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GeKaMac PoWer TIG Series User Manual

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PoWerPlus TIG 400
AC/DC Pulse
Users Manual
Please Read and Understand This Manual
Before Operating The Welding Machine
www.gedikwelding.com

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  • Page 1 PoWerPlus TIG 400 AC/DC Pulse Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
  • Page 2 THANK YOU FOR USING OUR PRODUCTS OPERATOR’S MANUAL PoWer PlusTIG 400 AC/DC Pulse IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your distributor if you do not fully understand this manual.
  • Page 3 CONTENT CONTENT §1 SAFETY ..............................1 §2 SUMMARY ............................... 8 §2.1 Brief Introduction ........................... 8 §2.2 Parameters ............................. 10 §2.3 Duty cycle & Over heat ........................11 §2.4 Working Principle ..........................11 §2.5 Volt-Ampere Characteristic ......................12 §3 Installation & Operation ......................... 1 3 §3.1 Layout for Front and Rear panel ..................... 13 §3.2 Layout for Control panel ........................14 §3.3 Installation & Operation for MMA welding ................. 22 §3.3.1 Set up installation for MMA Welding ...................... 22 §3.3.2 Operation for MMA Welding ........................24 §3.3.3 MMA Welding ..............................25 §3.3.4 MMA Welding Fundamentals ........................26 §3.4 Installation & Operation for TIG welding ..................28 §3.4.1 Set up installation for TIG Welding ......................28 §3.4.2 Operation for TIG Welding ......................... 30 §3.4.3 DC TIG Welding .............................. 31 §3.4.4 TIG Welding Fusion Technique .
  • Page 4 SAFETY §1 SAFETY Notice: The instructions are for reference only. The manufacturer reserves the right to explain the differences between the description and the product due to product changes and upgrades! The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: l Injury or death to the operator.
  • Page 5 SAFETY is 104°F (40°C). Low temperature may lead to performance degradation or damage of components inside the product, resulting in ice inside the water tank. Usually the lowest operating temperature is 14°F (-10°C). Please keep warm and add antifreeze in the water tank if necessary. Too humid environment may lead to rust of shell and circuit components.
  • Page 6 SAFETY Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin. l Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
  • Page 7 SAFETY l Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. l Shielding gases used for arc welding can displace air and cause injury or death.
  • Page 8 SAFETY l Vent hollow castings or containers before heating, cutting or welding. They may explode. l Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair. l Connect the work cable to the work as close to the welding area as practical.
  • Page 9 SAFETY “hot” parts to touch a cylinder. l Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. l Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. Touching live electrical parts can cause fatal shocks or severe burns.
  • Page 10 SAFETY According to the domestic and international standards, the ambient devices’ electromagnetism situation and anti-interference ability must be checked: l Safety device. l Power line, Signal transmission line and Date transmission line. l Date processing equipment and telecommunication equipment. l Inspection and calibration device. Supporting measures for avoidance of EMC problems: 1.

  • Page 11: Brief Introduction

    SUMMARY §2 SUMMARY §2.1 Brief Introduction TIG AC/DC PULSE welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work...
  • Page 12 SUMMARY ★ TIG/DC operation, if the tungsten electrode touches the workpiece when welding, the current will drop to short-circuit current to protect tungsten. ★ Intelligent protection: Over-voltage, over-current, over-heat, when the problems listed before occurred, the alarm indicator on the front panel will be on and the output current will be cut off.
  • Page 13 SUMMARY decoration, car repair, bicycle, handicraft and common manufacture. MMA——Manual Metal Arc welding; PWM——Pulse-Width Modulation; IGBT——Insulation Gate Bipolar Transistor; TIG——Tungsten Inert Gas welding. The module explanation of arc welding machine must accord with the correlative prescripts of National Standard GB10249. It is explained as the following. §2.2 Parameters Models PoWer Plus TIG 400 AC/DC PULSE...

  • Page 14: Duty Cycle & Over Heat

    SUMMARY Note: The above parameters are subject to change with the improvement of machines. §2.3 Duty cycle & Over heat The letter “X” stands for duty cycle, which is defined as the proportion of the time that a machine can work continuously within a certain time (10 minutes).

  • Page 15: Volt-Ampere Characteristic

    SUMMARY continuously and steplessly to meet with the requirements of welding craft. §2.5 Volt-Ampere Characteristic TIG AC/DC PULSE welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the conventional rated loading voltage U and the conventional welding current I is as follows: When I...
  • Page 16 INSTALLATION & OPERATION §3 Installation & Operation §3.1 Layout for Front and Rear panel Negative output: The welder’s negative polarity output. Shield gas connector: Is connected to the gas input pipe of torch. Aero socket: Is connected to torch switch control wire. Positive output: The welder’s positive polarity output.
  • Page 17 INSTALLATION & OPERATION §3.2 Layout for Control panel 1. Wave output select button. * 2. MMA welding mode indicator. 3. Welding mode select button. 4. Lift TIG welding mode indicator. 5. HF TIG welding mode indicator. 6. JOB indicator. * 7.
  • Page 18 INSTALLATION & OPERATION 15. Hot Start indicator. * 16. Welding current indicator. 17. Arc Force indicator. * 18. TIG parameter setting: Here are 14 indicators about TIG welding mode.* 19. Control knob: Press down the knob to choose parameter, rotate the knob to adjust value of current or parameter.

  • Page 19: Alarm Indicator

    INSTALLATION & OPERATION Alarm Indicator (12) Lights when over voltage, over current or electrical overheating (due to exceeding duty cycle) is detected and protection is activated. When protection is activated, welding output will be disabled until the safety system senses the overload has reduced sufficiently and indicator lamp goes out.
  • Page 20 INSTALLATION & OPERATION Press Wave output select button to select four output waveforms: three AC waveforms and one DC waveform, as follows: AC Square Wave Focused arc for maximum penetration, fast travel speed with best directional control. AC Sine Wave Welding Output Traditional AC TIG welding wave form.
  • Page 21 INSTALLATION & OPERATION TIG Parameter Setting (18) Pre gas flow setting indicator 1) Pre-flow controls the period shielding gas will flow for when the torch is triggered before the arc starts. This purges the work area of atmospheric gas which could contaminate the weld before the weld starts.
  • Page 22 INSTALLATION & OPERATION Unit (A) and setting range (10~400A). Down slope setting indicator 6) When the trigger is released, the welding current will reduce gradually over the time selected down to 0. This allows the operator to complete the weld without leaving a ‘crater’ at the end of the weld pool.
  • Page 23 INSTALLATION & OPERATION the AC cycle gives the ‘cleaning’ effect on the weld material, while the forward cycle melts the weld material. Neutral setting is 0. Increased reverse cycle bias will give greater cleaning effect, less weld penetration and more heat in the torch tungsten, which gives the disadvantage of reducing the output current that can be used for a given tungsten size, to prevent the tungsten overheating.
  • Page 24 INSTALLATION & OPERATION shielding gas stars to flow. (2) 0～t1: Pre-gas time (0.1~2.0s) (3) t1～t2: Arc is ignited and the output current rises to the setting welding current (I ) from the min welding current. (4) t2～t3: During the whole welding process, the gun switch is pressed and held without releasing.

  • Page 25: Set Up Installation For Mma Welding

    INSTALLATION & OPERATION Introduction: (1) 0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas stars to flow; (2) 0～t1: Pre-gas time (0.1~2.0S); (3) t1～t2: Arc is ignited at t1 and then output the setting value of start current; (4) t2: Loosen the gun switch, the output current slopes up from the start current;...
  • Page 26 INSTALLATION & OPERATION Connection of Output Cables Two sockets are available on this welding machine. For MMA welding the electrode holder is shown be connected to the positive socket, while the earth lead (work piece) is connected to the negative socket, this is known as DCEP. However various electrodes require a different polarity for optimum results and careful attention should be paid to the polarity, refer to the electrode manufacturer’s information for the correct polarity.

  • Page 27: Operation For Mma Welding

    INSTALLATION & OPERATION (4) Each machine is equipped with a power cable should be based on the input voltage welding power cable connected to the appropriate position, not to pick the wrong voltage; (5) With the corresponding input power supply terminal or socket good contact and prevent oxidation;...

  • Page 28: Mma Welding

    INSTALLATION & OPERATION should be larger to reduce cable voltage drop. §3.3.3 MMA Welding One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’.
  • Page 29 INSTALLATION & OPERATION Manual metal arc (stick) electrodes have a solid metal wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode.

  • Page 30: Arc Length

    INSTALLATION & OPERATION >8.0 mm 5.0 mm The size of the electrode generally depends on the thickness of the section being welded, and the thicker the section the larger the electrode required. The table gives the maximum size of electrodes that may be used for various thicknesses of section base on using a general purpose type 6013 electrode.

  • Page 31: Set Up Installation For Tig Welding

    INSTALLATION & OPERATION transfer of metal. When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When vertical up welding, the angle of the electrode should be between 80 and 90 degrees to the work piece.
  • Page 32 INSTALLATION & OPERATION (1) Insert the earth cable plug into the positive socket on the front of the machine and tighten it. (2) Plug the welding torch into the negative socket on the front panel, and tighten it. (3) Connect the gas line of TIG Gun to outlet gas connector on the front of the machine. (4) Connect the control cable of torch switch to 12 pin socket on the front of the machine.

  • Page 33: Operation For Tig Welding

    INSTALLATION & OPERATION (9) Carefully open the valve of the gas cylinder, set the required gas flow rate. (10) Connect the power cable of welding machine with the output switch in electric box on site. Turn on the power switch. (11) With a multi meter measure the input voltage is within the fluctuation range.

  • Page 34: Dc Tig Welding

    INSTALLATION & OPERATION §3.4.3 DC TIG Welding The DC power source uses what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal).

  • Page 35: Tig Welding Fusion Technique

    INSTALLATION & OPERATION §3.4.4 TIG Welding Fusion Technique Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the work piece.

  • Page 36: Tungsten Electrodes

    INSTALLATION & OPERATION pool as the torch is moved forward. Also a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward. It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects the end of the wire from being oxidized and contaminating the weld pool §3.4.5 Tungsten Electrodes...
  • Page 37 INSTALLATION & OPERATION when it is enclosed in a tungsten matrix the risks are negligible. Thoriated tungsten should not get in contact with open cuts or wounds. The more significant danger to welders can occur when thorium oxide gets into the lungs. This can happen from the exposure to vapours during welding or from ingestion of material/dust in the grinding of the tungsten.
  • Page 38 INSTALLATION & OPERATION Lanthanated (Color Code: Gold) Lanthanated tungsten electrodes (AWS classification EWLa-1.5) contain a minimum of 97.80 percent tungsten and 1.30 percent to 1.70 percent lanthanum, and are known as 1.5 percent lanthanated. These electrodes have excellent arc starting, a low burn off rate, good arc stability, and excellent re-ignition characteristics.

  • Page 39: Tungsten Preparation

    INSTALLATION & OPERATION §3.4.6 Tungsten Preparation Always use DIAMOND wheels when grinding and cutting. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as Aluminium oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects.
  • Page 40 INSTALLATION & OPERATION Electrode Included Angle/Taper - DC Welding Tungsten electrodes for DC welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities.
  • Page 41 INSTALLATION & OPERATION §3.4.7 Gun swltch control current UP/DOWN GUN Remote Control Socket Socket Pin Functlon Not connected Not connected Not connected Not connected Not connected The button of "UP" input The button of "DOWN" input Trigger Switch Input Trigger Switch Input Not connected The button of "UP"&...
  • Page 42 INSTALLATION & OPERATION §3.4.8 Pedal swltch control ● When plug the twelve-lead aero-socket of pedal switch in it. Welder will identify the pedal switch, the welding current knob on the front panel will can’t use，and only 2T can be selected. ●...
  • Page 43 INSTALLATION & OPERATION Socket Pin Functlon Be shorted with 2 Be shorted with 1 20k ohm (maximum) connection to 20k ohm remote control potentiometer Wiper arm connection to 20k ohm remote control potentiometer Zero ohm (minimum) connection to 20k ohm remote control potentiometer Not connected Not connected Trigger Switch Input...

  • Page 44: Operation Environment

    INSTALLATION & OPERATION §3.5 Operation Environment l Height above sea level is below 1000m. l Operation temperature range: -10°C ~ 40°C. l Relative humidity is below 90% (20°C). l Preferably site the machine some angles above the floor level, the maximum angle does not exceed 15°.

  • Page 45: Maintenance

    INSTALLATION & OPERATION §4 Malntenance & Troubleshootlng §4.1 Maintenance In order to guarantee that arc welding machine works high-efficiently and in safety, it must be maintained regularly. Let customers understand the maintenance methods and means of arc welding machine more, enable customers to carry on simple examination and safeguarding by oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to lengthen service life of arc welding machine .Maintenance items in detail are in the following table.

  • Page 46: Troubleshooting

    INSTALLATION & OPERATION inductance, IGBT module, the fast recover diode and PCB, etc. Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is skid, please replace. If it is rusty, please erase rust on bolt to ensure it works well.
  • Page 47 INSTALLATION & OPERATION Troubles Reasons Solution welding cable Connect the welding cable to the connected with the two output of welder’s output. the welder. The welding cable damaged. Repair or change it. There earth cable connected spark Check the earth cable. unstably.

  • Page 48: List Of Error Code

    INSTALLATION & OPERATION §4.3 List of error code Error Type Error code Description Lamp status Yellow lamp (thermal Over-heating (1st thermal relay) protection) always on Yellow lamp (thermal Over-heating (2nd thermal relay) protection) always on Yellow lamp (thermal Thermal relay Over-heating (3rd thermal relay) protection) always on Yellow lamp (thermal...
  • Page 50 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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Powerplus tig 400 ac/dc pulse

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