GeKaMac PoWer ARC 500 User Manual
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GeKaMac PoWer ARC 500 User Manual

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PoWer ARC 500
Users Manual
Please Read and Understand This Manual
Before Operating The Welding Machine
www.gedikwelding.com

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Summary of Contents for GeKaMac PoWer ARC 500

  • Page 1 PoWer ARC 500 Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 2 This machine is for internal use only. It complies with the WEEE Directive. This machine has been designed in accordance with the EN 60974-1 and EN 60974-10 standards. The machine is safe when installation, operation, and maintenance are performed in accordance with the user manual and regulations.
  • Page 3 Ankara Cad. No.306 Seyhl> Pend>k ISTANBUL TURKIYE Ürün / Product ARC WELDING MACHINE Marka-Model / Brand- Model POWER ARC 500 Yukarıda tanımlanan beyanın nesnes> >lg>l> uyumlaştırılmış AB mevzuatı >le uyumludur. The object of the declarat/on descr/bed above, /s /n conform/ty w/th the relevant un/on harmon/sat/on leg/slat/on.

  • Page 4: Dear Customer

    Production specification may change without advance notice. The model you purchase is:  PoWer ARC 500 Please find corresponding models from the "Contents". Important: Please take special note of safety rules and operate as...

  • Page 5: Safety Rules

    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.
  • Page 6 the work or ground. • Connect the primary input cable according to rules. Disconnect input power or stop machine bef ore installing or maintenance. • If welding must be perf ormed under electrically hazardous conditions as f ollow: in damp locations or wearing wet clothing; on metal structures such as f loors, gratings, or scaf f olds;...
  • Page 7 material. Fumes and gases can be dangerous • Welding may produce f umes and gases, breathing these f umes and gases can be hazardous to your health. • When welding, keep your head out of the f ume. If inside, ventilate the area at the arc to keep f umes and gases away f rom the breathing zone.
  • Page 8 Cylinder can explode if damaged. • Pressure gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them caref ully. • Cylinders should be located away f rom areas where they may be struck or subjected to physical damage.
  • Page 9 • Have only qualif ied persons remove doors, panels, covers, or guards f or servicing and maintenance. • Reinstall doors, panels, covers, or guards when servicing and maintenance is f inished and bef ore reconnecting input power. Overuse can cause overheating •...

  • Page 10: Table Of Contents

    3-1 Utilization for intended purpose only ........12 3-2 Machine installation rules ..........12 3-3 Power source connection ..........13 3-4 Welding cables instruction ..........13 4-PoWer ARC 500................15 4-1 System components ............15 4-2 Basic equipments for welding ..........15 4-3 Interface ................16 4-4 Control panel ..............17 4-5 Control socket ..............19...
  • Page 11 6-TROUBLE SHOOTING..............30 7-CARE AND MAINTENANCE ............32...

  • Page 12: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features The rated current of the machine is 500A,which are high-efficient and energy-saving DC Arc welding machine. Enjoy reasonable static characteristic . Features and benefits: - Strong ability against power grid fluctuation and arc length change. Strong capacity of arc self-adjustment.

  • Page 13: Output Characteristics

    1-3 Output characteristics Fig. 1-3-1: Output characteristics 1-4 Duty cycle Duty cycle is percentage of 10 minutes that a machine can weld at rated load without overheating. If overheats, thermostat(s) will open, output stops. Wait for fifteen minutes for the machine to cool down. Reduce amperage or duty cycle before welding.

  • Page 14: Applications

    1-5 Applications It is not only used in carbon steel and low alloy steel welding, but also used in stainless steel, high alloy steel, copper, silver, molybdenum and titanium welding. The power source is designed for the following recommend areas: - Shipbuilding and offshore engineering - Pipeline industry - Shipyard...

  • Page 15: 2-Versions Briefs

    Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding. ◼ PoWer ARC 500 The power sources have logical arranged control panel for convenient operation, which can perform SMAW and Gouging (≥500A). Welding cable can be extended to 50m.

  • Page 16: Power Source Connection

    3-3 Power source connection - The power source is designed to run on the voltage given on the nameplate. - The mains cables and plugs must be mounted in accordance with the relevant technical standards. - The power supply sockets that come with power source are designed to use strictly according to the marked voltages.
  • Page 17 Correct When the excess cables are only be used by rolling up, coil the cables to two windings in reverse direction and overlap them. The number of turns for A is same as the number for B. Handle the welding cable and ground cable according to above-mentioned method.

  • Page 18: 4-Power Arc 500

    4-PoWer ARC 500 4-1 System components This series of machines can be equipped with many different accessories. Fig. 4-1-1: System components 4-2 Basic equipments for welding Basic equipments are needed for normal welding. Below are the lists: SMAW ⚫ - Power source...

  • Page 19: Interface

    - Carbon rod - Air compressor 4-3 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine.

  • Page 20: Control Panel

    It is 4-pin cable. The mixed-colored wire must be firmly grounded(PE), the rest wires connect to corresponding power supply. 9.Circuit breaker The function of circuit breaker is to protect welding machine and operator by automatic trip to turn-off power supply when overload or short circuit happens to the power source.
  • Page 21 1.“Amp/Volt” display When display mode switch indicates to “A”: LCD display preset current value, Min. current is 20A; LCD display real welding current during working. When display mode switch indicates to “V”, LCD display voltage between output terminals of welding machine. 2.Power indicator Indicator indicates when power source is power on.

  • Page 22: Control Socket

    4-5 Control socket Pin no. Description Null Power supply 9VDC Remote welding current signal Power GND Remote arc force current signal Remote controller display signal Table 4-5-1: Connections 4-6 Installation and operation Warning! Electric shock is very dangerous. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage.
  • Page 23 capacity (KVA) Generator Fuse Input protection Circuit breaker Input cable Min. cable size Output cable Protective GND wire Table 4-6-1: power supply and cable requirement Note! Welding machine must be taken special design if it is powered by generator, please contact with manufacturer if you have such needs. ●...
  • Page 24 ● Installation and Operating Warning! Operating the welding machine incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood all the following guides: “safety rules” “before commissioning” Warning! Electric shock is very dangerous. As soon as the power source is switch on, the welding electrode is power on.
  • Page 25 5.Adjust arc start current, arc force current, welding current according to electrode diameter, welding position; 6.Welding Gouging process Note! “GOUGING” process only is available for the machine which rated current is ≥500A. Fig. 4-6-3:GOUGING process installation 1.Power off;2.Plug one end of the ground cable to the output terminal (-); 3.Connect the other end of the ground cable to the work piece;...

  • Page 26: 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 PoWer ARC 500 3 phase, AC400V±10%, 50/60Hz Primary power voltage Rated output capacity (KW)

  • Page 27: Disassembly And Reassembly

    4-9 Disassembly and reassembly Fig.4-9-1 Disassembly and reassembly...
  • Page 28 Item Stock No.for 500 Remarks Digital display 755001-00023 Indicator light (red) 715002-00026 Waterproof cap 745090-00003 Potentiometer 720031-00030 Toggle switch 745003-00008 Left plate 262017-00801 Top plate 262029-00436 Handle 766003-02388 Main transformer 220629-00163 Current exchange inductor 220281-00008 Resonance capacitor 722001-00074 Resonance inductor 220521-00004 Main control board 210580-00134...
  • Page 29 Output reactor 763004-00010 Shunt 720041-00010 Front panel 262005-01039 Control socket 740001-00030 Quick socket 740002-00026 Plastic front panel 262005-01040 Potentiometer 720031-00042 Control panel 262035-00327 Potentiometer knob 720031-00138 Potentiometer knob 720031-00137 Varistor 720021-00017 Input filter inductance 220479-00002 IGBT protection board 220005-00135 Polypropylene 722001-00070 Three phase rectifier module 735005-00002...

  • Page 30: 5-Remote Controller

    Radiator support 766002-00090 Fast recovery diode module 735006-00029 Diode protection board 220455-00002 Table.4-9-2 Main spare parts Note: This table is for reference only, and the detail of actual product shall prevail. If no special remarks, the input voltage mentioned in above table is three phase. 5-REMOTE CONTROLLER 5-1 Wire remote controller for ARC The analog wire remote controller can be used for current regulation of this series...

  • Page 31: Wireless Remote Controller

    2.Choose “Remote control” on welding machine control panel; 3.Adjust proper welding current, arc force current. 5-1-1 Spare parts Item Stock NO. Remarks Digital display 220545-00002 Potentiometer 720031-00028 4.7KΩ Potentiometer knob 720031-00070 Control socket 740001-00030 Table.5-1-1 spare parts 5-2 Wireless remote controller Note:Welding equipment with high-frequency or high-voltage arc ignition can damage the remote control.
  • Page 32 Fig. 5-2-1. Wireless remote controller 1.Current digital display Indicate welding current when adjust welding current. Indicate arc force current when adjust arc force current. The initial display is welding current. 2.Welding current increasing button Press the button to increase welding current value. Hold the button will increase welding current at a faster pace.

  • Page 33: Troubleshooting

    Arc force current (A) 0-160 0-200 0-250 Table 5-2-1: Parameter adjustment range Operating guide 1.Set the control mode at “Remote control”on welding machine control panel; 2.Attach the remote controller to the work piece, and ensure good contact; 3.Connect the clamp with electrode holder to supply power to remote controller; 4.The digital display shows the current value;...
  • Page 34 Check connection Circuit The following components may Check and replace breaker on damaged: IGBT module, When IGBT Module is rear panel 3-phase rectify module, output damaged, please check trips while 12Ω, 5.1Ω resistance or diode module, other components SR160 on drive board is machine is Drive board is damaged damaged or not...

  • Page 35: Care And Maintenance

    7-CARE AND MAINTENANCE ⚫ Before open the machine Warning! An electric shock can be fatal. Before opening the machine: -Switch it off and unplug it from the mains -Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching it back on again -Check make sure...
  • Page 37 Item Stock No.ARC500 SAP KODU Left plate 262017-00629 Top plate 262029-00467 Handle 766003-00138 Resonance capacitor 722001-00075 Resonance inductor 220521-00029 Main transformer 220629-00016 6064100372 Current transformer 220149-00007 Main control board 210580-00198 6064000196 210310-00032 Drive board 6064100594 763001-00052 Power transformer Mid-layer board 263071-00130 Circuit breaker fix plate 766003-02578...
  • Page 38 Output diode radiator 264011-00027 6064100173 Fast recovery diode module 735006-00029 6064000200 Diode protection board 220455-00002 6064100378 Current exchange inductor 220281-00012 Radiator connecting plate 775004-00009 Radiator support frame 766002-00079...
  • Page 39 Gedik Welding Inc. Ankara Caddesi No: 306 Şeyhli 34906 Pendik - İstanbul / Turkey +90 216 378 50 00 • +90 216 378 20 44 www.gedikwelding.com...

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