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GeKaMac PoWer TIG Series User Manual

Ac/dc dc pulse
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Power TIG 3200
AC/DC DC Pulse
Users Manual
Please Read and Understand This Manual
Before Operating The Welding Machine
www.gedikwelding.com

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  • Page 1 Power TIG 3200 AC/DC DC Pulse 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: Safety Rules

    Safety rules Danger! “Danger” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning! “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 4 protection while performs the welding. • Insulate yourself from work and ground using dry insulating protection which is large enough to prevent you full area of physical contact with the work or ground. • Connect the primary input cable according to rules. Disconnect input power or stop machine before installing or maintenance.
  • Page 5 • Welding may produce fumes and gases, breathing these fumes and gases can Fumes and gases can be dangerous be hazardous to your health. • When welding, keep your head out of the fume. If inside, ventilate the area at the arc to keep fumes and gases away from the breathing zone.
  • Page 6 subjected to physical damage. Use proper equipment, procedures, and sufficient number of persons to lift and move cylinders. • Always install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling over or tipping. •...

  • Page 7: Table Of Contents

    Contents 1-GENERAL REMARKS ..........7 1-1 Power source features .......... 7 1-2 Functional principle ........... 7 1-3 Output characteristics .......... 7 1-4 Duty cycle ........... 8 1-5 Applications ..........8 1-6 Warning label ..........8 2- VERSIONS BRIEFS ..........9 3- BEFORE COMMISSIONING ........
  • Page 8 5- Power TIG 3200 AC/DC DC Pulse ..Hata! Yer işareti tanımlanmamış.38 5-1 System components .......... 38 5-2 Basic equipments for welding ........38 5-3 Control panel ..........38 5-4 Interface ........... 53 5-5 Water-cooling system ......... 53 5-6 Installation and operation ........54 5-7 Technical data ..........

  • Page 9: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features This series of power sources are microprocessor controlled and apply MCU + DSP control technology to improve the control precision. The strong ability of arc self- adjustment ensures a highly stable welding current against grid fluctuation and arc length change to get optimal results.

  • Page 10: Duty Cycle

    Output characteristics Fig. 1-3-1: 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 11: 2- Versions Briefs

    Warning label Fig. 1-6-1: 2- VERSIONS BRIEFS Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different weldings. ● Power TIG 3200 AC/DC DC Pulse This fully digitized power sources have control panel for convenient operation, which can logically arranged perform SMAW, DC TIG, DC Pulse TIG, AC TIG and AC Pulse TIG.

  • Page 12: 3- Before Commissioning

    3- BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the machine until you have read "Safety rules". 3-1 Utilization for intended purpose only The power source may only be used for SMAW and TIG welding. Utilization for any other purposes, or in any other manner, shall be deemed to be "not in accordance with the intended purpose".
  • Page 13 Correct Straighten the ground cable and welding cable and make them close to each other Bundle the ground cable and welding cable together, running the wires close to the ground Correct When the excess cables can only be used by rolling up, coil the cables to two widings in reverse directions and overlap them.

  • Page 14: 4- Power Tig 3200 Ac/Dc Dc Pulse

    Power TIG 3200 AC/DC DC Pulse 4-1 System components This series of machines can be equipped with many different accessories and can be used in various special sites with different configurations (as shown in Fig. 4-1-1). System components Fig. 4-1-1: 4-2 Basic equipments for welding Depending on the selected welding processes, the power sources must be equipped with necessary accessories for welding.

  • Page 15: Control Panel

    - TIG torch - Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) - Welding wire ● SMAW welding - Power source - Ground cable - Electrode holder - Electrode 4-3 Control panel The functions on the control panels are all arranged in a logical way, and the welding waveforms make the operation easier and convenient.
  • Page 16 Torch operation modes: Fig. 4-3-2: Press torch trigger Fig. 4-3-3: Hold torch trigger Fig. 4-3-4: Release torch trigger 2-step operation mode (Fig. 4-3-5): a. Press and hold torch trigger to start welding. ● Open solenoid valve, shielding gas will flow out to expel air from torch hose (pre-gas time depends on the hose length).
  • Page 17 ● Output current increases from initial current to welding current, and the time is called up slope time. ● If the initial current is not required, the torch trigger need not to be held. Quickly press torch trigger to start arc, then quickly release it and output current will increase to welding current.
  • Page 18 ＆ Cause: Over-voltage protection Remedy: Contact after-sale service ＆ Cause: Overheat protection Remedy: Shut down the machine and cool down by fan running for 15 minutes ＆ Cause: The torch trigger is pressed for a long time without welding. Remedy: Release torch trigger, if the error keeps occurring, check and repair the torch or foot pedal. ＆...
  • Page 19 Fig. 4-3-8: Set to Gas-Cooling State In TIG welding, this series power sources can output multiple waveforms and control them precisely. The simple waveform graph on control panel makes the operation easier. Detailed introduction of waveforms as follows: ● Waveform and parameter in DC constant current (Fig. 4-3-9) Fig.
  • Page 20 Fig. 4-3-10: Waveform and parameter in AC constant current –Positive half-wave current. To heat welding wire and work piece, and form a molten pool, thus also known as welding current. –Positive half-wave time –Reverse half-wave current. Used for cleaning the oxide film on aluminum, magnesium and its alloy, thus also known as clean current.

  • Page 21: Pre-Gas Time

    Fig. 4-3-12: The waveform and parameter in AC Pulse –Peak current. Supply thermal input for welding wire and work piece to form a molten pool. –Peak current time. –Base current. Maintains the arc burning and makes the molten pool cooled. –Base current time.

  • Page 22: Peak Current

    CLEAN RATIO –Time proportions of clean current output in AC mode. Unit: ％ Range: -40～+40 Factory setting: 0 In AC TIG welding, the clean ratio can be adjusted in order to alter the width of oxide surface and the size of penetration for excellent welding result. The adjustment effect is as shown in Fig. 4-3-13: Clean ratio Weld effect Waveform...
  • Page 23 Factory setting: 100 DUTY CYCLE –The time proportion of peak current in single cycle under DC pulse or AC pulse mode, can be used for controlling penetration in all-position or thin sheet welding. Unit: ％ Range: 1～100 Factory setting: 30 FREQUENCY –The frequency of welding current in DC pulse or AC pulse mode.
  • Page 24 Factory setting: 50 ⑤ - In TIG welding process, it is used for adjusting the parameters that are described in ③. 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; - In SMAW welding process, it is used for adjusting welding current.

  • Page 25: Interface

    4-4 Interface ● Interface on front panel (Fig. 4-4-1): Fig. 4-4-1: Interface on front panel...
  • Page 26 ● Interface on rear panel (Fig. 4-4-2): Fig. 4-4-2: Interface on rear panel ● Output socket There are two types of output sockets: quick-plug type and compression joint. They must be matched with different cable plugs when use, as shown in Fig. 4-4-3. Fig.

  • Page 27: Water-Cooling System

    Fig. 4-4-5: Analog remote controller 4-5 Water-cooling system The water-cooling unit is powered by the power source. The water-cooling unit is in operation when the power source is switch on. The interfaces are as shown in Table 4-5-1. Water-cooling system Table 4-5-1: Notice! Please check the coolant level and purity before using.
  • Page 28 Please note the size of fuse and circuit breaker in the table below are for reference only. Single voltage: Model Power supply Three phase AC380V/400V/415V, 50/60Hz Min. capacity (KVA) Fuse Input protection (A) Circuit breaker Input cable Cable size Output cable Protective GND wire Table 4-6-1: Input power supply cable installation -single voltage Multi voltage:...
  • Page 29 Connection between input cable and distributor box Fig. 4-6-1: ● Shielding gas regulator installation Warning! The inert gas can be hazardous to your health. Work in a place only if it is well ventilated. Please do not use the shielding-gas cylinder until you have completely read and followed all the instructions about shielding-gas cylinder and accessories.
  • Page 30 Warning! If the machine is plugged into the mains supply and the mains switch is in "O" position during preparation, there is a high risk of very serious injury and damage. Only carry out preparation when the machine is unplugged from the mains and the mains switch is off. •...
  • Page 31 Fig. 4-6-3: Connection and operation for gas-cooling TIG welding Important! In order to obtain optimal welding results in TIG welding, sometimes it is necessary to set the tungsten electrode diameter. Press and hold the parameter selection knob and 2-step/4-step button at same time for 3 seconds to enter the tungsten electrode diameter selection menu, then turn knob to select the desired tungsten electrode diameter (Range: 0.8~6.0 mm, factory setting: 2.0 mm), as shown in Fig.
  • Page 32 connect the other end of water hose to the water outlet (blue) of water-cooling unit. 2. Connect the water inlet hose at end of torch to the water outlet on front panel of power source and fasten it. 3. Connect another water hose to the water return of torch and fasten it with hose clamp; connect the other end of water hose to the water return (red) of water-cooling unit.
  • Page 33 Fig. 4-6-6: Integrated with power source water-cooling unit connection ● SMAW 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 34 Fig. 4-6-7: SMAW welding connection ● Hot start function In order to obtain optimum welding results, sometimes it is necessary to set this function. The advantages are as follows: - Improved ignition, even when using electrodes with poor ignition properties; - Better fusion of base metal in the start-up phase, meaning fewer cold crack defects;...

  • Page 35: Technical Data

    Fig. 4-6-9: Hot start current adjustment ● Example of hot start function: Fig. 4-6-10: Hot start function legend Legend: …………Preset welding current H02 ………Hot start time H01 ………Hot start current During the preset hot start time (H02), the welding current increases to a certain value. The value (H01) is 10-200A higher than the preset welding current.
  • Page 36 Rated input current(A) 18.3 34.5 Duty cycle(％) Efficiency(％) Power factor 0.95 Dimension(mm） 655×325×560 Weight(Kg) Isolation degree Main transformer Output reactor Table 4-7-1: Power TIG 3200 AC/DC DC Pulse technical data-single voltage Multi voltage Power TIG 3200 Model AC/DC DC Pulse 3 phase, AC Rated input voltage/Frequency 220/380/440V, 60Hz...

  • Page 37: Main Components List

    Pulse ratio 1-100％ AC frequency (Hz) 20-200 Pulse frequency (Hz) 0.2-20 Pulse width 1-100％ TIG mode High frequency Arc force current (A) 10-200 Dimension(mm） 655×325×560 Weight(Kg) Main transformer Isolation degree Output reactor Table 4-7-2: Power TIG 3200 AC/DC DC Pulse technical data-multi voltage 4-8 Main components list ●...
  • Page 38 Fig. 4-8-1 : Inner structure Item Stock no. Remark 740002-00038, 380V/50Hz Quick plug 740002-00037, 380V/50Hz Potentiometer 720031-00071, 380V/50Hz Display board 220503-00017, 380V/50Hz Circuit breaker 745011-00021, 380V/50Hz 746001-00017, 380V/50Hz 746001-00035, 400V/50Hz 746001-00019, 415V/50Hz 746001-00018, 460V/60Hz Solenoid valve 752001-00007, 380V/50Hz Water flow switch 745005-00003, 380V/50Hz Main control board...
  • Page 39 220629-00189, 460V/60Hz Main transformer Wire-wound resistor 50W, 30Ω 720005-00028 380V/50Hz Isolation transformer 763003-00023 380V/50Hz Charging inductor 220095-00001 380V/50Hz Charging rectifier board 220089-00004 380V/50Hz Arc starting board 220575-00003 380V/50Hz High leakage reactance 763003-00018 380V/50Hz transformer Polypropylene capacitor 20uf 722001-00070 380V/50Hz 1400V Output reactor 763004-00112 380V/50Hz...

  • Page 40: 5-Power Tig 3200 Ac/Dc Dc Pulse

    5-Power TIG 3200 AC/DC DC Pulse 5-1 System components System components Fig. 5-1-1: 5-2 Basic equipments for welding Please refer to " Power TIG 3200 AC/DC DC Pulse " the relevant "Basic equipments for welding" in detail. 5-3 Control panel The functions on the control panels are all arranged in a logical way, and the welding waveforms make the operation easier and convenient.
  • Page 41 Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood this operating manual. Control panel Fig. 5-3-1: ① Press the button to switch between TIG and MMA, the indicator for the selected progress will light up. ②...
  • Page 42 In TIG process, press the button to select AC, AC pulse, DC and DC pulse (Fig. 5-3-2). Fig. 5-3-2: AC, AC pulse, DC and DC pulse selection - When AC mode is selected, the AC indicator lights up - When AC Pulse mode is selected, the AC and PULSE indicators both light up - When DC mode is selected, the DC indicator lights up - When DC Pulse mode is selected, the DC and PULSE indicators both light up ③...
  • Page 43 Fig. 5-3-4: Press torch trigger Fig. 5-3-5: Hold torch trigger Fig. 5-3-6: Release torch trigger 2-step and 4-step operation modes For 2-step and 4-step operation mode, please refer to "ATIG-PAC-315/500/630" the relevant "Torch operation modes" in detail. Repeat mode (Fig. 5-3-7): Fig.
  • Page 44 a. Press and hold torch trigger to start welding. ● Open solenoid valve to start flow of shielding gas so as to expel air from torch hose (pre-gas time can be set depending on hose length), then the HF ignition device starts the arc. ●...
  • Page 45 Fig. 5-3-9: Wave form selection Five AC waveforms: Standard square wave: Responsive arc with fast zero crosses and reduced peak current. Stable arc with good puddle control and fast travel speed, Minimizes tungsten superheating. (Fig. 5-3-10) Fig. 5-3-10: Standard square wave Irregular square wave: Stronger arc with slow zero crosses and lose noise;...
  • Page 46 Fig. 5-3-12: Sine wave Triangle wave: Minimized area (heat) under the curve shape with high peaks. Lower amperages can minimize heat input to the weld High peaks more forceful for anodized applications. (Fig. 5-3-13) Fig. 5-3-13: Triangle wave Mixture wave: Alternate output AC current and DC current, high Efficiency. (Fig. 5-3-14) Fig.
  • Page 47 ⑥ - In TIG mode, it is used for adjusting parameters in waveforms on panel. When the parameter is selected by , turn clockwise to increase the value; turn anticlockwise to decrease the value. Press the button and turn left or right for quick adjustment. - In SMAW mode, it is used for adjusting welding current;...

  • Page 48: Peak Current

    Unit: ％ Range: -40～+40 Factory setting: 0 In AC TIG welding, the clean ratio can be adjusted in order to alter the width of oxide surface and the size of penetration for excellent welding result. The adjustment effect is as shown in Fig. 7-3-15: Clean ratio Weld effect Waveform...
  • Page 49 - Time that welding current is continuously lowered until it reaches to crater filler current. Unit: S Range: 0.1～15 Factory setting: 0.4 STOP ARC - The current before arc blowout. Unit: A Range: 5～315 (Power TIG 3200 AC/DC DC Pulse) Factory setting: 40/80 POST-GAS - Time of gas flow after arc blowout.
  • Page 50 Turn to select "parameter code" and turn to adjust parameter value. Important! In sub-menu parameter adjustment, the welding machine can’t work. Do not adjust sub-menu parameters when welding machine is in use! Press the button again (release it within 5s) and the indicator lights off to exit from sub-menu parameter adjustment.
  • Page 51 time for 5s and water shortage error code "E09" disappears, meaning the torch type has changed from "on" to "off". Channel selection (CHA) - In TIG mode, the welders need to write down technical parameters for some repeated jobs. Thanks to this function, up to 30 job records can be stored and loaded. Range: n0～n29 Factory setting: n0 Proceed as follows:...
  • Page 52 d. Press and Ch indicator lights up, meaning the job parameter which stored in present channel is loaded. At this time, the knobs and buttons on the panel are locked and the present parameters can’t be changed. e. Press again (release it within 5s) and the indicator lights off to exit from job loading;...
  • Page 53 Range: PoS/nEG Factory setting: nEG Spot weld time (SPt) – Used for setting spot weld time in TIG mode. The welding will stop if release torch trigger within the spot weld time. Unit: S Range: 0.1～10.0 Factory setting: 0.1 Hot start current (Hcu) - Select hot start current in SMAW mode. Unit: A Range: 20～200 Factory setting: 50...
  • Page 54 a. Press (release with 5s) and the indicator lights up to enter into sub-menu parameter adjustment; b. Select code "t-L" or "t-H" by to check specific value. "t-L" indicates the low-order value and "t-H" indicates the high-order value. Combine both values to read the timing time; c.

  • Page 55: Interface

    Used for displaying the welding current, voltage and other parameters. If different parameters are selected, the relevant indicator will light up. 5-4 Interface ● Interface on front panel For the interface on front panel of this series, please refer to "ATIG315/500/630PAC" the relevant "Interface on front panel"...

  • Page 56: Installation And Operation

    5-6 Installation and operation Please refer to " Power TIG 3200 AC/DC DC Pulse " the relevant "Installation and operation" in detail. 5-7 Technical data Note! For machines designed for special voltages, the technical data on the rating plate applies (Table 5-7- 1- Table 5-7-4,).
  • Page 57 Crater filler current (A) 5-315 Up-slope time (s) 0.2-10 Down –slope time (s) 0.1-15 Pre-gas flow time (s) 0.1-15 Post-gas flow time (s) 0.1-60 Pulse frequency (Hz) 0.2-20 Pulse ratio 1-100％ AC frequency (Hz) 20-200 Pulse frequency (Hz) 0.2-20 Pulse width 1-100％...

  • Page 58: Main Components List

    5-8 Main components list ● Power TIG 3200 AC/DC DC Pulse...
  • Page 59 Fig. 5-8-1: Inner structure Item Stock no. Remark 740002-00038, 380V/50Hz Quick plug 740002-00037, 380V/50Hz Potentiometer 720031-00071, 380V/50Hz Display board 220503-00018, 380V/50Hz Circuit breaker 745011-00021, 380V/50Hz 746001-00017, 380V/50Hz 746001-00034, 400V/50Hz 746001-00019, 415V/50Hz Solenoid valve 752001-00007, 380V/50Hz Water flow switch 745005-00003, 380V/50Hz Main control board 210580-00111, 380V/50Hz...

  • Page 60: 6-Trouble Shooting

    Current exchange inductor 220281-00008, 380V/50Hz Secondary IGBT components 220221-00001, 380V/50Hz Secondary IGBT protection board 220215-00001, 380V/50Hz Output diode module 735006-00055, 380V/50Hz MMF200S060DK Diode protection board 220233-00004, 380V/50Hz Output diode module 735006-00056, 380V/50Hz MMF200S060DA Current sensor 753001-00023 380V/50Hz Main components list Table 5-8: 6-TROUBLE SHOOTING Notice! The following troubles and causes are uncertain.

  • Page 61: 7-Care And Maintenance

    E04 (or 804) wait for cooling ●Too high temperature ●Temperature relay is damaged ● Replace temperature relay ● Pressing the torch switch for long ●Release torch switch time without current output Torch switch abnormal, E02 (or 805) ●Torch switch (pedal switch) is ●Check or replace torch (pedal damaged switch)

  • Page 62: 8- Welding Technique Guide

    Daily maintenance Daily maintenance Fig. 7: 8- WELDING TECHNIQUE GUIDE Note! This section being general welding technique guide is for reference only. Specific functions of your machine please refer to previous chapters. 8-1 TIG (GTAW) basic welding technique Fig. 8-1-1: Heat Input 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).
  • Page 63 Fig. 8-1-2: TIG ARC DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal work piece. The weld area is shielded by an inert gas flow to prevent contamination of the tungsten, molten pool and weld area. When the TIG arc is struck the inert gas is ionized and superheated changing it’s molecular structure which converts it into a plasma stream.
  • Page 64 Fig. 8-1-7: Arc Ignition Fig. 8-1-8: Established TIG Arc TIG Welding Fusion Technique Fig. 8-1-9: TIG Arc 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 workpiece.
  • Page 65 Fig. 8-1-13: Add TIG Filler Wire It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size.

  • Page 66: Stick (Smaw) Basic Welding Technique

    Table 8-1-1: Tungsten Electrodes Rating for Welding Currents Tungsten DC Current Diameter Amps Torch Negative 2% Thoriated 1.0mm 15 - 80 1.6mm 70 -150 2.4mm 150 - 250 3.2mm 250 - 400 4.0mm 400 - 500 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.
  • Page 67 Fig. 8-2-1: Stick ARC Fig. 8-2-2: ARC Ignition Fig. 8-2-3: Weld pool Protection Fig. 8-2-4: Slag • 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 68 MMA (Stick) Welding Fundamentals 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. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work.
  • Page 69 Material and Joint Preparation The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others.

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