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GeKaMac PoWer MIG Series User Manual

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POWER MIG 3500
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 MIG Series

  • Page 1 POWER MIG 3500 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 4: Dear Customer

    Dear Customer This instruction manual will help you get to know your new machine. Read the manual carefully and you will soon be familiar with all the many great features of your new product. Meanwhile, please remember well safety rules and operate as instruction. If you treat your product carefully, this definitely helps to prolong its enduring quality and reliability–things which are both essential prerequisites for getting outstanding results.

  • 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. Caution “...
  • Page 6 Connect the work cable to the work piece as close as possible to the area being welded. Lay tem well away from other cables. Do not place your body between your electrode and work cables. Equipotential bonding Workpiece grounding (earthing) Shielding Shield the entire welding equipment and other equipment nearby.
  • Page 7 Hot parts can burn • Do not touch hot parts with bare hand or skin. • Ensure equipment is cooled down before perform any work. • If touching hot parts is needed, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

  • Page 8: Table Of Contents

    Contents 1- GENERAL REMARKS ........................... 6 1-1 Power source features ......................... 6 1-2 Functional principle ..........................6 1-3 Output characteristics .......................... 6 1-4 Duty cycle ............................. 7 1-5 Applications ............................7 1-6 Warning label ............................7 2-VERSIONS BRIEFS ............................8 3-BEFORE COMMISSIONING ..........................

  • Page 9: 1- General Remarks

    1- GENERAL REMARKS This series of power sources apply IGBT soft switch inverter technology. Its internal control system applies digital signal processor which ensures quick response to any change during the welding process so as to achieve precise control of welding process and ensure optimal welding results.

  • Page 10: Duty Cycle

    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

    2-VERSIONS BRIEFS Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding. ● POWER MIG 3500/5000 MIG-M series is designed in accordance with the industrial standard. It has constant voltage (CV) and constant current (CC) characteristics, and has five different welding process: CO2/MAG, STICK, TIG, GOUGING, FCAW.

  • Page 12: Welding Cables Instruction

    3-4 Welding cables instruction When welding, please pay attention to the followings: a. The welding cables should be kept as short as possible; b. If extended cable is used, please do as shown in Fig. 3-4-1. Wrong Coil the excess ground cable and welding cable in same direction respectively.

  • Page 13: 4-Power Mig 3500/5000

    4-POWER MIG 3500/5000 4-1 System components POWER MIG 3500/5000 can be equipped with many different accessories and can be used in different special sites with different configurations. Fig. 4-1-1: System components 4-2 Basic equipments for welding Only be equipped with the necessary accessories, can the power source MIG-M operate well. The following is the needed accessories list.

  • Page 14: Control Panel

    4-3 Control panel The functions on the control panels are all arranged in a very logical way. The various modes and parameters needed for welding are easy to select by pressing the appropriate button; parameters are easy to be adjusted by rotating encoder. Synergic adjustment makes the complicated operation much easier.
  • Page 15 During welding, display the actual welding current value. 4.Power indicator Show whether the welding machine is power on or not. 5.Overheat protection indicator During normal welding, this indicator is off; Lights up when the power source overheats and machine will automatically stop welding. Once the power source cools down，this light will go OFF and everything will be back to normal.

  • Page 16: Interface

    - Stick: to adjust the arc force current value; - TIG/Gouging: inactive. 9.Crater filler current/welding current control knob - In 4-step mode under CO2/MAG, it is used to adjust the preset crater filler current. Important! The digital meter does not display the preset crater filler current value when presetting. When comes into the actual crater filler status, it will display the actual crater filler current value.

  • Page 17: Installation

    Please refer to the nameplate for the technical parameters of the welding machine. 6.Power supply socket for gas heater (AV36V) It is used to connect the heater coil of the gas regulator. 7.Quick socket (+) In CO2/MAG solid wire: it is used to connect with welding cable of wire feeding cable. In CO2/MAG Flux core wire: it is used to connect with welding cable of wire feeding cable.
  • Page 18 ● Welding cable components assembly Fig. 4-5-2: Welding cable components assembly ●Gas cylinder installation 1. Stand the gas cylinder on the trolley and secure it by fixing the cylinder strap around a point in the top third of the cylinder-but never around the neck of the cylinder.
  • Page 19 Note! If the wire hose is too tight or too loose, it will increase resistance for wire feeding and cause wire feeding instable. ● Installation environment requirements 1. It should be placed indoors without direct sunlight, rainproof, low humidity and less dust. The ambient air temperature range is -10℃~+40℃.

  • Page 20: Welding Process Installation

    4-6 welding process installation Warning! Operating the equipment incorrectly can cause serious injury and damage. This part is about operating. Do not use the functions until you have read and completely understood content of this manual. ●MAG/CO2 welding process installation: Fig.

  • Page 21: Technical Data

    4-7 Technical data Model Power MIG 3500 Power MIG 5000 Voltage Frequency(3~)) AC400V±10％,50Hz Rated input capacity (KVA) Rated input current (A) Range of welding current 60～350 60-500 Range of welding voltage 14～40 14-50 OCV (V) Duty cycle (%) Full-load efficiency (%) ≥87 Power factor ≥0.95...

  • Page 22: Disassembly And Reassembly

    4-9 Disassembly and reassembly Fig. 4-9-1: Disassemble and reassembly...
  • Page 23 Description Stock No. Potentiometer knob 720031-00070 Digital displayer 755001-00003 Waterproof indicator 715002-00026 Band switch 745013-00002 Potentiometer 720031-00041 Toggle switch 745002-00003 Left panel 262017-00632 Top panel 262029-00477 Welding machine handle 766003-02388 Polypropylene 722001-00074 Main transformer 220629-00015 Resonant inductor 220521-00004 Main control board 210580-00078 Power transformer Ⅰ...
  • Page 24 Potentiometer knob 720031-00066 Varistor 720021-00017 Screw 779001-00051 Spring washer 779007-00008 Flat washer 779007-00019 Three phase rectifier module 735005-00003 Polypropylene 722001-00067 IGBT protection board 220005-00135 IGBT module 735007-00038 Input filter inductance 220479-00002 Temperature relay 745008-00007 IGBT radiator 264005-00033 Radiator support 766002-00090 Output diode radiator 264011-00116 Current exchange inductor...

  • Page 25: 5-Trouble Shooting

    5-TROUBLE SHOOTING Warning! An electric shock can be fatal. Before doing any work on 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 on again -Check to make sure the electrically charged components (e.g.

  • Page 26: -Care And Maintenance

    6 –CARE AND MAINTENANCE Before open the machine Warning! An electric shock can be fatal. Before doing any work on 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 on again -Check to make sure the electrically charged components (e.g.
  • Page 28 Description Stock No.3500 Stock No.5000 SAP KODU SAP KODU Stock Stock No.3500 No.5000 6064200442 6064200442 Potentiometer knob 720031-00137 720031-00137 6064000461 6064000461 Digital displayer 755001-00023 755001-00023 6064200487 6064200487 Waterproof indicator 715002-00025 715002-00025 Band switch 745013-00580 745013-00580 Potentiometer 720031-00041 720031-00041 6064200490 6064200490 Toggle switch 745002-00003 745002-00003...
  • Page 29 Potentiometer 720031-00042 720031-00042 Control panel 262035-00316 262035-00316 6064200486 6064200486 Waterproof indicator 715002-00026 715002-00026 6064200488 6064200488 Potentiometer knob 720031-00138 720031-00138 6064100167 6064100167 Varistor 720021-00017 720021-00017 6064200537 6064200537 Screw 779001-00051 779001-00051 6064200147 6064200147 Spring washer 779007-00008 779007-00008 6064200221 6064200221 Flat washer 779007-00019 779007-00019 6064100220 6064100168...
  • Page 30 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 3500

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