power
supply.
If the LEDs aren’t ON, chek the mainboard
15.14.254 using the procedure on page 32.
45
 11.2 - FAN

OPERATION FLOW SIGNAL

The fan works continually and it is supplied with a 230Vac voltage provides from auxiliary transformer.

BLOCK DIAGRAM

46
Fault Possible problem Suggestions
The FAN doesn’t work 1. Fan faulty Between CN1/4 CN1/12 on input
filter board 15.14.233 there is the 230Vac
supply voltage, but the fan doesn’t work.
Change the FAN.

2. Fuse faulty Chek the fuse F2 on input filter board

15.14.233.

3. No power supply Chek the presence of voltage supply using

the procedure on page 45.

47
 11.3 - THERMAL ALARM

OPERATION FLOW SIGNAL

The Genesis 200CLS machines are equipped with two thermal protection T1 and T2. The thermal protection are normally close and are
equal to a shortcircuit. When the limit temperature is reached the thermal protection will be open. When the thermal protection is open the
microprocessor board on the front panel blocks the machine and displays the alarm code on display of the front panel.

BLOCK DIAGRAM

48
Fault Possible problem
Machine on thermal alarm 1. No problem.
2. Thermal protection fault.
3. Logic faulty.
Suggestions
The machine was working correctly and en-
tered into temperature alarm because the
limit temperature was reached. Wait a few
minutes for it to cool (leaving the machine
on with the fan running to speed up the
operation). When the correct temperatu-
re is reached, the system will start working
again.
Chek that the thermal protections are equal
to a shortcircuit.
For T1 thermal protection, chek the shortcir-
cuit between CN1/1 CN1/2 on board
15.14.282.
For T2 thermal protection, chek the shortcir-
cuit between CN4/1 CN4/2 on board
15.14.254.
Chek the correct connection between the
PC boards and the mainboard 15.14.254.
49
 11.4 - OPEN CIRCUIT VOLTAGE

OPERATION FLOW SIGNAL

In MMA mode the machine present an open circuit voltage of +97Vdc.

BLOCK DIAGRAM

Fault Possible problem Suggestions

The machine doesn’t enable power Secondary diodes faulty Chek the secondary diodes using the proce-
dure on page 36.

Inverter faulty Chek the mainboard 15.14.254 using the

procedure on page 32.

50
51
12) Spare parts list
55.02.020 GENESIS 200 CLS

Lista ricambi, Spare parts list, Ersatzteilverzeichnis, Liste de pièces détachées, Lista de repuestos, Lista de
peças de reposição, Reserveonderdelenlijst, Reservdelslista, Liste med reservedele, Liste over reservedeler,
Varaosaluettelo,

52
 ITALIANO
POS. DESCRIZIONE CODICE
1 Pannello frontale plastico 01.04.262
2 Cofano superiore 03.07.067
3 Pannello posteriore plastico 01.05.220
4 Fondo plastico 01.06.100
5 Presa fissa 10.13.020
6 FP 134 15.22.134
7 Tappo 10.01.151
8 Interruttore 09.01.008
9 Manopola per interruttore 09.11.009
10 Trasformatore ausiliario 05.11.259
11 Scheda ingresso 15.14.233
12 Varistore 11.26.006
13 Ponte a diodi 14.10.161
14 Scheda raddrizzatore secondario 14.60.066
15 Diodo 14.05.081
16 Kit scheda logica+potenza 14.59.060 16 Logic+power board kit 14.59.060 16 Kit Logik- und Leistungskarte 14.59.060 16 Lot carte logique+puissance 14.59.060 16 Kit tarjeta lógica+potencia 14.59.060
17 Ventilatore 07.10.014
18 Cavo di alimentazione 49.04.057
19 Serracavo 08.22.001
20 Cinghia 21.06.004
21 Condensatore 12.03.020
22 Trasformatore di potenza 05.02.022
23 Induttanza risonante 05.04.215
24 Induttanza d’uscita 05.04.222
25 Sensore Hinode 11.19.005
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ENGLISH
POS. DESCRIPTION CODE
1 Plastic front panel 01.04.262
2 Upper cover 03.07.067
3 Plastic back panel 01.05.220
4 Plastic bottom 01.06.100
5 Fixed socket 10.13.020
6 FP 134 15.22.134
7 Plug 10.01.151
8 Switch 09.01.008
9 Switch Knob 09.11.009
10 Auxiliary transformer 05.11.259
11 Input board 15.14.233
12 Varistor 11.26.006
13 Diode bridge 14.10.161
14 Secondary rectifier board 14.60.066
15 Diode 14.05.081
17 Fan 07.10.014
18 Supply cable 49.04.057
19 Cable clamp 08.22.001
20 Belt 21.06.004
21 Capacitor 12.03.020
22 Power transformer 05.02.022
23 Resonant inductor 05.04.215
24 Output inductance 05.04.222
25 Hinode sensor 11.19.005
DEUTSCH
POS. BESCHREIBUNG CODE
1 Stirnseitiges Plastikpaneel 01.04.262
2 Oberes Gehäuse 03.07.067
3 Hinteres Plastikpaneel 01.05.220
4 Plastikboden 01.06.100
5 Fixer Griff 10.13.020
6 FP 134 15.22.134
7 Stöpsel 10.01.151
8 Schalter 09.01.008
9 Schaltergriff 09.11.009
10 Hilfstransformator 05.11.259
11 Eingangsplatine 15.14.233
12 Varistor 11.26.006
13 Diodenbrücke 14.10.161
14 Sekundär-Gleichrichter platine 14.60.066
15 Diode 14.05.081
17 Ventilator 07.10.014
18 Speisekabel 49.04.057
19 Kabelschelle 08.22.001
20 Riemen 21.06.004
21 Kondesator 12.03.020
22 Leistungstransformator 05.02.022
23 Resonanzdrosselswule 05.04.215
24 Ausgangsinduktanz 05.04.222
25 Sensor Hinode 11.19.005
FRANÇAIS
POS. DESCRIPTION CODE
1 Panneau avant plastique 01.04.262
2 Capot position haute 03.07.067
3 Panneau arrière plastique 01.05.220
4 Fond plastique 01.06.100
5 Prise inamovible 10.13.020
6 FP 134 15.22.134
7 Capot 10.01.151
8 Interrupteur 09.01.008
9 Bouton d'interrupteur 09.11.009
10 Transformateur auxiliaire 05.11.259
11 Carte entrée 15.14.233
12 Varistance 11.26.006
13 Pontet à diodes 14.10.161
14 Carte redresseur secondaire 14.60.066
15 Diode 14.05.081
17 Ventilateur 07.10.014
18 Câble d'alimentation 49.04.057
19 Serre-câble 08.22.001
20 Courroie 21.06.004
21 Condensateur 12.03.020
22 Transformateur de puissance 05.02.022
23 Inductance résonnante 05.04.215
24 Inductance de sortie 05.04.222
25 Détecteur Hinode 11.19.005
ESPAÑOL
POS. DESCRIPCION CODIGO
1 Panel frontal plástico 01.04.262
2 Capota superior 03.07.067
3 Panel posterior plástico 01.05.220
4 Fondo plástico 01.06.100
5 Enchufe fijo 10.13.020
6 FP 134 15.22.134
7 Tapón 10.01.151
8 Interruptor 09.01.008
9 Empuñadura para interruptor 09.11.009
10 Transformador auxiliar 05.11.259
11 Ficha entrada 15.14.233
12 Varistor 11.26.006
13 Puente de diodos 14.10.161
14 Tarjeta rectificador secundario 14.60.066
15 Diodo 14.05.081
17 Ventilador 07.10.014
18 Cable de alimentación 49.04.057
19 Abrazadera 08.22.001
20 Correa 21.06.004
21 Condensador 12.03.020
22 Transformador de potencia 05.02.022
23 Bobina de inductancia resonante 05.04.215
24 Inductancia de salida 05.04.222
25 Captador Hinode 11.19.005
13) TECHNICAL DATA
GENESIS 200 CLS
Power supply voltage (50/60 Hz) 3x400V±10%
Max. absorbed power (x=40%) 6.6kW
Max. absorbed current (x=40%) 10.1A
Absorbed current (x=100%) 6.6A
Efficiency (x=40%) 0.85
Power factor (x=40%) 0.94
Cos (x=40%) 0.99
Welding current (x=40%) 200A
(x=60%) 160A
(x=100%) 140A
Adjustment range 6-200A
Open-circuit voltage (limited) 97V
Protection rating IP23
lnsulation class H
Construction standards EN60974-1/EN50199
Dimensions (lxdxh) 179x430x290mm
Weight 16Kg

Above data are referred to environment al 40°C.

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 Selco s.r.l. – Via Palladio, 19
35010 Onara di Tombolo(Padova) – Italy
Tel. +39 049 9413111 – Fax. +39 049 9413311
e-mail: info@selcoweld.com
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