GeKaMac Power MIG 255 Pulse User Manual
  1. Manuals
  2. Brands
  3. GeKaMac Manuals
  4. Welding System
  5. Power MIG 255 Pulse
  6. User manual

GeKaMac Power MIG 255 Pulse User Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Power MIG
255 Pulse
Users Manual
Please Read and Understand This Manual
Before Operating The Welding Machine
www.gedikwelding.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Power MIG 255 Pulse and is the answer not in the manual?

Questions and answers

Related Manuals for GeKaMac Power MIG 255 Pulse

Summary of Contents for GeKaMac Power MIG 255 Pulse

  • Page 1 Power MIG 255 Pulse Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...

  • Page 2: Table Of Contents

    The pointing out of any difficulties and their Operating features elimination The main feature of the welding unit Power MIG 255 Pulse are: Replacing the digital interface PCB • Metallic main structure with shockproof plastic front frame. Troubleshooting table •...

  • Page 3: Technical Data

    After several minutes the overheat cut-off rearms automatically and the welder is ready for use again. Table 1 Power MIG 255 Pulse Model MIG/MAG Single-phase input 50/60 Hz 400 ± 15% Mains supply: Z Ω...

  • Page 4: How To Lift Up The System

    (electrical and plumbing connections). The system essentially consists of: • Connect up the welder to the mains. • Power MIG 255 Pulse weld unit. • Connect up the wire-feeder/generator interconnection cable. • Separately: • Connect up the welding cables.

  • Page 5: Loading Wire

    Loading wire • Fit the reel (diam. 300 mm) on the support so that the wire unrolls clockwise, and center the projecting reference on the 3 4 4 3 support with the relative hold on the reel. • Thread the end of the wire into the back guide (Pos. 1, Fig. A) on the drawing mechanism.

  • Page 6: Mig-Mag / Pulse Mig / Double Pulse Mig

    MIG-MAG / PULSE MIG / DOUBLE PULSE MIG welding with GAS To begin MIG-MAG / PULSE MIG / DOUBLE PULSE MIG weld- ing, carry out the following tasks (with the machine switched off). 1 - Connecting the cables (Fig. C1) 1) Connect the gas hose to the pressure reducer fitted on the cylinder beforehand.

  • Page 7: Mig-Mag / Pulse Mig / Double Pulse Mig

    MIG-MAG / PULSE MIG / DOUBLE PULSE MIG welding without GAS To begin MIG-MAG / PULSE MIG / DOUBLE PULSE MIG weld- ing, carry out the following tasks (with the machine switched off). 1 - Connecting the cables (Fig. D1) 1) Screw the torch to the centralised connection on the front panel of the welding machine (Pos.

  • Page 8: Spot Welding

    Spot welding Electrode welding (MMA) On the Power MIG 255 Pulse machine, electrode welding is Welding can be done with or without gas. The substantial differ- used to weld most metals (different types of steel, etc.) using ence with MIG-MAG welding is essentially related to the torch...

  • Page 9: Welding Parameters

    WELDING PARAMETERS Table 3 Table 3 shows some general indications for the choice of elec- Welding thickness (mm) Ø electrode (mm) trode, based on the thickness of the parts to be welded. The 1,2 ÷ 2 values of current to use are shown in the table with the respec- 1,5 ÷...

  • Page 10: Maintenance

    The supply line is attributed with the cause of the most com- mon difficulties. In the case of breakdown, proceed as follows: Power MIG 255 Pulse 1) Check the value of the supply voltage. 2) Check that the power cable is perfectly connected to the IMPORTANT: For fully electronic welding machines, remov- plug and the supply switch.

  • Page 11: Troubleshooting Table

    Troubleshooting table WARNING: Any internal inspections or repairs are only to be done by qualified personnel! IMPORTANT: Remember to disconnect the mains power supply and wait for the internal capacitors to discharge (about 2 min- utes) before starting to check and repair the machine if necessary. Defect Solution The welding machine does...

  • Page 12: Meaning Of Graphic Symbols On Machine

    Meaning of graphic symbols on machine Power supply switch Negative pole snap-in connector System for use in environments with in- Warning! creased risk of electroshock Before using the equipment you should Product suitable for free circulation in the carefully read the instructions included in European Community this manual Danger! Parts moving...
  • Page 13 2101AC73...
  • Page 14 Power MIG 255 Pulse Spare Parts List Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 15 Pos. Power MIG 255 Pulse Description 352386 Front rack transparent visor 258238J Rack panel with software 466895 Adhesive label "MACHINE NAME" 438849 Ø22mm Knob without index 438888 Ø29mm Knob without index 352385 Frame 235254 Reverse polarity cable 430752 Lock ring...
  • Page 16 Pos. Description Power MIG 255 Pulse 438207 Handle 468286 Mains switch sticker 438720 Mains switch knob 427875 Cable clamp 430755 Lock ring 235948 Mains cable 485040 Gas tube 404887 Base 419049 Cooling system power connector 431329 Rubber support foot 420604...
  • Page 17 (assembly) Pos. Power MIG 255 Pulse Description 435755 Mains switch 425938 Solenoide valve 444527 Fan motor 353449 Cover insulation 241269 Power inverter assembly 247494 Secondary inductor 444474 Horizontal drive motor 24VDC 481954 Hall effect transformer 418746 DC-LINK capacitor 377204 Cooling pump control pcb...
  • Page 18 Pos. Power MIG 255 Pulse Description 488315 Quick connection protection capacitor Wire feed mechanism 240618 assembly with drive motor 407479 Insulating bushing 427865 Spiral cable clamp 430750 Lock ring 241848 Spool holder 420435 Spool cover...
  • Page 19 EN Power inverter assembly 55 56 Pos. Power MIG 255 Pulse Description 241269 Power inverter assembly 455514 Three phase rectifier 286048 Primary IGBT 240249 Inductance 478777 Secondary NTC thermostat 423241 Secondary diode 90A 200V 423252 Secondary diode 60A 300V 481451...
  • Page 20 EN Wire feeder unit assembly with 4 rolls Pos. Cod. Description 449041 Woodruff Key 441210 Pressure spring Ø 2 mm 437075 Pressure Adjustment Unit (2 mm spring) 676510 Tapered Pin 356971 Pressure Arm right assembly 356966 Pressure Arm left assembly 449027 Pressure Roll Axle Tab.
  • Page 21 Table A - SUITABLE ROLLS STANDARD ROLLS FOR HARD WIRE ONLY Pressure flat roll for all diameters with bushing Feed roll double groove Ø 37 mm with keyway and coloured front ring Wire Wire diameter Upper roller Colored lower roller Ø 37 mm Groove 0,6 ÷...
  • Page 22 EN Wire feeder maintenance Interval of Item Action maintenance Every 500 hours or Inspect, clean or Rolls as needed replace Every 500 hours or Wire Guides Inspect, replace as needed Every 2500 hours Roll Fixation Screw Inspect, replace or as needed EN Ordering spare parts To ask for spare parts clearly state: 1) The code number of the piece...
  • Page 23 Power MIG 255 Pulse Control Panel Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 24 ENGLISH Introduction Special processes Control panel Electrode (MMA) KEY AND KNOB COMMANDS 1 - WELDING PROCESS SELECTION DISPLAY AND LED INDICATIONS 2 - SELECTION OF WELDING PROGRAM 3 - SPECIAL FUNCTIONS “Fx” SELECTION Switching on the welding machine and initial screen 4 - PRE-SETTING 5 - WELDING 6 - HOLD...

  • Page 25: Control Panel

    TWO STROKE (2T) Control panel 2T LED ( ) switched on Pressing the TORCH TRIGGER starts the welding cycle, which KEY AND KNOB COMMANDS will stop when it is released. FOUR STROKE (4T) 4T LED ( ) switched on ▪ ENCODER knob - A ▪ ENCODER knob - V 1) Pressing and releasing the TORCH TRIGGER will start the welding cycle.

  • Page 26: Display And Led Indications

    ■ SPECIAL FUNCTIONS key “Fx” (T ≥ 2 s) ■ PARAMETER DISPLAY screen - V This key is used to display and edit some parameters (ADJUST- This Display shows the values / numbers (set or measured) of the ABLE FUNCTIONS “Fx”) that are necessary and fundamental for following parameters (if active): welding and that have already been set by the manufacturer in • ARC LENGTH ADJUSTMENT (...

  • Page 27: Loading Of The Wire

    2) On both displays appears a running string that indicates the WARNING: Changes to values are immediately activated (no fur- VERSION OF THE SOFTWARE installed on the welder. ther confirmation is required and they will be displayed immedi- The rotation of one of the two ENCODER Knobs - A (E1) or ately) or, at least they will become active the next time welding is V (E2) by the operator during the display of the string version done.
  • Page 28 Table 1 SETTINGS RANGE WELDING PROCESS MIG-MAG WELDING MODE MIG MAG / PULSE FUNCTION DISPLAY Spot Stitch FACTORY RANGE Cycle ADJUSTABLE FUNCTIONS “Fx” Fx > 3s MIG-MAG process PRE GAS 0.1s (0.0 ÷ 2.0)s ● ● ● ● ● ● ●...

  • Page 29: Setup Menu

    3) To exit the SPECIAL FUNCTIONS “Fx” menu, push and re- TIMER ARC ON lease the SPECIAL FUNCTIONS “Fx” (T3) key once. This indicates the actual time the machine was used for welding. WARNING: This time can only be zeroed using the FACTORY DE- FAULT (FAC in the SEtUP menu) for the welding plant.

  • Page 30: Error Log

    ERROR LOG TEST This allows the operator to know about the error states that have This configuration allows the operator to check that some func- arisen on the welding plant. tions of some devices. 1) Rotate the ENCODER - A (E1) knob, until both the displays 1) Rotate the ENCODER - A (E1) knob, until both the displays (D1-D2) read Err Log.

  • Page 31: Menu Special Functions

    MOTOR CALIBRATION (Mot CAL) Menu SPECIAL FUNCTIONS From the SEtUP menu, push the PRG key (T5) for more than 3 ATTENTION: This procedure allows you to calibrate the wire seconds to access the SPECIAL FUNCTIONS menu, which pro- speed (only in MIG welding processes). vides access to additional functions that can only be managed by an expert, responsible operator.

  • Page 32: Arc Length Adjust

    Calibration parameter SM3 (MAXIMUM SPEED) CYCLE Then turn the ENCODER - A knob (E1) until the PARAM- If enabled, this function allows the operator to have a further ETER DISPLAY - A screen (D1) shows the SM3 parame- welding mode (CYCLE) available, in MIG (pulsed, double pulsed, ter.

  • Page 33: Password

    3) To change the mode, repeat steps 1 and 2. BLOCKS 4) To exit the SEtUP menu, push the SAVE “MEM” (T2) key twice. If enabled, this function allows the operator to block or limit use of the welding machine and/or certain welding parameters / functions. There are 4 possible options to choose from: • BLOCK no - Does not allow any block to be activated for the welding machine, but allows the operator to unblock the machine...

  • Page 34: Mig-Mag Synergic / Mig Pulse / Double Pulsed Mig

    3D) To access the vision.COLD welding process: rotate the EN- MIG-MAG synergic / MIG pulse CODER knob - A (E1) until obtaining on the PARAMETER / double pulsed MIG DISPLAY screen - A (D1) and the writing CLd. Start the welder by pressing the switch, located on the back pan- el, at the position I.

  • Page 35: Welding Mode Selection

    WARNING: This table is merely an example, the welding programs the factory setting value. Higher numbers correspond to more can be updated and extended. See the table on the welding ma- burning of the wire. chine for the correct list of the programs available. • POST GAS (PoG) - Provides an additional quantity of gas for a defined time, after welding ends.

  • Page 36: Pre-Setting

    5 - PRE-SETTING During the welding the operator can change the following param- Before welding it is possible to set the following parameters: eters: • THICKNESS OF WELDED ITEM ( • WELDING CURRENT ( ). THICKNESS OF WELDED ITEM • WIRE SPEED ( • ARC LENGTH ADJUSTMENT ( WELDING CURRENT • ELECTRONIC INDUCTANCE (...

  • Page 37: Mig-Mag Manual

    • CRATER START TIME (F10) - This function defines the time MIG-MAG manual in which the current remains at the value of CRATER START SPEED or CRATER START VOLTAGE. Start the welder by pressing the switch, located on the back pan- • CRATER START SLOPE (F11) - Time taken to go from the CRA- el, at the position I.

  • Page 38: Pre-Setting

    • Hold the SAVE “MEM” key (T2) down for at least 2 consecu- • PARAMETER DISPLAY screen - V (D2) tive seconds. T ≥ 2 s WELDING VOLTAGE ELECTRONIC INDUCTANCE • The program in use has now been completed successfully. To confirmation the above, the control panel of the welder performs a short operation of MACHINE CHECK (all of the LED stay lit simultaneously so as to verify their actual operation), the gen-...

  • Page 39: Special Processes

    (ba- sic, rutile, and chrome-nickel). vision.ULTRASPEED (SPd) Power MIG 255 Pulse This is an innovative MIG/MAG process devel- oped by CEA for welding steel and non ferrous materials that, due to the increased magnetic resistance of the arc and the tighter cone, al- lows a significant increase in welding speed.

  • Page 40: Special Functions "Fx" Selection

    3 - SPECIAL FUNCTIONS “Fx” SELECTION 4 - PRE-SETTING Before welding it is possible to set the following parameters: ADJUSTABLE FUNCTIONS “Fx” Fx > 3s SETTINGS RANGE FUNCTION DISPLAY WELDING CURRENT FACTORY RANGE HOT START 0 ÷ 100 ARC FORCE 0 ÷...

  • Page 41: Welding

    6 - HOLD This function automatically starts itself at the conclusion of eve- ry welding operation welding and it is indicated to the operator by means of a flashing light of the HOLD FUNCTION LED for a spe- cific amount of time. Once the welding has been terminated, for about 15 seconds, both the DISPLAYS should show the same val- ues of the parameters during the welding.

  • Page 42: Pre-Setting

    ■ PROGRAM DEFAULT (dEF) 4 - WELDING During the welding the display shows: • PARAMETER DISPLAY screen - A (D1) WARNING: If carried out, this operation resets the program in use to the factory default settings. To carry out the reset of the settings / parameters, proceed in the WELDING CURRENT following manner: • Rotate the ENCODER - A (E1) knob until both the displays read...

  • Page 43: Job

    To interrupt the HOLD function and go back to the PRESETTING WARNING: If all the automatic welding points (JOBS) are occu- phase before 15 seconds have passed, simply turn one of the two pied, the check automatically goes to the first automatic welding ENCODER (E1-E2) knobs.

  • Page 44: Welding

    4 - WELDING 7 - DELETING A JOB SAVED During the welding the display shows the values, if possible meas- In JOB mode, holding down the PARAMETER SELECTION - A ured, of the active parameters, based on the type of welding pro- (T1) and PARAMETER SELECTION - V (T4) keys down simulta- cess, memorised within the selected JOB.

  • Page 45: Error Condition

    Error condition This paragraph describes the error conditions that may arise on the welding machine, the codes and messages shown on both op- erator interface displays, and the diagnoses for attempting to cor- rect and resolve them. In an “error condition” the operator’s interface uses both displays to display: ▪ ERROR CONDITION display ▪ ERROR DESCRIPTION display...
  • Page 46 Error condition Error code Error description and possible diagnosis STICKING This error is displayed when a shortcircuit has been formed between the machine’s output terminals for more than 1.2 seconds. NON automatic reset error. E3.2 To remove the error state, eliminate the short circuit so that the voltage on the torch goes above the threshold value again.
  • Page 47 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...

This manual is also suitable for:

Power mig series

Table of Contents