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GeKaMac PoWer MIG Series User Manual

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Power MIG 200 SYN
Users Manual
Please Read and Understand This Manual
Before Operating The Welding Machine
www.gedikwelding.com

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  • Page 1 Power MIG 200 SYN 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, 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 4 AT UYGUNLUK BEYANI EU DECLARATION OF CONFORMITY Bu uygunluk beyanı yalnızca /malatçının sorumluluğu altında düzenlen/r. Th#s declarat#on of conform#ty #s #ssued under the sole respons#b#l#ty of the manufacturer İstanbul, Turkey, 08.03.2024 İmalatçı / Manufacturer GEDİK KAYNAK SANAYİ ve TİCARET A.Ş. Ankara Cad.

  • 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 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. The input power circuit and machine internal circuits are also live when power is on. In MIG/MAG welding, the wire, drive rollers, wire feed housing and all metal parts touching the welding wire are electrically live.
  • Page 7 Shielding 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 8 • Remove stick electrode from electrode holder or cut off welding wire at contact tip when not in use. Apply correct fuses or circuit breakers. Do not oversize or bypass them. Cylinder can explode if damaged. • Pressure gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

  • Page 9: Table Of Contents

    • Keep all doors, panels, covers, and guards closed and securely in place. • Have only qualified persons remove doors, panels, covers, or guards for servicing and maintenance. • Reinstall doors, panels, covers, or guards when servicing and maintenance is finished and before reconnecting input power.
  • Page 10 2-VERSIONS BRIEFS ............................. 12 3-BEFORE COMMISSIONING ........................13 3-1 Utilization for intended purpose only ....................13 3-2 Machines set-up regulations ......................13 3-3 Power source connection ........................ 14 3-4 Welding cables instruction ....................... 14 4-PoWer MIG 200 SYN ........................... 15 4-1 System components ........................

  • Page 11: 1-General Remarks

    1-GENERAL REMARKS 1-1 Features PoWer MIG 200 SYN multi function inverter welding machine can use for MIG/MAG and flux cored welding. Also it possesses STICK, Lift TIG function. This series welding machine enjoys reasonable static characteristic and sound dynamic characteristic. Features and benefits: Inverter technology ensures stable welding voltage when network voltage fluctuates and arc length changes.

  • Page 12: Output Characteristics

    Input Output HF transformer 1-phase rectifier HF Inverter Rectifier & filter Transformer Rectifier Control circuit Fig. 1-2-1: Schematic diagram 1-3 Output characteristics Please refer to Fig. 1-3-1 for output characteristics. MIG/MAG mode STICK mode LIFT TIG mode 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.

  • Page 13: Applications

    Fig. 1-4-1: Duty cycle 1-5 Applications This series power source can use for carbon steel, stainless steel, aluminum and al-mg alloy welding with solid wire (Ф0.6, Ф0.8, Ф1.0mm) and flux-cored wire (Ф0.8, Ф1.0mm).

  • Page 14: Warning Label

    The power source is designed for the following recommend areas: Automobile Steel door and window Furniture Decoration Fitness equipment manufacture Maintenance and repair 1-6 Warning label The warning label is affixed onto the top of the power source, and it must not be removed or painted over.

  • Page 15: 2-Versions Briefs

    Fig. 1-6-1: Warning label 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 200 SYN It is multi function inverter welding machine, can use for MIG/MAG, FCAW-S, STICK and Lift TIG function. Built-in wire feeder with 5kg wire spool, closed type, small size, light weight and easy to start arc, enjoy stable arc length, pretty welding seam formation and welding current continuous adjustment capability.

  • Page 16: 3-Before Commissioning

    3-BEFORE COMMISSIONING 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 the safety rules. 3-1 Utilization for intended purpose only The power source may only be used for MIG/MAG, FCAW-S, STICK and Lift TIG. Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in accordance with the intended purpose”.

  • Page 17: Power Source Connection

    The venting duct is very important for safety protections. When choosing the machine location, make sure it is possible for the cooling air to freely enter and exit through the louvers on the front and back of machine. Any electro conductive metallic dust like drillings must not be allowed to get sucked into the machine.

  • Page 18: 4-Power Mig 200 Syn

    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 are only be used by rolling up, coiling the cables to two windings in reverse direction and overlap them.

  • Page 19: Basic Equipments For Welding

    Fig. 4-1-1: System components 4-2 Basic equipments for welding Basic equipments are needed for normal welding. Below are the lists: MIG/MAG - Power source - Ground cable - MIG/MAG welding torch - CO2 gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) FCAW-S - Power source - Ground cable...

  • Page 20: Interface

    STICK - Power source - Ground cable - Electrode holder - Electrode Lift TIG - Power source - Ground cable - TIG torch - Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) 4-3 Interface Front panel Fig.
  • Page 21 3) Welding machine output terminal (-) MIG/MAG, STICK: connect with work piece via ground cable; FCAW-S/Simple TIG: connect with welding torch. 4) Polarity conversion plug It is used to change polarity (positive and negative) of welding torch. 5) Welding machine output terminal (+) MIG/MAG: connect with welding torch;...
  • Page 22 runs. 2. Power supply cable The mixed-colored wire must be firmly grounded; the rest 2 wires connect to one phase AC power supply. 3. Gas inlet Connect to gas regulator with gas hose (MIG/MAG ONLY). 4. Fan Cool down the heat components inside welding machine. 5.

  • Page 23: Control Panel

    Fig. 4-3-4: Side panel 1. Wire feeding system Single drive wire feeder, can weld solid wire and flux cored wire; Solid wire: V type wire roller, wire diameter Φ0.6,Φ0.8,Φ1.0; U type wire roller, wire diameter Φ0.8,Φ1.0,Φ1.2; Flux cored wire: knurl type wire roller, wire diameter Φ0.8,Φ1.0. 2.
  • Page 24 Fig. 4-4-1: Control panel 1. Welding mode selection button Change welding modes between Fe/AL/JOB LIST/Synergic MIG/ STICK/ LIFT TIG, corresponding indicator lights up; Fe/Manual MIG: Fe mode: Non-expert library gas shielded welding mode, manual setting of welding parameters, welding of carbon steel, stainless steel and self-shielded flux cored wire; AL / Job-list /synergic MIG : MIG expert library mode, the factory setting is aluminum Ф...
  • Page 25 Fig. 4-4-5: 2T Step mode 4T Step mode Fig. 4-4-6: 4T Step mode 3. Wire feeding speed/ welding current/job list adjustment knob On Fe/Manual MIG mode, it is used for adjusting preset wire feeding speed; On AL/Synergic MIG mode, select Job-list code, preset wire feeding speed; On Lift TIG and STICK mode, it is used for adjusting preset welding current.

  • Page 26: Job List

    Display actual welding current when welding. 5. Welding voltage/down slope time/arc force adjustment knob On Fe/Manual MIG mode, it is used for adjusting preset welding voltage; On AL/Synergic MIG mode, adjust matched voltage, middle zone of knob scale is standard zone,The welding machine automatically matches the appropriate voltage, and can also adjust the voltage knob to fine-tune the matching voltage to ±3V according to requirements.
  • Page 27 2. Press and hold the mode selection button 5S to enter the job list menu. At this time, the voltage displayer shows “Job” and the current displayer shows the previously set job code. Adjust the Job-list knob to select the desired job code. Fig.

  • Page 28: Sub Menu

    4.After waiting for 5 seconds or press and hold the mode selection button for 5S , the welder will automatically exit the Job code interface (if the job code is not 240, the job list indicator will keep flashing). If you choose aluminum/pull (spool gun) code(232-238), you can refer to the welding specifications listed in Table 4-9-2 for adjustment, or you can adjust the parameter values of sub menu P11～P13 according to the needs of weld scale patterns;...
  • Page 29 VRD function selection ON/OFF STICK mode Table 4-6-1 Submenu parameter - P01 Burn back time When the gas shielded welding or self-shielded flux cored welding is completed and the welding wire sticks to the workpiece, press the 2T Step/4T Step button to increase the parameter value; when the welding wire is burned back to the contact tip, press the mode selection button to decrease parameter value;...

  • Page 30: Reset Factory Setting

    Appears only in the job number 232 ~ 236 of Job code.Adjust the parameter value through the 2T Step/4T Step button and the mode selection button. The larger the value, the greater the depth of the fish scale; when the parameter is reduced to 1, the pulsating wire feed function is canceled. - P14 High pulse group duty cycle Appears only in the job number 232~236 of Job code.Adjust the parameter value through the 2T Step / 4T Step button and the mode selection button.

  • Page 31: Control Socket

    4-8 Control socket Pin NO. Description Connect motor (+24VDC) positive of spool gun 2, 3 Connect torch trigger cable Connect 0Ω end of remote control potentiometer (4.7 KΩ) Connect wiper end of remote control potentiometer (4.7 KΩ) Connect motor (+24VDC) negative of spool torch Note: when use spool torch, should place wire pushing/wire pulling selection switch on side panel on wire pulling position, then wire feeding power supply of pin 1, 6 is connected.
  • Page 32 POWER MIG 200 SYN Model AC 220/230V±15%, 50/60Hz Power supply(1-phase) Fuse Min. power capacity (KVA) Circuit breaker Input protection (A) Input cable Output cable Cable size Protective GND wire (mm²) Table 4-9-1: Input power supply cable installation The connection between input power supply cable and switch box (Fig. 4-5-1). Warning! - Never connection when equipment is power on! - The connection must be carried out by a qualified electrician!
  • Page 33 Warning! Operating the welding machine incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understand all the following documents: - “safety rules” - “before commissioning” Warning! Electric shock is very dangerous. As soon as press the torch trigger, the welding wire is power on.
  • Page 34 Fig. 4-9-2: Installation - MIG/MAG with push gun When welding aluminum and aluminum alloy welding wire, the wire guide tube of the welding gun and wire feeder is replaced with a Teflon hose, and a U-type roller is used. The installation is shown in Figure 4-9-3.
  • Page 35 MIG/MAG, FCAW-S welding with pull gun(spool gun) Open the side panel, and select the pull gun(spool gun) with the pushgun/pull gun switch on the vertical board Fig. 4-9-4: Installation - MIG/MAG with pull torch FCAW-S-Flux-cored wire welding Open the side panel, and select the push gun with the pushgun/pull gun switch on the vertical board.
  • Page 36 Fig. 4-9-5: Installation – FCAW-S welding with push gun 1.According to the above diagram and description, correctly set the insertion position of the welding torch conversion quick-plug cable and the push wire/drawing switch state; the grounding cable is reliably connected to the quick socket, and the welding torch is reliably connected to the welding torch socket; 2.
  • Page 37 Fig. 4-9-6: Installation - stick welding Connect welding cable to welding machine positive output terminal (+); Connect work piece with ground cable, and connect ground cable to negative output terminal (-); Connect well one phase power supply, and ensure good grounding; Turn on the power switch on rear panel;...

  • Page 38: Technical Data

    indicator lights up; 7.Adjust proper welding current; 8.Open gas cylinder, gas feeds out; 9.Start welding. Fig. 4-9-7: Installation - TIG welding 4-10 Technical data Note! Please use the machine under the allowed power supply voltage range marked in the nameplate. The technical data with the basic input voltage are listed as the Table 4-10-1. Model Power MIG 200 SYN Rated input voltage/frequency(1 phase) AC220/230V±15%, 50/60Hz...

  • Page 39: Dimension

    Table 4-10-1: Rated duty cycle (%,@40℃) Open circuit voltage (V) Shielding gas CO2, Ar+CO2, Ar Step 2T Step/4T Step Protection class IP21S Insulation grade Cooling way Air cooled Wire spool diameter (mm) 100, 200 200,300 Wire-feeding speed (m/min) 2-15 Down slope time (S) 0-10 Wire feeding system type Built-in...

  • Page 40: Disassembly And Reassembly

    4-12 Disassembly and reassembly Fig. 4-12-1: Power MIG 200 SYN Item Stock no. Circuit breaker 745011-00068 735004-00007 Rectifier bridge 735004-00006 746002-00025 746002-00049...
  • Page 41 Varistor 720021-00020 Polypropylene capacitor 722001-00023 Polypropylene capacitor 722001-00065 722004-00105 Aluminum electrolytic capacitor 722004-00146 IGBT tube 735003-00013 Diode tube for PFC 730003-00007 Inductor for PFC 763005-00145 Temperature relay for PFC 745008-00031 745008-00028 Temperature relay 745008-00032 745008-00030 763002-00026 Main transformer 763002-00029 Diode 730001-00007 Safety capacitor 722008-00011...

  • Page 42: 5-Trouble Shooting

    220179-00797 Solenoid valve 752001-00045 Power supply filter board 220900-00473 Power supply switch board 220900-00309 Quick socket 740002-00091 Quick plug 740002-00063 Table 4-12-1: Main components list Note: If no special remarks, the input voltage mentioned in above table is one phase. 5-TROUBLE SHOOTING Warning! An electric shock can be fatal.
  • Page 43 Error code Fault Cause Remedy Over current Output current is over rated current Reduce output current Over heat/fan does 1) Inner of welding machine is too hot 1) Wait until cool down not work 2) Temperature relay is damaged 2) Replace 3) Fan is damaged 3) Replace Short circuit of wire...
  • Page 44 TROUBLE CAUSES REMEDY 1) Check power switch and the fan 1) Power switch is damaged 2) Check power supply 2) No electricity on the electricity grid on the the electricity grid Power on, LED does not light up, fan does 3) Short circuit in the power supply cable 3) Check the connection not run, no output...

  • Page 45: 6-Care And Maintenance

    6-CARE AND MAINTENANCE l Before open the machine Warning! An electric shock can be fatal. Before opening 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 back on again Check to make sure the electrically charged components (e.g.capacitors) have been discharged...
  • Page 46 Fig. 6-1: Daily maintenance...
  • 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...

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