GeKaMac Power TIG Series User Manual
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GeKaMac Power TIG Series User Manual

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  • Page 2 Dear Customer This instruction manual will help you get to know your new machine. Read the manual carefully and you will soon be familiar with all the many great features of your new product. Meanwhile, please remember well safety rules and operate as instruction. If you treat your product carefully, this definitely helps to prolong its enduring quality and reliability things which are both essential prerequisites for getting outstanding results.
  • Page 3 Safety Rules “Danger” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. “Warning!” indicates a possible hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are explained in the text. “Caution”...
  • Page 4 reduced open-load voltage. • Maintain the electrode holder, ground clamp, welding cable and welding machine in good, safe operating condition. Replace damaged part immediately. Electric and magnetic fields (EMF)may be dangerous • If electromagnetic interference is found to be occurring, the operator is obliged to examine any possible electromagnetic problems that may occur on equipment as follow: - minas, signal and data-transmission leads - IT and telecoms equipment...
  • Page 5 • Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. • Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. Welding and cutting sparks can cause fire or explosion.
  • Page 6 regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. • Open the cylinder valve slowly and keep your head and face away from the cylinder valve outlet. Valve protection caps should be kept in place over valve expect when the cylinder is in use or connected for use.

  • Page 7: Table Of Contents

    Safety markings CSA marked equipment meets the requirements of the North American market safety certification implementation rules (e.g. relevant product standards according to CAN/CSA-E60974,ANSI/IEC 60974) Contents 1-GENERAL REMARKS ............................ 7 1-1 Power source features ........................7 1-2 Functional principle ..........................7 1-3 Output characteristics ........................

  • Page 8: 1-General Remarks

    4-7 Technical data ..........................26 4-8 Dimension ............................27 4-9 Disassembly and reassembly ......................29 5- TROUBLE SHOOTING ..........................30 6- CARE AND MAINTENANCE ........................32 1-GENERAL REMARKS 1-1 Power source features PoWer TIG 270 TP welding machine can perform DC TIG, Pulse TIG, and SMAW processes. This series welding machines enjoy reasonable static characteristic and sound dynamic characteristic.

  • Page 9: Output Characteristics

    welding performance.Welding machine has the following features: easy arc-starting, stable arc, good welding seam formation and capability of continuous welding current regulation.The schematic diagram is as shown in Fig. 1-2-1: Input Output Rectifier&filter Three phase rectifier HF inverter HF transformer Control circuit Fig.

  • Page 10: Applications

    NOTE! Exceeding duty cycle can damage unit and void warranty. Fig.1-4-1: Duty cycle 1-5 Applications The power source is suitable for mild steel, alloy steel, stainless steel, copper, silver and titanium welding, and is designed for the following recommended areas: l Electric power, petrochemical construction l Boiler and pressure vessel l Shipyards...

  • Page 11: Warning Label

    l Bicycle, fitness equipment, and stainless furniture manufacturing 1-6 Warning label The warning label is affixed onto the top of the power source, and it must not be removed or painted over. Fig.1-6-1: Warning label 2-VERSIONS BRIEFS Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding.

  • Page 12: 3-Before Commissioning

    3-BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause seriousinjury and damage. Do not use the functions described here until you have read and completely understood the safety rules. 3-1 Utilization for intended purpose only The power source may only be used for TIG, SMAW. Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in accordance with the intended purpose”.

  • Page 13: Welding Cables Instruction

    Note! Inadequately dimensioned electrical installations can lead to serious damage. The mains lead, and its fuse protection, must be dimensioned in accordance with the local power supply. The technical data shown on the nameplate shall apply. 3-4 Welding cables instruction When welding, please pay attention to the followings.

  • Page 14: 4-Power Tig 270 Tp

    Correct When the excess cables are only be used by rolling up, coiling the cables to two windings in reverse direction and overlap them. The number of turns for A is same as the number of turns for B. Handle the welding cable and ground cable according to the above-mentioned method.

  • Page 15: Basicequipments For Welding

    Fig. 4-1-1: System components 4-2 Basicequipments for welding Basic equipments are needed for normal welding. Below are the lists: TIG: - Power source - Ground cable - TIG welding torch - Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) SMAW: - Power source - Ground cable...

  • Page 16: Control Panel

    - Electrode 4-3 Control panel Note! You may find that your machine has certain functions orsome parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. However, these controls function in exactly the same way. Fig.
  • Page 17 Torch operation mode: Legend: Fig. 4-3-2: Press torch trigger Fig. 4-3-3: Hold torch trigger Fig. 4-3-4: Release torch trigger 2-STEP mode Fig. 4-3-5:2-STEP operation mode 4-STEP mode...
  • Page 18 Fig. 4-3-6: 4-STEP operation mode Repeat mode Fig. 4-3-7: Repeat mode Spot weld mode Fig. 4-3-8: Spot weld mode 4. Strike current/Arc force current selection button/Gas test SMAW mode:Selection of stike current and arc force current. TIG mode:use to gas test . 5.
  • Page 19 TIG mode:it is used for selecting the parameters that are described in “6”. Rotate clockwise to select parameter from left to right; rotate anticlockwise to select parameter from right to left. 6. Parameters Fig. 4-3-9:Parameters Setting Factory PARAMETER Description Unit range setting PRE-GAS FLOW...

  • Page 20: Sub-Menu

    7. Parameter adjustment knob TIG mode: it is used for adjusting the parameters that are described in “6”. When a parameter is selected by rotate clockwise to increase the selected parameter; rotate anticlockwise to decrease the selected parameter. Press this button and turn to left or right for quick adjustment. SMAW mode: adjustment welding current Note! Thanks to the microprocessor control, the following functions can be realized: - All parameters that have been set can be automatically stored and will retain until the next time they are...
  • Page 21 Submenu parameters CODE PARAMETER Description Factory setting Operation mode FF0:2-Step;FF1:4-Step;FF2: Repeat FF3: Spot welding;FF3: Special 2-step FF4: Special 4-step Pilot arc mode FHY: HF TIG;FHn：Lift TIG Pulse frequency F-L:Low Pulse frequency （0.4~30Hz） F-H:High Pulse frequency （20~500Hz） Arc length of SMAW L15~L20 Tungsten diameter d0.8~6.0（mm）...

  • Page 22: Interface

    4-5 Interface Note! You may find that your machine has certain functions orsome parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. However, these controls function in exactly the same way. Fig.

  • Page 23: Installation

    2.Quick socket (+) Connect electrode holder when in SMAW mode; Connect with the workpiece when in TIG mode. 3.Gas outlet Connect gas hose of TIG torch. 4.Quick socket (-) Connect work piece when in SMAW mode, connect with TIG torch when in TIG mode. 5.Control panel 6.Fuse 7.Circuit breaker...
  • Page 24 ● Installation environment requirements 1. It should be placed indoors without direct sunlight, rainproof, low humidity and less dust. The ambient air temperature range is -10℃~+40℃. 2. The inclination to the ground should not exceed 10°. 3. There should be no wind in the welding station, if any, it should be covered. 4.
  • Page 25 Fig. 4-6-1:Connection between power cord and distributor box ● Gas regulator installation 1. Take the protective cap off the shielding-gas cylinder. 2. Briefly open the shielding-gas cylinder valve anticlockwise to blow off any dust and dirt. 3. Check the tightness of pressure regulator. 4.
  • Page 26 Fig. 4-6-2: Gas regulator installation ● TIG welding Warning! Operating the machine incorrectly can cause serious injury and damage. Do not use the machine until you have read the following: - Safety rules - Before putting the machine into service Warning! If the machine is plugged into the mains supply and the mains switch is in "O"...

  • Page 27: Technical Data

    ● STICK welding Fig. 4-6-4: STICK welding connection 4-7 Technical data Note! Please use the machine under the allowed power supply voltage range marked in the nameplate. The technical data with the basic input voltage are listed as the Table 4-7-1. Model Rated input voltage 3 phase,AC400V±10% 50Hz...

  • Page 28: Dimension

    TIG：5A/10.2V～270A/20.8V Rated current / voltage range SMAW：5A/20.2V～270A/30.8V IP class IP23S Insulation class Power factor Weight (Kg) 17-18 Table. 4-7-1: Technical data 4-8 Dimension Item Unit(mm) Unit(inches) length 17.1 Width Height 16.2 Fig. 4-8-1: Dimension Table. 4-8-1: Dimension...
  • Page 29 4-9 Disassembly and reassembly...

  • Page 30: Disassembly And Reassembly

    Fig. 4-9-1: Disassembly and reassembly Item Stock NO. Remark Drive board 210310-00135 Display board 210580-01309 Polypropylene capacitor 722001-00141 Current exchange inductor 220281-00008 Quick socket 740002-00080 Remote adapter board 220569-00002 Current transformer 220149-00175 IGBT module 735007-00046 Temperature relay 745008-00008 Polypropylene capacitor 722001-00062 Varistor 720021-00017...

  • Page 31: 5- Trouble Shooting

    Current sensor 753001-00010 Main transformer 220629-00372 Fast recovery diode module 735006-00029 Table. 4-9-1: Main components list 5- TROUBLE SHOOTING Warning! An electric shock can be fatal. Before opening the machine: -Switch it off and unplug it from the mains -Unplug machine from the mains -Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching it back onagain -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.
  • Page 32 The air inlet of the welding machine is too close to the wall Air inlet of welding machine is blocked The radiator has accumulated too much dust and has not been cleaned for a long time 2) Reason for use Welder use exceeds rated load rate Welding specifications are greater than rated output 3) Circuit failure...

  • Page 33: 6- Care And Maintenance

    5) -The base material has oil, impurities or paint coating on the surface 6) -Damaged display control board 7) -Defective current sensor The welding machine -Damaged torch switch does not work after -The control cable is broken or has poor contact Check and replace pressing the torch switch -Damaged display control board...
  • Page 34 l Maintenance of welding power source Please follow the instructions as below to ensure normal use of power source - Conduct safety check at regular intervals (see “Safety rules”) - Dismantle machine side panels and clean machine inside with clean and low-pressurecompressed air by professional technician, not less than twice per year.

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Power tig 270 tp

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