GeKaMac PoWerTech Series User Manual
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GeKaMac PoWerTech Series User Manual

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PoWerTech
325 and 405 Pulse
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 PoWerTech Series

  • Page 1 PoWerTech 325 and 405 Pulse Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...

  • Page 2: Table Of Contents

    ENGLISH Introduction Introduction Description Thank you for buying our product. In order to get the best performance out of the plant and ensure Operating features the maximum lifespan of its parts, the use and maintenance instructions contained in this manual must be read and strictly Technical data complied with, as well as the safety instructions contained Usage limits (IEC 60974-1)

  • Page 3: Technical Data

    arc will introduce a slope down and it will switch off auto- Technical data matically. - “Energy Saving” function to operate the power source cool- The general technical data of the system are summarized in ing fan and the torch water cooling only when necessary. table 1.

  • Page 4: How To Lift Up The System

    This system is cooled by means of the forced circulation of air, How to lift up the system and must therefore be placed in such a way that the air may be easily sucked in and expelled through the apertures made Strap the system safely and securely in the slings working from in the frame.

  • 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 Welding

    2 - Welding 1) Switch the welding machine on by moving the power sup- ply switch to I (Pos. 6, Fig. B). 2) Make the adjustments and do the parameter settings on the CM / CP control panel (for further information see the CM / CP control panel manual).

  • Page 7: Aluminium Welding

    A fairly approximate indication of the average current to use in Aluminium welding the welding of electrodes for ordinary steel is given by the fol- lowing formula: To weld with aluminum wire proceed as follows: • Replace the drive rolls with special ones for aluminium wire. I = 50 ×...

  • Page 8: Tig Welding With "Lift

    Table 5 TIG welding with “Lift” ELECTRODE TYPE In the TIG process welding is achieved by melting the two met- Current adjustment field (A) al pieces to be joined, with the possible addition of material Ø ELECTRODE TIG DC from the outside, using an arc ignited by a tungsten electrode. (mm) Tungsten Tungsten...

  • Page 9: The Pointing Out Of Any Difficulties And Their Elimination

    Replacing the digital interface PCB The pointing out of any difficulties and their elimination Proceed as follows: • Unscrew the 4 screws fastening the front rack panel. The supply line is attributed with the cause of the most com- • Remove both the adjustment knobs. mon difficulties.

  • Page 10: Meaning Of Graphic Symbols On Machine

    Meaning of graphic symbols on machine Negative pole snap-in connector Power supply switch 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 11 2101AC33 POWERTECH 325 PULSE...
  • Page 12 2101AD30 POWERTECH 405 PULSE...
  • Page 13 PoWerTech 325 and 405 Pulse Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 14 POWERTECH 325 POWERTECH 405 PULSE Pos. PULSE Description 352461 352461 Front rack transparent visor 258225B 258225D Rack panel with software 466897 466898 Adhesive label "MACHINE NAME" 438849 438849 Ø22mm Knob without index 438888 438888 Ø29mm Knob without index 468725 468725 GEKA logo sticker Ø30mm Front panel without GEKA logo sticker 352473...
  • Page 15 POWERTECH 305 PULSE POWERTECH 405 PULSE Pos. Description 438111 438111 Handle 468286 468286 Mains switch sticker 438720 438720 Mains switch knob 427883 427883 Cable clamp with lock ring 235948 235999 Mains cable 447044 447044 Rear panel 485040 485040 Gas tube 419049 419049 Cooling system power connector...
  • Page 16 POWERTECH 325 PULSE POWERTECH 405 PULSE Pos. Description 404895 404895 Base 241852 241852 Spool holder 466159 466159 Wire feed mechanism support 488315 488315 Quick connection protection capacitor Wire feed mechanism assembly with 240618 240618 drive motor 444474 444474 Horizontal drive motor 24VDC 443076 443076 Dividing wall...
  • Page 17 (assembly) POWERTECH 325 PULSE POWERTECH 405 PULSE Pos. Description 435760 435760 Mains switch 427679 427679 EMC Filter 425938 425938 Solenoide valve 418746 418745 DC-LINK capacitor 377193 377193 Motor control and power source PCB 481394 481394 Auxiliary transformer 413430 413430 Auxiliary wiring with flat cable assembly 449602 449602 Upper shelf...
  • Page 18 POWERTECH 325 PULSE POWERTECH 405 PULSE Pos. Description 247497 247497 Secondary inductor 478867 478867 Primary thermostat 286046 286046 Primary IGBT 377194 377194A Primary inverter PCB 455513 455513 Primary rectifier 377105 377105 Snubber secondary PCB 486377 486377 Fan motor 478786 478786 Secondary thermostat 423236 423236...
  • Page 19 EN Wire feeder unit assembly with 4 rolls 14 15 16 1 Pos. Cod. Description 449041 Woodruff Key Pressure spring Ø 2 mm 441210 437075 Pressure Adjustment Unit (2 mm spring) 676510 Tapered Pin 356971 Pressure Arm right assembly 356966 Pressure Arm left assembly 449027 Pressure Roll Axle...
  • Page 20 Table A - SUITABLE ROLLS RULLI STANDARD STANDARD ROLLS SOLO PER ACCIAIO FOR HARD WIRE ONLY Rullo superiore piatto Pressure flat roll per tutti i diametri con boccola for all diameters with bushing Rullo inferiore a doppia cava Ø 37 mm Feed roll double groove Ø...
  • Page 21 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 1) To ask for spare parts clearly state: 1) The code number of the piece...
  • Page 22 PoWerTech 325 and 405 Pulse Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 23 ENGLISH Introduction 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 Viewing the software version installed...

  • Page 24: 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 ▪...

  • Page 25: 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): •...

  • Page 26: 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 27 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 28: 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 29: 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 30: 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 31: 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 32: 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: •...

  • Page 33: 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 34: 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. • POST GAS (PoG) - Provides an additional quantity of gas for a chine for the correct list of the programs available.

  • Page 35: 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 ( ). • WIRE SPEED ( THICKNESS OF WELDED ITEM •...

  • Page 36: Mig-Mag

    • 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- •...

  • Page 37: 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 38: Electrode (Mma)

    To interrupt the HOLD function and go back to the PRESETTING Electrode (MMA) phase before 15 seconds have passed, simply turn one of the two ENCODER knobs (E1-E2). Start the welder by pressing the switch, located on the back pan- el, at the position I.

  • Page 39: 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 40: Hold

    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 41: 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: •...

  • Page 42: 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 43: 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 44 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: ▪...
  • Page 45 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 46 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:

Powertech 325 pulsePowertech 405 pulse

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