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GeKaMac PoWer TIG Series User Manual

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PoWer TIG 3201
AC/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 3201 AC/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 avoided, could result in death or serious injury. The possible hazards are explained in the text. Caution “...

  • Page 4: Hot Parts Can Burn

    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 5: Noise Can Damage Hearing

    clothing to prevent burns. Flying metal or dirt can injure eyes • When welding, chipping, wire brushing, and grinding can cause sparks and flying metal. It can hurt your eyes. • Remember wear appropriate safety glasses with side shields when in welding zone, even under your welding helmet.

  • Page 6: 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 ..............................8 2-VERSIONS BRIEFS ............................. 8 3-BEFORE COMMISSIONING ..........................9 3-1 Utilization for intended purpose only ......................

  • Page 7: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features This series TIG welding machine can perform DC TIG, Pulse TIG, AC TIG,AC 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 -AC square wave and sine wave waveform output -30 sets of parameters can be stored...

  • Page 8: 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. Note! Exceeding duty cycle can damage the machine and greatly reduce its lifespan.

  • Page 9: Warning Label

    1-6 Warning label The warning label is affixed on the top of machine. 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 weldings. This fully digitized power sources have logically arranged control panel for convenient operation, which can perform SMAW, DC TIG, DC Pulse TIG, AC TIG and AC Pulse TIG.It can use the foot pedal to adjust the current.

  • Page 10: 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 11 Correct When the excess cables are only be used by rolling up, coil the cables to two windings in reverse direction and overlap them. The number of turns for A is same as the number for B. Handle the welding cable and ground cable according to above-mentioned method.

  • Page 12: 4-Power Tig 3201 Ac/Dc Pulse

    4-PoWer TIG 3201 AC/DC Pulse 4-1 System components 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 TIG 3201 AC/DC Pulse operate well. The following is the needed accessories list.
  • Page 13 Fig. 4-3-1: Control panel 1.Left displayer Used for displaying the welding current, voltage and other parameters. If different parameters are selected, the relevant indicator will light up. 2.Right displayer Used for displaying the welding current, frequency and other parameters. If different parameters are selected, the relevant indicator will light up.
  • Page 14 4-STEP operation mode Fig. 4-3-6: 4-STEP operation mode Repeat operation mode Fig. 4-3-7: Repeat operation mode Spot welding operation mode Fig. 4-3-8: Repeat operation mode 4.AC/DC and pulse button Press this button to switch AC TIG, DC TIG,DC PULSE TIG and AC PULSE TIG mode, the indicator will light up accordingly. 5.TIG/MMA button Press the button to switch between TIG and MMA, the indicator for the selected progress will light up.
  • Page 15 6.Welding parameters: Fig. 4-3-9: Parameters Parameters Description Unit Setting range Factory setting PRE GAS Time of gas flow before welding OFF~10.0 START The initial current after the arc is started 4~315 UP-SLOPE Time of starting current is increased until it reaches OFF~10.0 welding current CURRENT...
  • Page 16 Process Parameter selection knob Parameter adjustment knob CURRENT DC pulse DUTY CYCLE PEAK CURRENT CLEAN RATIO CURRENT AC pulse DUTY CYCLE PEAK CURRENT SMAW ARC FORCE CURRENT Table 4-3-1: Fast adjustment 10.Fn/Gas test button Press the button (release it within 5s) and the indicator lights up to enter into sub-menu interface; Press the button again(release it within 5s) and the indicator lights off to exit from sub-menu interface.
  • Page 17 Sine wave-Traditional smooth shaped waveform. Soft arc and less noise. Good for wide seam. Fig. 4-3-12: Sine waveform Triangle wave: Minimized area (heat) under the curve shape with high peaks. Lower amperages can minimize heat input to the weld High peaks more forceful for anodized applications. Fig.

  • Page 18: Submenu

    4-4 Submenu 4-4-1 Submenu parameter Process Sub-menu Parameter Code Setting range Default value Tungsten electrode diameter 0.8～6.0(mm) 2.0mm AC waveform Water cooling Channel selection n0～n29 HF selection Arc-start polarity(DC TIG mode) P～S Spot welding time OFF~10.0(s) 0.1s Hot start current 20~200(A) SMAW Hot start time...
  • Page 19 Save a job a. Set the parameter to be stored; b. Press Fn key(release it within 5s) and the indicator lights up to enter into sub-menu interface; c. Select code "CHA" by selection knob,Select channel No "n0～n29" by adjustment knob; d.

  • Page 20: Other Function

    Delete a job a. Press Fn key(release it within 5s) and the indicator lights up to enter into sub-menu interface; b. Select code "CHA" by selection knob,Select channel No "P0～P29" by adjustment knob; c. Press TIG/MMA button for 5s, the channel No is changed from "P0～P29" to "n0～ n29", meaning the job parameter which is stored in present channel is deleted;...

  • Page 21: Interface

    4-6-2 Reset to factory setting a. Press Fn key (release with 5s) and the indicator lights up to enter into sub-menu interface; b. Select code "Fac" by selection knob c. Press TIG/MMA button for 3s and "YES" appears on right-hand displayer, the factory setting is restored. d.
  • Page 22 Pin No. Pin No. Description Description Torch trigger 10VDC Torch trigger Remote preset current signal Remote enable(low level) Table. 4-7-1 Description of remote control socket 3.Output terminal (-) Connect work piece when processing SMAW; connect with TIG torch when processing TIG welding. 4.Water inlet Connect water hose of TIG torch.(optiional).

  • Page 23: Installation

    8.Fan Cooling down the heating components in the welding machine. 9. Water outlet 10 Gas inlet (part of solenoid valve) Connect with Argon gas regulator with gas hose. 11.Nameplate 12.Fuse 13.Circuit breaker The function of circuit breaker is to protect welding machine and operator by automatic trip to turn-off power supply when overload or short circuit happens to the power source.
  • Page 24 Fig.4-8-1: 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. 4-8-4: Connection and operation for water-cooling TIG welding(Combined one machine) Fig. 4-8-5: Connection and operation for water-cooling TIG welding (Separate water cooling machine) ●SMAW welding Fig.4-8-6: Connection and operation for SMAW welding...

  • Page 26: Technical Data

    4-9 Technical data Note! For machines designed for special voltages, below is the technical data on the name plate. Model PoWer TIG 3201 AC/DC Pulse Input voltage/frequency(3 phase) , AC380V/400/415V, 50Hz , AC220~440V, 50/60Hz Rated input capacity (KW) Rated input current (A) 21/20/19 25/20/18 Output current adjustment range (A)

  • Page 27: Disassembly And Reassembly

    4-11 Disassembly and reassembly Fig.4-11-1: DRAWING...
  • Page 28 Item Stock NO. REMARKS Quick socket 740002-00026 Control socket 740003-00047 Breathing copper mouth 766001-00095 Knob 730031-00074 Filter 752004-00017 CE standard Control panel sticker 771001-01951 Plastic front panel 262005-01040 Front panel 262035-01039 Display board 220503-00175 Left side panel COLOR Charging inductance assembly 220095-00001 Main transformer 220629-00018...
  • Page 29 High leakage transformer 763003-00018 Output reactor 763004-00112 Copper and aluminum joints 740016-00017 current sensor 220125-00023 Wire wound resistor 200W/20Ω 720006-00034 Wire wound resistor 50W/30Ω 720005-00028 Charging rectifier board 220089-00004 Secondary IGBT absorption board 220215-00001 Diode connection copper bar 1 766001-00228 Current sensor connection copper bar 1 766001-00020 DC bus output connection copper bar...

  • Page 30: 5-Remote Controller

    5-REMOTE CONTROLLER 5-1 Analog remote controller The analog remote controller can only adjust the welding current, suitable for ATIG***PAC welding machine. Fig.5-2-1-1:Analog remote controller 5-2 Digital remote controller Fig.5-2-1-1: Digtal remote controller...
  • Page 31 5-2-1 Control panel Fig.5-2-2-1: control panel Please refer to chapter 4-3 of the control panel of the welding machine. 5-2-2 Interface Connect to welding machine. Pin No. Pin No. Description 38VAC 38VAC Null Table 5-2-2-1 Description of control socket 5-2-3 Spare parts Fig.5-2-3-1:Spare parts...

  • Page 32: 6-Trouble Shooting

    Item Stock No. Remarks Display board 220503-00071 Control socket 740001-00034 Control plug(7pin) 740001-00002 Control plug(6pin) 740003-00004 knob PC sticker Table.5-2-3-1 Description of control socket 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...

  • Page 33: 7-Care And Maintenance

    Code Trouble Cause Remedy 1. The secondary IGBT is damaged Over voltage Check and replace 2. The main control board is damaged No current output after pressing torch Torch trigger fault Release torch trigger trigger for 2s The welding machine is over heat; Shut down the welding machine Over-heat protection Temperature Relay fault...
  • Page 34 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 3201 ac/dc pulse

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