GeKaMac PoWer ARC 200C Manual Instruction
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GeKaMac PoWer ARC 200C Manual Instruction

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PoWer ARC 200C
Manual Instructions
Please Read and Understand This Manual
Before Operating Welding Machine
www.gedikwelding.com

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Summary of Contents for GeKaMac PoWer ARC 200C

  • Page 1 PoWer ARC 200C Manual Instructions Please Read and Understand This Manual Before Operating 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 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 4: 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 great features of your new product. Meanwhile, please remember safety rules and operate as instructed.

  • Page 5: Safety Rules

    Safety Rules Danger! “Danger” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning “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.
  • Page 6 Safety • The owner/operator is obliged to perform safety inspection at inspecti regular intervals. • The manufacturer also recommends every 3-6 months for regular maintenance of power sources. Safety Equipment with CE-markings fulfils the basic requirements of the marking Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974).
  • Page 7 • 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; when in cramped positions such as sitting, kneeling, or lying; or in occasion when there is a high risk of unavoidable or accidental contact with the work piece or ground.
  • Page 8 Lay tem well away from other cables. Do not place your body between your electrode and work cables. - Equipotential bonding - Workpiece grounding (earthing) - Shielding Shield the entire welding equipment and other equipment nearby. • Visible and invisible rays can burn eyes and skin. rays •...
  • Page 9 is safe. Welding • When not welding, make sure the electrode circuit is not touching the work or ground. Accidental contact can cause cutting sparks, explosion, overheating, or fire. Make sure the area is sparks safe before doing any welding. •...
  • Page 10 • Keep a fire extinguisher readily available. • Empty containers, tanks, drums, or pipes which have combustibles before perform welding. • 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.
  • Page 11 the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. • Open the cylinder valve slowly and keep your head and face away from the cylinder valve outlet. • Valve protection caps should be kept in place over valve expect when the cylinder is in use or connected for use.
  • Page 12 maintenance is finished and before reconnecting input power. Overuse • Use machine follow duty cycle. Reduce current or reduce duty cycle before starting to weld again. cause • Allow cooling period. overhea • Do not block or filter airflow to unit. ting...

  • Page 13: Table Of Contents

    Contents 1-GENERAL REMARKS............................11 ............. 11 1-1 P OWER SOURCE FEATURES 1-2 S ................ 11 CHEMATIC DIAGRAM 1-3 O ..............11 UTPUT CHARACTERISTICS ..................12 1-4 D UTY CYCLE 1-5 A ................... 12 PPLICATIONS 2 - BEFORE COMMISSIONING..........................14 2-1 U ........14 TILIZATION FOR INTENDED PURPOSE ONLY ............

  • Page 14: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features PowerARC200C welding machine is suitable for DC MMA, CEL, Lift TIG process, which can weld carbon steel, stainless steel, copper, titanium, etc. Because of the ideal static characteristic and dynamic characteristics, machines highlights are as follows: •...

  • Page 15: Duty Cycle

    Stick process Lift TIG process Fig. 1-3-1: Output characteristics 1-4 Duty cycle Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) will close, output stops. Wait for fifteen minutes for unit to cool down. Reduce amperage or duty cycle before welding.
  • Page 16 stainless steel, etc. The recommend areas of use as follows: Boiler and pressure vessel fabrication Chemical industry Power generation and process Shipbuilding Automotive manufacture Machinery manufacturing Pipeline industry...

  • Page 17: Before Commissioning

    2 - BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the machine until you have read "Safety rules". 2-1 Utilization for intended purpose only The power source may only be used for SMAW and Lift TIG welding. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose".
  • Page 18 - When the extension cable is being used, please appropriately increase the cross-sectional area of the cable.

  • Page 19: -Powerarc200C

    3 –PowerARC200C 3-1 System components Fig. 3-1-1: System components 3-2 Basic equipments for welding STICK - Power source - Ground cable - Electrode holder - Electrode - Power source - Ground cable - Electrode holder - Cellulose electrode Lift TIG - Power source - Ground cable - TIG torch...

  • Page 20: Control Panel

    3-3 Control panel Note! Your machine has certain functions that are not in accordance with this operating manual, or vice versa. Also, certain illustrations may be slightly different from the actual controls on your machine. However, these controls function in exactly the same way. Warning! Operating the equipment incorrectly can cause serious injury and damage.

  • Page 21: Interface

    3-4 Interface Fig. 3-4-1: Interface 1. Welding cable quick socket (+) Stick mode: for connecting the electrode holder. Cellulose electrode mode: for connecting the work piece. Lift TIG mode: for connecting the work piece. 2. Welding cable quick socket (-) Stick mode: for connecting the work piece.

  • Page 22: Rear Panel

    3-5 Rear panel Fig. 3-5-1: Rear panel 1. Power switch Switch for single-phase AC power. Turn on this switch (on the position: “ON”), then the front panel digital meter lights up, and the fan runs. 2. Power supply cable The mixed-colored wire must be firmly grounded; the rest 2 wires connect to 1- phase AC110/220V ~50/60Hz power supply.
  • Page 23 Fuse Input protection Circuit breaker Input cable Cable size Output cable ( mm Protective GND wire Table 3-6-1: Specifications of mains input Note! The size of fuse and circuit breaker in the table are for reference only.  The connection between input cable and distribution box (Fig. 3-6-1) Warning! - Never perform hot-line work! - Electric connection should be done by professional electrician! - Two machines should not be connected to the same one circuit breaker!
  • Page 24 Table 3-6-2: Power socket selection Country Type Country Type Asian-Pacific region Hong-Kong Macau E, G Vietnam A, B, E, G Thailand A, B Malaysia Singapore Indonesia E, G India I, K Australia C, D New-Zealand C, D...
  • Page 25 Japan A, B Korea E, G Middle East region Saudi Arabia A, B, I Iran Dubai Europe region Italy E, N Austria E, F, G Poland E, F, G Hungary F, G Greece E, F, G Belgium E, F, G Netherlands E, F, G United Kingdom...
  • Page 26 Rep. South Africa Table 3-6-3: Using region selection Warning! Operating the machine incorrectly can cause serious injury and damage. Do not use the machine until you have read the following: Safety rules Before putting the power source into service Warning! If the machine is plugged into the mains supply and the mains switch is in “ON” position during preparation, there is a high risk of very serious injury and damage.

  • Page 27: Technical Data

    Screw the pressure regulator onto the gas cylinder and tighten it; Place the shielding-gas cylinder on the solid, level surface or use cylinder bracket to prevent from toppling over. The connection and operation for gas-cooling TIG welding  Plug the ground cable into the output socket (+) and fasten it; With the other end of ground cable, establish a connection to the work piece;...

  • Page 28: Disassembly And Reassembly

    Dimension (W×D×H) (mm) 381×155×298 Weight (Kg) Table 3-7-1: Technical data 3-8 Disassembly and reassembly Fig. 3-8-1: Disassembly and Reassembly Item Stock No. Diode 730001-00027 Quick socket 740002-00080 Digital displayer 755001-00028 Potentiometer 766003-00062 Temperature relay 745008-00028...

  • Page 29: Trouble Shooting

    Power transformer 763001-00245 Dual voltage switch board 220900-00309 Temperature relay 745008-00031 746002-00025 Circuit breaker 745011-00068 Waterproof cable clamp connector 773002-00025 PFC inductor 763005-00145 Polypropylene capacitor 722001-00065 Aluminum electrolytic capacitor 722004-00146 Main transformer 763002-00030 Output reactor 763005-00023 Main control and drive board 210580-00964 Table 3-8-1: Main components 4 - TROUBLE SHOOTING...
  • Page 30 № TROUBLE CAUSES REMEDY 1. Power switch is damaged 1. Check Power switch and the 2. No electricity on the electricity grid 2. Check power supply on the 3. Power supply cable is electricity grid Digital display meter does not disconnection or break 3.
  • Page 31 1.Fan does not work 1.Repair or replace 2.Too large of duty cycle 2.Use as duty cycle Protection LED is on 3.Temperature relay is marked on nameplate damaged 3.Replace Table 4-1: Trouble shooting...

  • Page 32: Care And Maintenance

    5 - 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 inadvertently switching it back on again Discharge the capacity if necessary Bolt in outer case also works for ground connection.

  • Page 33: Basic Welding Technique

    6 - BASIC WELDING TECHNIQUE Note! This section being general welding technique guide is for reference only. Specific functions of your machine please refer to previous chapters. 6-1 TIG welding technique Fig. 6-1-1: Heat Input 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 34 melting of most metals into a weld pool. TIG welding offers the user the greatest amount of flexibility to weld the widest range of material and thickness and types. DC TIG welding is also the cleanest weld with no sparks or spatter. Fig.
  • Page 35 TIG Welding Fusion Technique Fig. 6-1-9: TIG Arc 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 workpiece.
  • Page 36 It is necessary in many situations with TIG welding to add a filler wire into the weld pool to build up weld reinforcement and create a strong weld. Once the arc is started the torch tungsten is held in place until a weld pool is created, a circular movement of the tungsten will assist is creating a weld pool of the desired size.
  • Page 37 Tungsten DC Current Amps Diameter Torch Negative 2% Thoriated 1.0mm 15 - 80 1.6mm 70 -150 2.4mm 150 - 250 3.2mm 250 - 400 4.0mm 400 - 500 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.

  • Page 38: Stick (Smaw) Welding Technique

    3.2mm 25 - 250 6-2 STICK (SMAW) welding technique 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’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
  • Page 39 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. The Metal Wire Core works as conductor of the current that maintains the arc.
  • Page 40 The size of the electrode generally depends on the 2.0 - 5.0mm 3.2mm thickness of the section being welded, and the thicker the 5.0 - 8.0mm 4.0mm section the larger the electrode required. The table gives the 8.0 - > mm 5.0mm maximum size of electrodes that maybe used for various thicknesses of section base on using a general purpose type 6013 electrode.
  • Page 41 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. Travel Speed The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required.
  • Page 42 Gedik Welding Ankara Caddesi No: 306 Şeyhli Pendik, İstanbul / Türkiye T +90 216 378 50 00 F + 90 216 378 20 44 gedik@gedikwelding.com.tr www.gedikwelding.com...

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