Download
Share
Print this page
GeKaMac PoWer MIG 500 User Manual
  1. Manuals
  2. Brands
  3. GeKaMac Manuals
  4. Welding System
  5. PoWer MIG 500
  6. User manual

GeKaMac PoWer MIG 500 User Manual

Hide thumbs Also See for PoWer MIG 500:

Advertisement

Quick Links

Download this manual
1

Advertisement

loading
Need help?

Need help?

Do you have a question about the PoWer MIG 500 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for GeKaMac PoWer MIG 500

Summary of Contents for GeKaMac PoWer MIG 500

  • 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 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.
  • Page 4 Ankara Cad. No.306 Seyhl> Pend>k ISTANBUL TURKIYE Ürün / Product ARC WELDING MACHINE Marka-Model / Brand- Model POWER MIG 500 Yukarıda tanımlanan beyanın nesnes> >lg>l> uyumlaştırılmış AB mevzuatı >le uyumludur. The object of the declarat/on descr/bed above, /s /n conform/ty w/th the relevant un/on harmon/sat/on leg/slat/on.
  • Page 5 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 6 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 7 • The manufacturer also recommends every 3-6 months for regular maintenance of power sources. Safety Equipment with CE-markings fulfils the basic markings requirements of the Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). Equipment with CCC markings meets the requirements of implementations rules for China compulsory certification.
  • Page 8 • 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 9 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 ARC rays can burn.
  • Page 10 especially in confined areas, to insure breathing air is safe. • When not welding, make sure the electrode Welding circuit is not touching the work or ground. cutting Accidental contact can cause sparks, sparks can explosion, overheating, or fire. Make sure the cause fire area is safe before doing any welding.
  • Page 11 operator before perform any welding. • 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.
  • Page 12 the correct shielding gas for the and properly operating regulators designed for 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.
  • Page 13 panels, covers, orguards for servicing and maintenance. • Reinstall doors, panels, covers, or guards when servicing and maintenance isfinished and before reconnecting input power. • Use machine follow duty cycle. Reduce current Overuse can or reduce duty cycle beforestarting to weld cause again.
  • Page 14 4-9Main components list ......... 37 5-8 Technical data ....Hata! Yer işareti tanımlanmamış. 5-9 Main components list ....Hata! Yer işareti tanımlanmamış. 6-TROUBLE SHOOTING ........... 42 17-CARE AND MAINTENANCE ........44 18- WELDING TECHNIQUE GUIDE ......... 45 11-1 MIG (GMAW/FCAW) basic welding technique ....45 1-GENERAL REMARKS 1-1Power source features This series of welding machines apply IGBT soft switch inverter technology;...
  • Page 15 1-2 Functional principle This series of power sources adopt IGBT soft switch inverter technology to improve the dynamic response rate and make the machines with small size and light weight.The control circuit's closed-loop control makes the power source enjoy strong ability against power grid fluctuation and perfect welding performance. The schematic diagram is as shown in Fig.
  • Page 16 Fig.1-4-1: Duty cycle 1-5Applications The MIG power source can be used with solid and flux-cored welding wires for welding carbon steel, alloy steel, etc.The power source is designed for following recommended areas: Automobile and components supply industry Chemical plant construction Boiler and pressure vessel Shipyards Power plant construction...
  • Page 17 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. MIG 500/630 MIG 630 are designed in accordance with the industrial standards. The welding current and voltage can be adjusted separately.
  • Page 18 3-BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause seriousinjury 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 This power source may only be used for CO2/MAG, FCAW, Gouging. Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in accordance with the intended purpose”.
  • Page 19 fuse protection, must be dimensioned in accordance with the local power supply. The technical data shown on the rating plate shall apply. 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.
  • Page 20 Fig. 3-4-1: Welding cables instruction 4-MIG 500/ 630 4-1System components This series of machines can be equipped with many different accessories and can be used in various special sites with different configurations. Fig. 4-1-1: System components 4-2Basic equipment for welding Basic equipments are needed for normal welding.
  • Page 21 4-3 Control panel The control panel is easy to operate. Operators can select various processes by control switch and adjust welding parameters by potentiometer. Notes! You may find that your machine has certain functions orsome parameters that are not described in this operating manual.
  • Page 22 During welding, display actual voltage value When disconnected from control cableof wire feeder, displayed value will be higher: 70-90; B、Welding current displayer When in standby, display preset current value: 3-100 During welding, display actual current value When disconnected from control cable of wire feeder, displayed value will be higher: 150-180 C、Power indicator Indicate whether the welding machine is power on or not.
  • Page 23 4 - STEP This mode is mainly used for long seam welding and process that needs crater filling welding. Symbols Fig. 4-3-2: Press torch switch Fig. 4-3-3: Hold torch switch Fig. 4-3-4: Release torch switch P03……Pre-gas time(this parameter is not adjustable) I……Welding current:Uniform thermal input for the preheated base metals P06……Crater-filling:Prevent burn-through caused by too much heat at the welding ends.
  • Page 24 Fig. 4-3-6: 4-step mode G、Wire feeder control socket Connect with control cable of wire feeder. H、Negative welding terminal (-) Connect with work piece via ground cable. I、Positive welding terminal (+) Connect with the wire feeder welding cable. J、Inductance control knob To change the welding stability, penetration and spatter.
  • Page 25 filler status, it will display the real crater filler voltage value. ● Rear Panel Fig. 4-3-7: Rear panel M、Fan cover N、Power supply socket for gas heater It is used to connect with the heater coil of the gas regulator. Note! The voltage degree of gas regulator must match with the voltage supplied by the gas heater socket.
  • Page 26 R、Earthing bolt It is used to connect with the ground cable. Warning! To ensure the operator’s safety and welding machine’s normal use, please make sure the ground wire in power supply cable is firmly grounded, or make sure the earthing bolt is firmly connected to earth. S、Power supply cable 4-4 Connections Wire feeder control socket...
  • Page 27 Fig. 4-4-2: Output socket 4-5 Wire feeder Fig. 4-5-1: Wire feeder T、Torch connector The photo above is European type. And this connector can be American or Panasonic type according to customer requirement. U、Welding current control knob When standby, it is used to preset wire feeding speed (0-100). During welding, it is used to adjust the actual welding current.
  • Page 28 welding voltage. W、Inch feeding button Press this button, welding wire will quickly be fed in. When changing the welding wire, it is very time saving for wire feeding. 4-6 Water cooling system There are two types of water cooling systems: Integrated type: The welding power source and water cooling system is integrated type, the cooling unit is powered by the power source.
  • Page 29 4-7 Installation and operation Warning! An electric shock can be fatal. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the machine when - the mains switch is in the “OFF”...
  • Page 30 Table 4-7-1: Input power supply cable installation-single voltage Note! Welding machine must be taken special design if it is powered by generator, please contact with manufacturer if you have such needs. The connection between input power supply cable and switch box (Fig. 4-7-2 and Fig. 4-7-3). Warning! - Never connecting when equipment is power on! - The connection must be carried out by a qualified electrician!
  • Page 31 Fig. 4-7-2 Connection between input power supply cable and switch box Fig. 4-7-3: Connection between input power supply cable and switch box (MIG 630) l Shielding gas regulator installation 1. Take the protective cap off the gas cylinder; 2. Gently turn the gas-cylinder valve anticlockwise to open it, and blow off any dust and dirt; 3.
  • Page 32 1. Plug the ground cable into the negative welding terminal (-) and turn it to fasten it; 2. Connect the other end of the ground cable with the work piece. l Wire feeder cable connection 1. Connect the wire feeder control cablewith the power source control socket (G); 2.
  • Page 33 Fig. 4-7-5: Torch connector l Installation of wire feeding rollers The MIG series welding machine can work with different types of wire feeders. When welding wires of different materials and diameters are used, different types of wire feeding rollers need to be chosen. l Types of wire feeder rollers: Type 1 for hard wire, such as solid carbon steel wire, stainless steel wire.
  • Page 34 Fig. 4-7-7: Close type double drive wire feeder Put the power switch on “OFF” position; Open the side panel of wire feeder; Push down the pressure handle; Lift up the pressure device; With screw driver to take off the screw that fix the wire pressure roller or wire feeding roller; Replace suitable wire pressure roller or wire feeding roller;...
  • Page 35 Replace suitable wire pressure roller or wire feeding roller; Tighten the screw to fasten the wire pressure roller or wire feeding roller; Important! Too much pressure will cause wire being crushed, wire coating being damaged, and fast wearing out of wire feeding rollers and increasing wire feeding resistance. Pressures on wires of different materials and diameters are as follows (Fig.
  • Page 36 Fig. 4-7-11: Close type wire feeding system Switch off the power source; Open the cover of wire spool; Screw off the end-cover of the shaft; Fix the wire spool into the shaft and make sure of the correct direction; Insert driving lever into reserved hold of wire spool; Adjust the force by adjusting control screw (1);...
  • Page 37 Draw out the welding wire from the wire spool fixed orifice, and hold the part about 20cm to the end of the wire and cut off the curve part; Straighten the front 15cm part of the wire; Make the welding wire go through the guide tube and enter the torch's wire feeding hose about 5cm;...
  • Page 38 Warning! Electric shock is very dangerous. As soon as press the torch trigger, the welding wire is power on. Make sure that the welding wire does not touch any person or conductor or earthed parts (e.g. lifting appliance etc.) Note! Insufficient coolant will cause damage to the equipment. Please regularly check the coolant flow while welding –...
  • Page 39 Range of welding current 60～320 60～500 Range of welding voltage 15～30 15～50 Rated duty cycle (%) Full-load efficiency (%) ≥87 Power factor ≥0.95 Wire size (mm) Ф1.0～Ф1.6 CO2 gas flow rate (L/min) 10～25 Dimensions (mm) 636×322×584 Weight (Kg) Main Insulation transformer class /Output...
  • Page 40 4-9Main components list MIG500 Fig. 4-9-3: Inner structure Item Stock Number Remarks Assembly type cable socket 740004-00053 Red, 380V/50Hz 740004-00052 Black, 380V/50Hz Potentiometer knob 720031-00066 380V/50Hz Circuit breaker 745011-00022 380V/50Hz 746001-00017 380V/50Hz 746001-00019 415V/50Hz Main control board 210580-00406 380V/50Hz Power transformer I 220179-00199 380V/50Hz 220179-00388...
  • Page 41 Main transformer 220629-00015 380V/50Hz Temperature relay 745008-00006 380V/50Hz IGBT protection board 220005-00007 380V/50Hz IGBT module 735007-00038 380V/50Hz Polypropylene capacitor 722001-00067 380V/50Hz 0.47uf,1200VAC Three phase rectifier module 735005-00003 380V/50Hz Varistor 720021-00017 380V/50Hz 720021-00021 415V/50Hz Input filter inductor 220479-00002 380V/50Hz Polypropylene capacitor 20uf 722001-00070 380V/50Hz...
  • Page 42 Assembly type cable socket 740004-00053 Red, 380V/50Hz 740004-00052 Black, 380V/50Hz Potentiometer knob 720031-00066 380V/50Hz, 415V/50Hz 720031-00071 CE module Circuit breaker 745011-00026 380V/50Hz 746001-00017 380V/50Hz 746001-00032 415V/50Hz Main control board 746001-00035 CE module Power transformer I 210580-00406 380V/50Hz 220179-00199 380V/50Hz Power transformer II 220179-00388 415V/50Hz 220179-00320...
  • Page 43 50uf 500VAC Output reactor 763004-00116 380V/50Hz Current exchange inductor 220281-00012 380V/50Hz Diode protection board 220455-00002 380V/50Hz Output diode module 735006-00029 380V/50Hz Rack capacitor board 220293-00008 380V/50Hz Table 4-9-4: Main components list Note: If no special remarkes, the input voltage mentioned in above table is three phase.
  • Page 45 5-TROUBLE SHOOTING Note! The following troubles and causes are uncertain. However, during the normal welding, that might happen. № FAULT CAUSE &REMEDY Cause: Input is default phase Remedy: Stop work Main switch is ON, but indicators Cause: Circuit breaker is damaged are not lit up.
  • Page 46 Cause: main control board is damaged When torch trigger is pressed, wire Remedy: Fix or replace main control board feeding is ok, while no shielding Cause: The solenoid valve is damaged Remedy: Change the solenoid valve Cause: Torch trigger is damaged Remedy: Replace or fix When torch trigger is pressed, wire Cause: Control cable for wire feeder is broken...
  • Page 47 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 inadvertentlyswitching it on again Check to make sure the electrically charged components (e.g.capacitors) have been discharged.
  • Page 48 7- WELDING TECHNIQUE GUIDE Note! This section being general welding technique guide is for reference only. Specific functions of your machine please refer to previous chapters. 11-1 MIG (GMAW/FCAW) basic welding technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
  • Page 49 Fig. 7-1-2: FCAW process Position of MIG torch The angle of MIG torch to the weld has an effect on the width of the weld. Fig. 7-1-3: Position of TIG torch The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times.
  • Page 50 Fig. 7-1-4: Butt & horizontal welds Fig. 7-1-5: Horizontal fillet weld...
  • Page 51 Fig. 7-1-6: Vertical fillet welds Fig. 7-1-7: Overhead weld Distance from the MIG torch nozzle to the work piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded. Travel speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run.
  • Page 52 short-arc welding of 24gauge (0.024”, 0.6mm) to 1/4” (6.4mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables. Preselected variables Preselected variables depend upon the type of material being welded, the thickness of the material, the welding position, the deposition rate and the mechanical properties.
  • Page 53 the center line of the welding gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading (pushing). Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel.
  • Page 54 wire needs more Wirespeed to achieve the same current level. A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece. If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt.
  • Page 55 Item Stock No. 400 Stock No. 500 Stock No. 630 MİG 400 MİG 500 Stock No. 630 Left plate 262017-00557 262017-00579 262017-00629 6064200480 Top plate 262029-00387 262029-00412 262029-00467 6064200481 Handle 766003-00138 766003-00138 766003-00138 6064200129 6064200129 6064200129 Resonance capacitor 722001-00073 722001-00074 722001-00075 6064100180 6064100154...
  • Page 56 IGBT module 735007-00048 735007-00038 735007-00073 6064100170 6064100175 6064100604 Temperature relay 745008-00042 745008-00045 745008-00044 6064100613 6064100578 Input filter inductor 220479-00002 220479-00002 220479-00004 6064100171 6064100171 Radiator bracket 766002-00090 766002-00090 766002-00090 6064200149 6064200149 6064200149 IGBT Radiator 264005-00028 264005-00090 264005-00088 6064200148 Diode Radiator 264011-00121 264011-00116 264011-00027 6064200491...

This manual is also suitable for:

Power mig 630