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GeKaMac PoWer MIG Series User Manual

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PoWer MIG 3500 C
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 C 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: 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, pleaseremember 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 4: 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 5: Safety Inspection

    Safety inspection • The owner/operator is obliged to perform safety inspection at regular intervals. • The manufacturer also recommends every 3-6 months for regular maintenance of power sources. Electric shock can kill • Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on.
  • Page 6 Shield the entire welding equipment and other equipment nearby. ARC rays can burn • Visible and invisible rays can burn eyes and skin. • Wear an approved welding helmet or suitable clothing made from durable flame-resistant material (leather, heavy cotton, or wool) to protect your eyes and skin from arc rays and sparks when welding or watching.
  • Page 7 cylinders. • Always install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling over or tipping. • Keep a safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
  • Page 8 • Use proper static-proof bags and package to store or move PCB. Safety markings • Equipment with CE-markings fulfils the basic requirements of the Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). Safety markings •...

  • Page 9: Table Of Contents

    Contents 1-GENERAL REMARKS ............................ 9 1-1 Power source features ......................... 9 1-2 Functional principle ..........................9 1-3 Output characteristics ........................10 1-4 Duty cycle ............................10 1-5 Applications ............................11 1-6 Warning label ............................. 11 2-VERSIONS BRIEFS ............................. 12 3-BEFORE COMMISSIONING ........................12 3-1 Utilization for intended purpose only ....................
  • Page 10 5-TROUBLE SHOOTING ..........................35 6-CARE AND MAINTENANCE ........................37...

  • Page 11: 1-General Remarks

    1-GENERAL REMARKS This series welding machines apply IGBT soft switch inverter technology; the power source enjoys highly stable welding voltage against the fluctuation of power grid and arc length change. The internal control system achieves precise control of welding process to ensure optimal welding results. 1-1 Power source features Highlights as follows: - Enjoy reasonable static characteristic and sound dynamic characteristic...

  • Page 12: Output Characteristics

    1-3 Output characteristics Fig.1-3-1: Output characteristics 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 13: Applications

    1-5 Applications Recommended areas of use as follows: - Automobile and car manufacture industry - Chemical structure and engineering - Shipbuilding and offshore engineering - Electric power construction - Vehicle manufacturing - Mechanical industry - Other industries 1-6 Warning label The warning label is affixed on the top of machine.

  • Page 14: 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 weldings. ● PoWer MIG 3500 C PoWer MIG 3500C welding machine is an all-in-one design, with a push-pull handle, a cylinder holder, and 4 wheels at the bottom, so the cylinder can be placed at the back of the welding machine for easy movement.

  • Page 15: Welding Cables Instruction

    - The power supply sockets that come with power source are designed to use strictlyaccording to the marked voltages. Note!Inadequately dimensioned electrical installations can lead to serious damage. The mains lead, and its fuseprotection, must be dimensioned in accordance with the local power supply. The technical data shown on thenameplate shall apply.
  • Page 16 Correct When the excess cables are only be used byrolling up, coil the cables to two windings inreverse direction and overlap them. The number of turns for A is same as thenumber for B. Handle the welding cable and ground cableaccording to above-mentioned method.

  • Page 17: 4-Power Mig 3500 C

    4-PoWer MIG 3500 C 4-1 System components PoWer MIG 3500 C welding machine 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 PoWer MIG 3500 C operate well.

  • Page 18: Control Panel

    Welding wire 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 selectby pressing the appropriate button; parameters are easy to be adjusted by rotating encoder. Synergic adjustment makes the complicated operation much easier.
  • Page 19 1. Crater filler current/ Spot weld time knob - Preset crater filler current when on 4-step mode; Preset spot weld time when on spot welding mode, adjust range is 0.5~5s. 2. Crater filler voltage knob Preset crater filler voltage when on 4-step mode. On sub-menu interface, adjust parameters value.
  • Page 20 18. Working mode selection button Choose between 2-step/4-step/spot welding modes. Torch operation mode introduction: Graphic symbol Fig. 4-3-2: Press torch trigger Fig. 4-3-3: Hold torch trigger Fig. 4-3-4: Release torch trigger P03 (811)……Pre-gas time I……Welding-current: Uniform thermal input into the preheated base metals. P06……Crater filler standard: To prevent burn-through of the base metal due to too much heat input at the end of welding.

  • Page 21: Submenu

    - Spot welding mode Fig. 4-3-7: Spot welding mode 19. FCAW/GMAW selection button Choose according to wire type, corresponding indicator lights up. 20. Wire test button Press to feed wire, release to stop feeding wire (this button has same function with wire feeder controller inch wire feeding button) 4-4 Submenu ●...
  • Page 22 Special 2-step arc start time OFF~10S 0.1s Special 2-step arc stop time OFF~10S 0.1s Separate adjustment mode OFF/ON ―― Pulse current when start arc -5.0~5.0 Pulse time when start arc -99~99 Inch wire feeding speed 1.0~21.0m/min 3m/min Ball removing voltage 0~100% 1％...
  • Page 23 During the special 4-step mode, the time cost from starting current to normal welding current and then to post current. - P08 Spot welding time Choose spot welding process and set the welding time. - P09 Panel control /Remote control /PLC control mode selection Panel control mode,perset current &...
  • Page 24 ● Enter submenu Press “inductance” knob and “wire diameter” button at the same time for 3s, then enter sub-menu. Fig. 4-4-1: Enter submenu Fig. 4-4-2: Select parameters Fig. 4-4-3: Adjust value ● Submenu parameters adjustment Adjust “crater filler current/spot weld time” knob to select parameters between P01 to P35; Adjust “crater filler voltage”...
  • Page 25 Item Function Adjust method If the welding wire strikes the workpiece quickly before starting the arc, the spatter is severe during the starting arc → reduce Wire feed speed before ignition arc the P02 value; if the arc is not open or the starting is very slow →...

  • Page 26: Save&Load Function

    Item Function Adjust method Transitional time from welding Weld seam formation is narrow – increase the paramter value period to crater filler period Weld seam formation is wide – reduce the parameter value Crater filler time, default is OFF No problem of weld seam formation - OFF Crater filler period Wire sticks with work piece, work piece burns seriously - increase the P01 value...

  • Page 27: Shift Between Preset Current And Preset Wire Feeding Speed

    this channel no.is recalled. 3. Re-press the ”LOAD” button to exit. Fig. 4-5-2 Load function 4-6 Shift between preset current and preset wire feeding speed Press the “crater filler current” and “crater filler voltage” together for 1s; the current displayer will display the preset current and the preset wire feeding speed alternately.

  • Page 28: Interface

    4-8 Interface Fig. 4-8-1: Interface 1. Euro-type connector (+) In MIG/MAG: connect to welding torch 2. Polarity conversion plug It is used to connect with polarity conversion socket. Only when they connect well, welding torch can work. In MIG/MAG solid wire: it is used to connect with output termial (+); In FCAW: it is used to connect with output termial (-).

  • Page 29: Installation

    7.Fuse Control transformer fuse, protect control circuit parts. 8. Power supply socket for gas heater (AV36V) It is used to connect the heater coil of the gas regulator. 9. Gas inlet Connect with gas cylinder by gas hose 10. Fan For cooling down the heating spare parts inside of the welding machine.
  • Page 30 Fig. 4-9-1: Installation of the system components ●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. 2.
  • Page 31 Fig. 4-9-5: Installation for steel wire feed tube 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 32: Technical Data

    Protective GND wire ≥2.5 Table4-9-1: Power supply and cable requirement Note! Welding machine must be taken special design if it is powered by generator, please contact with manufacturer if you have such needs. ● connections of Power cord and distribution box Warning! -Avoid hot-line work - Operating by professional electrician - Avoid connecting two power sources to one breaker...

  • Page 33: Dimension

    Range of welding current(A) 60~350 Range of welding voltage(V) 14~40 OCV(V) Duty cycle (%) Full-load efficiency(%) ≥87 Power factor ≥0.95 Wire diameter (mm) Ф0.8,Ф1.0,Ф1.2 Gas flow(L/min) 10~25 Dimension(mm 630×330×570 Weight (Kg) Isolation degree IP class IP21S Table 4-10-1: PoWer MIG 3500 C technical data 4-11 Dimension Fig.

  • Page 34: Disassembly And Reassembly

    Item Unit(mm) Unit(inches) length 37.2 Width 19.7 Height Table. 4-11-1: Dimension 4-12 Disassembly and reassembly...
  • Page 35 Fig. 4-12-1: Disassemble and reassembly Item Stock No. Remarks Polypropylene capacitor 722001-00070 Reactor 763004-00158 Current sensor 753001-00020 Current transformer board 220149-00016 Quick socket 740002-00026 Display board 220503-00007 handle 766002-01188 Power transformer I 763001-00048 Power transformer II 763001-00049 Main control board 210580-01108 Drive board 210310-00020...
  • Page 36 Solid state relay 715004-00003 746001-00087 Polypropylene capacitor 722001-00067 IGBT module 735007-00048 IGBT protection board 220005-00137 Three phase rectifier module 735005-00002 Varistor 720021-00017 Input filter inductance 220479-00002 Current exchange inductor 220281-00008 Fast recovery diode module 735006-00029 Diode protection board 220455-00002 Wire spool shaft 324029-00001 Toggle switch 745003-00026...

  • Page 37: Troubleshooting

    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 inadvertentlyswitching it on again -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.
  • Page 38 configuration of the power source, and get in touch with our after-sale service, giving them a detailed description of the error. ● Power source trouble shooting Note! The flowing troubles and causes are uncertain. However, during the process of MIG Pulse and the normal using conditions, that might happen.

  • Page 39: 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 inadvertentlyswitching it on again -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.
  • Page 40 Fig. 6-1: Daily maintenance...

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Power mig 3500 c

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