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GeKaMac PoWer TIG Series User Manual

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PoWer TIG 4000 DC
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 PoWer TIG Series

  • Page 1 PoWer TIG 4000 DC PULSE Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...

  • Page 2: Dear Customer

    Dear Customer Thank you for choosing our product! 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. Please also take special note of the safety rules in the manual and follow exactly the instructions.

  • Page 3: 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 voided, could result in death or serious injury. The possible hazards are explained in the text.
  • Page 4 • Connect the primary input cable according to rules. Disconnect input power or stop machine before installing or maintenance. • If welding must be performed under electrically hazardous conditions as follow: in damp locations or wearing wet clothing; on metal structures such as floors, gratings, or scaffolds;...
  • Page 5 the arc nor expose themselves to the arc rays or to hot spatter or material. Fumes and gases can be dangerous • Welding may produce fumes and gases, breathing these fumes and gases can be hazardous to your health. • When welding, keep your head out of the fume. If inside, ventilate the area at the arc to keep fumes and gases away from the breathing zone.
  • Page 6 • 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.
  • Page 7 Moving parts can injure • Stay away from moving parts such as fans. • Stay away from pinch points such as drive rolls. • 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.

  • Page 8: Table Of Contents

    Contents 1-GENERAL REMARKS ................8 1-1 Power source features .............. 8 1-2 Functional principle ..............8 1-3 Output characteristics ............... 9 1-4 Duty cycle ................. 9 1-5 Applications ................10 1-6 Warning label ................10 2-VERSIONS BRIEFS ................11 3-BEFORE COMMISSIONING .............. 12 3-1 Utilization for intended purpose only ........

  • Page 9: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features This series pulse TIG welding machine can perform DC TIG, Pulse TIG, and SMAW processes. This series welding machines enjoy reasonable static characteristic and sound dynamic characteristic. Features and benefits: -MCU controlled technology -Self-diagnostic function with error code display -Precise pulse control, good welding performance -Pre-gas, post-gas, up-slope time, down-slope time, adjustable parameters, easy to control -Pulse frequency, pulse ratio, pulse width can be adjusted to improve the welding...

  • Page 10: 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. Note! Exceeding duty cycle can damage the machine and greatly reduce its lifespan.

  • Page 11: Applications

    1-5 Applications The power source is suitable for mild steel, alloy steel, stainless steel, copper, silver and titanium welding, and is designed for the following recommended areas: Electric power, petrochemical construction Boiler and pressure vessel Shipyards Bicycle, fitness equipment, and stainless furniture manufacturing Nuclear power station 1-6 Warning label The warning label is affixed on the top of machine.

  • Page 12: 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 4000 DC Pulse Digital control panel. Accurate preset and adjustable parameters. Suitable for thin plate pulse mode welding.

  • Page 13: 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 “safety rules”. 3-1 Utilization for intended purpose only The power source may only be used for SMAW ,TIG. Utilization for other purposes, or in any other manner, shall be deemed to be "not in accordance with the intended purpose".

  • Page 14: 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 15: 4-Power Tig 4000 Dc Pulse

    4-POWER TIG 4000 DC PULSE 4-1 System components This series 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 operate well. The following is the needed accessories list.

  • Page 16: Control Panel

    -Ground cable -Electrode holder -Electrode 4-3 Control panel Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual. Also, certain illustrations may be very slightly different from the actual controls on your machine. However, these controls function in exactly the same way.
  • Page 17 Fig. 4-3-5: 2-step operation mode 4-STEP operation mode Fig. 4-3-6: 4-step operation mode Repeat mode(only POWER TIG 4000 DC PULSE welding machine has this function, please refer to the sub menu)
  • Page 18 Fig. 4-3-7: Repeat mode Spot weld mode(only POWER TIG 4000 DC PULSE welding machine has this function, please refer to the sub menu) Fig. 4-3-8: Spot weld mode 2.CC/PULSE button on “TIG”: switch between “Constant” DC TIG and “Pulse” DC TIG; On “SMAW”: switch between “Amp”...
  • Page 19 lights up if power source is effectively connected to power supply. 6.Protection indicator The indicator is yellow; it doesn’t light on when working normally. Welding machine stops welding automatically while in overheat or water insufficient, and the indicator is on. 7.Welding parameters: Fig.

  • Page 20: Sub-Menu Parameters

    parameter from left to right; rotate anticlockwise to select parameter from right to left. Important! Thanks to the microprocessor control, the following functions can be realized: All parameters that have been set can be automatically stored and will retain until the next time they are changed.

  • Page 21: Interface

    4-4-3 Reset to factory setting Press and hold the selection knob and 2/4 step button at same time for 5 seconds to reset to factory setting (Fig. 4-4-3). Fig. 4-4-3: Reset to factory setting 4-5 Interface Fig. 4-5-1: Front panel Fig.

  • Page 22: Installation

    Pin No. Pin No. Description Remote control signal Table 4-5-1 Description of remote control socket 6.Fan Cooling down the heating components in the welding machine. 7. Gas inlet (part of solenoid valve) Connect with Argon gas regulator with gas hose. 8.Nameplate 9.Fuse 10.Circuit breaker...
  • Page 23 ● power supply and cable requirement Please note the size of fuse and circuit breaker in the table below are for reference only. Model Power supply AC380/400/415V±10% Power grid Electricity grid min. power (KVA) Generator Fuse Input protection(A) Circuit breaker power cord ≥4 Output...
  • Page 24 Fig.4-6-1: Connections of power cord and distribution box ●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 25 ●TIG welding(water cooling) Fig. 4-6-4:Water-cooling TIG welding (Combined one machine) Fig. 4-6-5: Water-cooling TIG welding(Separate water cooling machine)

  • Page 26: Technical Data

    ●SMAW welding Fig.4-6-6:SMAW welding 4-7 Technical data Note! For machines designed for special voltages, below is the technical data on the name plate. Model Input voltage/frequency AC380V/400/415V Rated input capacity (KW) Rated input current (A) 28/26.6/25.6 Output current adjustment range (A) 4～400 Duty Cycle (%) OCV (V)

  • Page 27: Dimension

    4-8 Dimension Fig. 4-8-1: Dimension Item Unit(mm) Unit(inches) length 26.4 Width Height 22.5 Table. 4-8-1: Dimension...

  • Page 28: Disassembly And Reassembly

    4-9 Disassembly and reassembly...
  • Page 29 Fig.4-9-1:Disassembly and reassembly Stock No.for Item Stock No.for 500 Qty Remarks 315/400 Quick socket 740002-00026 740002-00026 Control socket 740003-00011 740003-00011 Quick socket 740002-00026 740002-00026 Breathing copper mouth 766001-00095 766001-00095 Output socket mounting plate 766003-02398 766003-02398 Plastic front panel 262005-01040 262005-01040 Front panel 262005-01039 262005-01039...
  • Page 30 746001-00101 746001-00019 415V electromagnetic valve 752001-00014 752001-00014 Back panel 262011-00738 262011-00738 Fuse holder 740007-00004 740007-00004 Circuit breaker cover 766003-02217 766003-02217 769001-00288 769001-00289 Cable 769001-00026 769001-00027 Control socket 740001-00184 740001-00184 Control socket 740003-00012 740003-00012 Fan cover 766003-02403 766003-02403 Right side panel 262023-00586 262023-00586 Bottom plate...
  • Page 31 Fast recovery diode module 735006-00029 735006-00029 Diode protection board 220455-00002 220455-00002 Exchange current inductance 220281-00008 220281-00008 Positive connection plate 766003-00399 766003-00399 Radiator connecting plate 775004-00033 775004-00027 Radiator support 766002-01112 766002-00078 Table.4-9-1: spare parts...

  • Page 32: 5-Remote Controller

    5-REMOTE CONTROLLER 5-1 Analog remote controller The analog remote controller can only adjust the welding current, suitable for PoWer*** welding machine. Fig.5-1-1:Analog remote controller...

  • Page 33: 6-Trouble Shooting

    6-TROUBLE SHOOTING Warning! An electric shock can be fatal. Before opening the machine: -Switch it off and unplug it from the mains -Unplug machine 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 34: 7-Care And Maintenance

    Shut down the welding The welding machine is over heat; Over-heat machine and wait for Temperature Relay fault protection cooling; or replace Main control board damaged Temperature Relay Water-cooling No circulating water in water cooling Check and repair is abnormal system Water flow sensor damaged Table 6-2: Displayed error code 7-CARE AND MAINTENANCE...
  • Page 35 Daily maintenance Fig.7-1: Daily maintenance Ver.20210531...
  • Page 36 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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Power tig 4000 dc pulse

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