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Summary of Contents for GeKaMac PoWerPlus TIG 320
- Page 1 PoWer Plus+ TIG 320 AC-DC Pulse Manual Instructions Please Read and Understand This Manual Before Operating Welding Machine www.gedikwelding.com...
- Page 2 THANK YOU FOR USING OUR PRODUCTS OPERATOR’S MANUAL PoWerPlus TIG 320 AC/DC Pulse IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your...
- Page 3 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 5 CONTENT CONTENT §1 SAFETY ..............................1 §2 SUMMARY ............................... 9 §2.1 Brief Introduction ........................... 9 §2.2 Parameters ............................. 11 §2.3 Duty cycle & Over heat ........................12 §2.4 Working Principle ..........................12 §2.5 Volt-Ampere Characteristic ......................13 §3 Installation & Operation ......................... 1 4 §3.1 Layout for Front and Rear panel ..................... 14 §3.2 Layout for Control panel ........................15 §3.3 Installation & Operation for MMA welding ................. 23 §3.3.1 Set up installation for MMA Welding ...................... 23 §3.3.2 Operation for MMA Welding ........................24 §3.3.3 MMA Welding ..............................25 §3.3.4 MMA Welding Fundamentals ........................27 §3.4 Installation & Operation for TIG welding ..................29 §3.4.1 Set up installation for TIG Welding ......................29 §3.4.2 Operation for TIG Welding ......................... 30 §3.4.3 DC TIG Welding .............................. 31 §3.4.4 TIG Welding Fusion Technique .
- Page 6 SAFETY §1 SAFETY Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades! The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: l Injury or death to the operator.
- Page 7 SAFETY Excessive ambient temperature will cause the machine heat dissipation is not smooth, so that the internal components of the machine heat seriously. Usually the maximum operating temperature is 104°F (40°C). Low temperature may lead to performance degradation or damage of components inside the product, resulting in ice inside the water tank.
- Page 8 SAFETY Many harmful phenomena, such as noise, bright light and harmful gas, will inevitably occur in the welding process. In order to avoid harmful By product phenomena causing harm to the human body, it is necessary to make corresponding preparations in advance. Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
- Page 9 SAFETY Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. l Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
- Page 10 SAFETY Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating or fire. l Welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 11 SAFETY cylinder outlet valve and gas regulator. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
- Page 12 SAFETY maintenance. Don’t sling cables or leads around either the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc) must l Never be immersed. l Never be touched when current is flowing. When the machine is connected to the power supply, there is electricity inside the machine.
- Page 13 SAFETY l Shield off entire welding installation. Radiation Class A Device. l Only can be used in the industrial area. l If it is used in other area, it may cause connection and radiation problems of circuit. Radiation Class B device. l Satisfy the emissions criteria for residential and industrial areas.
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Page 14: Brief Introduction
SUMMARY §2 SUMMARY §2.1 Brief Introduction TIG AC/DC PULSE welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work... - Page 15 SUMMARY welding, the current will drop to short-circuit current to protect tungsten. Intelligent protection: Over-voltage, over-current, over-heat, when the ★ problems listed before occurred, the alarm indicator on the front panel will be on and the output current will be cut off. It can self-protect and prolong the using life.
- Page 16 SUMMARY MMA——Manual Metal Arc welding; PWM——Pulse-Width Modulation; IGBT——Insulation Gate Bipolar Transistor; TIG——Tungsten Inert Gas welding. §2.2 Parameters PoWerPlus TIG 320 Models AC/DC Pulse Parameters Power source 3-400V±10%，50/60Hz Rated input current (A) 23.5 24.7 18.7 18.9 Rated input power (KW) 16.3 17.2...
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Page 17: Duty Cycle & Over Heat
SUMMARY §2.3 Duty cycle & Over heat The letter “X” stands for duty cycle, which is defined as the proportion of the time that a machine can work continuously within a certain time (10 minutes). The rated duty cycle means the proportion of the time that a machine can work continuously within 10 minutes when it outputs the rated welding current. -
Page 18: Volt-Ampere Characteristic
SUMMARY §2.5 Volt-Ampere Characteristic TIG AC/DC PULSE welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the conventional rated loading voltage U and the conventional welding current I is as follows: When I ≤600A, U =10+0.04I... - Page 19 INSTALLATION & OPERATION §3 Installation & Operation §3.1 Layout for Front and Rear panel Negative output: The welder’s negative polarity output. Shield gas connector: Is connected to the gas input pipe of torch. Aero socket: Is connected to torch switch control wire. Positive output: The welder’s positive polarity output.
- Page 20 INSTALLATION & OPERATION §3.2 Layout for Control panel 1. Wave output select button. * 2. MMA welding mode indicator. 3. Welding mode select button. 4. Lift TIG welding mode indicator. 5. HF TIG welding mode indicator. 6. JOB indicator. * 7.
- Page 21 INSTALLATION & OPERATION 16. Welding current indicator. 17. Arc Force indicator. * 18. TIG parameter setting: Here are 14 indicators about TIG welding mode.* 19. Control knob: Press down the knob to choose parameter, rotate the knob to adjust value of current or parameter. *Denotes more detailed explanation of function to follow.
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Page 22: Alarm Indicator
INSTALLATION & OPERATION Alarm Indicator (12) Lights when over voltage, over current or electrical overheating (due to exceeding duty cycle) is detected and protection is activated. When protection is activated, welding output will be disabled until the safety system senses the overload has reduced sufficiently and indicator lamp goes out. - Page 23 INSTALLATION & OPERATION AC Square Wave Focused arc for maximum penetration, fast travel speed with best directional control. AC Sine Wave Welding Output Traditional AC TIG welding wave form. Quieter, ‘soft’ arc characteristic. AC Triangle Wave Welding Output Reduced heat input for same current setting. Especially useful for welding thin metal. DC Welding Output It is suitable for DC TIG welding.
- Page 24 INSTALLATION & OPERATION TIG Parameter Setting (18) Pre gas flow setting indicator 1) Pre-flow controls the period shielding gas will flow for when the torch is triggered before the arc starts. This purges the work area of atmospheric gas which could contaminate the weld before the weld starts.
- Page 25 INSTALLATION & OPERATION selected down to 0. This allows the operator to complete the weld without leaving a ‘crater’ at the end of the weld pool. Unit (S) and setting range (0~10.0S). End current setting indicator 7) Available in 4T trigger mode only, sets a welding current 5~100% of the main welding current activated when the trigger is held on to ‘unlatch’...
- Page 26 INSTALLATION & OPERATION tungsten size, to prevent the tungsten overheating. Increased forward cycle bias will give the opposite effect, less cleaning effect, greater weld penetration and less heat in the tungsten. Setting range (-5 ~ +5). AC Frequency Adjustment 14) Only be available in AC welding mode.
- Page 27 INSTALLATION & OPERATION (4) t2～t3: During the whole welding process, the gun switch is pressed and held without releasing. Note: Select the pulsed output, the base current and welding current will be outputted alternately; otherwise, output the setting value of welding current; (5) t3: Release the gun switch, the welding current will drop in accordance with the selected down-slope time.
- Page 28 INSTALLATION & OPERATION (3) t1～t2: Arc is ignited at t1 and then output the setting value of start current; (4) t2: Loosen the gun switch, the output current slopes up from the start current; (5) t2～t3: The output current rises to the setting value (I or I ), the upslope time can be adjusted;...
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Page 29: Operation For Mma Welding
INSTALLATION & OPERATION (1) Connect the earth lead to “-”, tighten clockwise; (2) Connect the earth clamp to the work piece. Contact with the work piece must be firm contact with clean, bare metal, with no corrosion, paint or scale at the contact point. (3) Connect the electrode lead to “+”, tighten clockwise;... -
Page 30: Mma Welding
INSTALLATION & OPERATION (2) Set to ‘MMA’ welding mode. (3) Set the welding parameters as required using the parameters control knob (following the instructions in the previous section). (4) Place the electrode into the electrode holder and clamp tight. (5) Strike the electrode against the work piece to create and arc and hold the electrode steady to maintain the arc. - Page 31 INSTALLATION & OPERATION ● The arc is initiated by momentarily touching the electrode to the base metal. ● The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode. ●...
- Page 32 INSTALLATION & OPERATION Covered electrodes serve many purposes in addition to filler metal to the molten pool. These additional functions are provided mainly by the covering on the electrode. §3.3.4 MMA Welding Fundamentals n Electrode Selection As a general rule, the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal.
- Page 33 INSTALLATION & OPERATION the current set too low, difficulty is experienced in striking and maintaining astable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied by overheating of the electrode resulting undercut and burning through of the base metal and producing excessive spatter.
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Page 34: Set Up Installation For Tig Welding
INSTALLATION & OPERATION shearing, machining, flame cutting and others. In all case, sedges should be clean and free of any contaminates. The type of joint will be determined by the chosen application. §3.4 Installation & Operation for TIG welding §3.4.1 Set up installation for TIG Welding (1) Insert the earth cable plug into the positive socket on the front of the machine and tighten it. -
Page 35: Operation For Tig Welding
INSTALLATION & OPERATION Regulator. Check for Leaks! (8) Connect the gas line to the machine inlet gas connector via the quick push lock connector located on the rear panel. Check for Leaks! NOTE: Air cooling mode without cooling device，and the water pipe is not needed for the air cooling mode. - Page 36 INSTALLATION & OPERATION minutes. This allows the fan to run and cool the internal components. (9) Switch the ON/OFF Switch to the OFF. §3.4.3 DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal).
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Page 37: Tig Welding Fusion Technique
INSTALLATION & OPERATION powerful arc with more heat so more current (amps) are necessary to melt the material. §3.4.4 TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the work piece. -
Page 38: Tungsten Electrodes
INSTALLATION & OPERATION fed into the leading edge of the molten pool, the arc will melt the filler wire into the weld pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. - Page 39 INSTALLATION & OPERATION users have switched to other alternatives. Regarding the radioactivity, thorium is an alpha emitter but when it is enclosed in a tungsten matrix the risks are negligible. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger to welders can occur when thorium oxide gets into the lungs.
- Page 40 INSTALLATION & OPERATION Lanthanated (Color Code: Gold) Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30 percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics.
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Page 41: Tungsten Preparation
INSTALLATION & OPERATION §3.4.6 Tungsten Preparation Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as Aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects. - Page 42 INSTALLATION & OPERATION Electrode Included Angle/Taper - DC Welding Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities.
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Page 43: Gun Switch Control Current
INSTALLATION & OPERATION §3.4.7 Gun switch control current UP/DOWN GUN Remote Control Socket Socket Pin Function Not connected Not connected Not connected Not connected Not connected The button of "UP" input The button of "DOWN" input Trigger Switch Input Trigger Switch Input Not connected The button of "UP"&... -
Page 44: Pedal Switch Control
INSTALLATION & OPERATION §3.4.8 Pedal switch control ● When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the welding current knob on the front panel will can’t use，and only 2T can be selected. ●... - Page 45 INSTALLATION & OPERATION Socket Pin Function Be shorted with 2 Be shorted with 1 20k ohm (maximum) connection to 20k ohm remote control potentiometer Wiper arm connection to 20k ohm remote control potentiometer Zero ohm (minimum) connection to 20k ohm remote control potentiometer Not connected Not connected Trigger Switch Input...
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Page 46: Operation Environment
INSTALLATION & OPERATION §3.5 Operation Environment l Height above sea level is below 1000m. l Operation temperature range: -10°C ~ +40°C. l Relative humidity is below 90% (20°C). l Preferably site the machine some angles above the floor level, the maximum angle does not exceed 15°. -
Page 47: Maintenance And Troubleshooting
MAINTENANCE & TROUBLESHOOTING §4 Maintenance & Troubleshooting §4.1 Maintenance In order to guarantee that arc welding machine works high-efficiently and in safety, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machine more, enable customers to carry on simple examination and safeguarding by oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service life of arc welding machine .Maintenance items in detail are in the following table. -
Page 48: Troubleshooting
MAINTENANCE & TROUBLESHOOTING Observe that whether the fast connector is loose or overheated. If the arc welding machine has the above problems, it should be fastened or changed. Observe that Whether the current output cable is damaged. If it is damaged, it should be wrapped up, insulated or changed. - Page 49 MAINTENANCE & TROUBLESHOOTING Troubles Reasons Solution There is something in the fan Clear out Turn power source, and the power start capacitor Change capacitor lamp is on, but fan damaged doesn’t work The fan motor damaged Change fan number The LED in the display is broken Change the LED display is not intact.
- Page 50 MAINTENANCE & TROUBLESHOOTING Troubles Reasons Solution not good or damaged The min value displayed isn’t Adjust potentiometer in on the welding current accordant with the actual value. power board. displayed isn’t accordant The max value displayed isn’t Adjust potentiometer Imax on the with the actual value.
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Page 51: List Of Error Code
MAINTENANCE & TROUBLESHOOTING §4.3 List of error code Error Type Error code Description Lamp status Yellow lamp (thermal Over-heating (1st thermal relay) protection) always on Yellow lamp (thermal Over-heating (2nd thermal relay) protection) always on Yellow lamp (thermal Thermal relay Over-heating (3rd thermal relay) protection) always on Yellow lamp (thermal... - Page 54 S.006RM.565-TR POWER PLUS TIG 320 AC/DC PULSE G.Ü. Item code SAP KODU Description Unit QTY 8.253RM.003-B 6064200067 FLAMA handle 8.301RM.565-C Shell 8.511RM.020 Connecting Copper Bars (II) 8.511RM.021 Connecting Copper Bars (III) 7.201.112 AC contactor 7.411.115-B 6064100062 Three Phase rectifier 7.202.123 Fuses (extended) 22307070005 6X30 fuse holder with wire...
- Page 55 W.496RM.427-Q 6064000081 ACDC power board W.496RM.286-D 6064000072 Wide voltage EMC board 2120I040010 Metallized thin film capacitors...
- Page 56 Gedik Welding Ankara Caddesi No: 306 Şeyhli Pendik, İstanbul / Türkiye T +90 216 378 50 00 F + 90 216 378 20 44 gedik@gedikwelding.com.tr www.gedikwelding.com...
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