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GeKaMac Power MIG 210 Pulse User Manual

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PoWer MIG 210 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 MIG 210 Pulse

  • Page 1 PoWer MIG 210 Pulse Users Manual Please Read and Understand This Manual Before Operating The 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 4: Dear Customer

    Production specification may change without advance notice. The model you purchase is for: o PoWer MIG 210 Pulse Please find corresponding models from the "Contents". Important: Please take special note of safety rules and operate as...

  • Page 5: 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 6 • Do not touch live electrical parts of the welding circuit, electrodes and wires with your bare skin or wet clothing. • The operator must wear dry hole-free insulating welding gloves and body protection while performs the welding. • Insulate yourself from work and ground using dry insulating protection which is large enough to prevent you full area of physical contact with the work or ground.
  • Page 7 Keep these as short as possible Connect the work cable to the work piece as close as possible to the area being welded. Lay tem well away from other cables. Do not place your body between your electrode and work cables. Equipotential bonding Workpiece grounding (earthing) Shielding...
  • Page 8 Make sure the area is safe before doing any welding. • Welding and cutting on closed containers, such as tanks, drums, or containers, can cause them to blow up. Make sure proper steps have been taken. • When pressure gas is used at the work site, special precautions are required to prevent hazardous situations.
  • Page 9 support or cylinder rack to prevent falling over or tipping. • Keep a safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. • No touching cylinder by welding electrode, electrode holder or any other electrically “hot”...
  • Page 10 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 11: Table Of Contents

    3-2 Machines set-up regulations ..............15 3-3 Power source connection ..............15 3-4 Welding cables instruction ..............15 4-PoWer MIG 210 Pulse ..................17 4-1 System components ................17 4-2 Basic equipments for welding .............. 17 4-3 Interface ....................19...
  • Page 12 4-4 Control panel ..................21 4-5 Job list ....................26 4-6 Sub menu .................... 29 4-7 Reset Factory setting ................33 4-8 Contorl socket ..................34 4-9 Installation and operation ..............34 4-10 Technical data ................... 39 4-11 Dimension ..................40 4-12 Disassembly and reassembly ............

  • Page 13: 1-General Remarks

    1-GENERAL REMARKS 1-1 Features PoWer MIG 210 Pulse multi function inverter welding machine can use for pusle MIG and CV MIG. Also it possesses STICK, Lift TIG function. This series welding machine enjoys reasonable static characteristic and sound dynamic characteristic.

  • Page 14: Output Characteristics

    Fig. 1-2-1: Schematic diagram 1-3 Output characteristics MIG/MAG mode STICK mode LIFT TIG mode 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 close, output stops. Wait for fifteen minutes for the machine to cool down.

  • Page 15: Applications

    NOTE! Exceeding duty cycle can damage unit and void warranty. Fig. 1-4-1: Duty cycle 1-5 Applications This series power source can use for carbon steel, stainless steel, aluminum and al-mg alloy welding with wire (Ф0.8,Ф1.0,Ф1.0mm). The power source is designed for the following recommend areas: R Automobile R Steel door and window...

  • Page 16: Warning Label

    R Furniture R Decoration R Fitness equipment manufacture R Maintenance and repair 1-6 Warning label The warning label is affixed onto the top of the power source, and it must not be removed or painted over. Fig. 1-6-1: Warning label...

  • Page 17: 2-Versions Briefs

    Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding. PoWer MIG 210 Pulse It is multi function inverter welding machine, can use for MIG/MAG, FCAW-S, STICK and Lift TIG function. Built-in wire feeder with 15kg wire spool, closed type, small size, light weight and easy to start arc, enjoy stable arc length, pretty welding seam formation and welding current continuous adjustment capability.

  • Page 18: Machines Set-Up Regulations

    3-2 Machines set-up regulations According to test, protection degree of this power source is IP21S (optional IP23S). However, the internal key components must be protected from direct soaking. Warning! A machine that topples over or falls can easily cause harm to people. Please firmly install the machine on a stable place.
  • Page 19 Wrong Coil the excess ground cable and welding cable in same direction respectively. Correct Straighten the ground cable and welding cable and make them close to each other. Bundle the ground cable and welding cable together, running the wires close to the ground.

  • Page 20: 4-Power Mig 210 Pulse

    4-PoWer MIG 210 Pulse 4-1 System components This machine can be equipped with many different accessories and can be used in various special sites with different configurations. Fig. 4-1-1: System components 4-2 Basic equipments for welding Basic equipments are needed for normal welding. Below are the lists:...
  • Page 21 - Ground cable - MIG/MAG welding torch - CO2 gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) FCAW-S - Power source - Ground cable - MIG/MAG welding torch STICK - Power source - Ground cable - Electrode holder - Electrode Lift TIG...

  • Page 22: Interface

    4-3 Interface Fig. 4-3-1: Interface 1.Control panel 2.Torch connector Euro-type connector, connect to the MIG torch. 3.Welding machine output terminal (+) MIG/MAG: connect with Transfer cable; FCAW-S/Lift TIG: connect with work piece via ground cable; STICK: connect with electrode holder. 4.Transfer cable MIG/MAG: connect to output terminal (+);...
  • Page 23 Lift TIG: connect with welding torch. 6. Control socket Control interface of wire drawing torch. 7.Power cord The mixed-colored wire must be firmly grounded; the rest 2 wires connect to one phase AC power supply. 8.Gas inlet Connect to gas regulator with gas hose (MIG/MAG ONLY) 9.Main circuit breaker Main circuit breaker for one phase AC power supply.

  • Page 24: Control Panel

    Side panel Fig. 4-3-4: Side panel 1.Wire feeding system Single drive wire feeder, can weld solid wire and flux cored wire; 2.Wire pushing/wire pulling selection switch In wire pushing, wire feeder power supply will provide power to wire feeding system inside of welding machine;...
  • Page 26 Note!VRD is anti-electric shock device on STICK mode, but should also pay attention to safe operation requirements in this manual. 2.Voltage displayer On open load mode, display preset voltage (Manual MIG/ Synergic MIG mode ONLY); display actual welding voltage during welding. 3.Current/job list code displayer On open load, display preset welding current;...
  • Page 27 Fig. 4-4-2: Press trigger Fig. 4-4-3: Hold trigger Fig. 4-4-4: Release trigger 2- STEP mode Fig. 4-4-5: 2-STEP mode 4- STEP mode...
  • Page 28 Fig. 4-4-6: 4-STEP mode Special 4-STEP mode Fig. 4-3-7: Special 4-step mode 6.Voltage adjustment knob On MIG mode, it is used for adjusting preset welding voltage;Turn left to decrease the voltage value, turn right to increase the voltage value; press the knob and turn left to decrease the voltage value quickly, turn to the right to increase the voltage value quickly.

  • Page 29: Job List

    8.Inductance adjustment knob Pulse MIG: can be used to adjust the arc force. The smaller the value. Arc concentration The larger the value, the softer arc and less splash. MIG (CV) mode: It can be used to adjust the arc stiffness during short-circuit transition. The smaller the value.
  • Page 30 CS-0 0.8/1.0/1.2 011/012/013 Ar82%+CO218% 0.8/1.0/1.2 021/022/023 CO2100% SS-1 PUSLE 0.8/1.0/1.2 101/102/103 Ar97.5%+CO22.5% 0.8/1.0/1.2 111/112/113 CuAL-2 PUSLE 0.8/1.0/1.2 201/202/203 0.8/1.0/1.2 211/212/213 CuSi-3 PUSLE 0.8/1.0/1.2 301/302/303 0.8/1.0/1.2 311/312/313 Ar100% ALSi-4 PUSLE 0.8/1.0/1.2 401/402/403 0.8/1.0/1.2 411/412/413 ALMg-5 PUSLE 0.8/1.0/1.2 501/502/503 0.8/1.0/1.2 511/512/513 AL-6 PUSLE 0.8/1.0/1.2 601/602/603...
  • Page 31 Table. 4-5-1 JOB list 1. Press the mode selection button to make the Job-list indicator light on, and adjust the voltage setting knob to the standard area; Fig. 4-5-1: Enter Job list menu 2.Press and hold the mode selection button 5S to enter the job list menu. At this time, the voltage displayer shows “Job”...

  • Page 32: Sub Menu

    Fig. 4-5-3: adjustment Job list parameter 4-6 Sub menu 1.In the standby state, often press the " 2-Step/4-step” button for 5s until the digital tube displays "P01", which means it has entered the sub-menu adjustment mode. Fig. 4-6-1: Enter submenu Fig.
  • Page 33 Min. Factory Item Parameters Setting Range Value Setting 0.01～2.00s Burn back time 0.01s 0.04s Slow wire feeding 1.0～21.0 m/min 0.1 m/min 1.5 m/min 0.1～10.0s Gas pre-flow time 0.1s 0.20s Gas post-flow time 0.1～10 0.1s 1.0s 1～200％ 1％ 135％ Initial period 1～200％...
  • Page 34 Fan-on demand cooling time Special 2-step arc start time OFF/0.1～10s 0.1s OFF/0.1～10s Special 2-step arc stop time 0.1s Separate adjustment mode OFF/ON ―― Table4-6-1: Sub-menu parameter for MIG/P-MIG Note! P11-P14 is available on double pulse function - P01 Burn back time If too long time, the wire will burn back too much with too large melting ball at the end of wire;...
  • Page 35 arc length of the crater filler. Press F2 again to exit. - P07 Transition period During the special 4-step mode, the time cost from starting current to normal welding current and then to post current. - P11 Double pulse frequency The double pulse welding is added modulated by low frequency pulse and the low frequency pulse between 0.5-5.0 Hz.

  • Page 36: Reset Factory Setting

    Set the wire feeding in double pulse, the changing arrange of wire feeding means adjusting the depth of ripple pattern. - P14 High pulse group duty cycle Set ratio between the high pulse group time T1 and low frequency period T in double pulse mode, to adjust the ratio of ledge and groove in the whole ripple pattern.

  • Page 37: Contorl Socket

    Fig. 4-7-1 Reset factory settng 4-8 Contorl socket Pin NO. Description Connect motor (+24VDC) positive of spool gun 2, 3 Connect torch trigger cable Connect 0 Ω end of remote control potentiometer (4.7 KΩ) Connect wiper end of remote control potentiometer (4.7 KΩ) Connect motor (+24VDC)
  • Page 38 - the machine is unplugged from the mains Power supply and cable requirement Please note the size of fuse and circuit breaker in the table below are for reference only. Model PoWer MIG 210 Pulse Power supply(1-phase) AC 220/230V±15%, 50/60Hz Min. power capacity (KVA)
  • Page 39 - Connected to the correct input voltage, circuit breaker, input cable as per the specification on Table 4-9-1. Fig. 4-9-1: Connection between input power supply cable and switch box Warning! Operating the welding machine incorrectly can cause serious injury and damage.Do not use the functions described here until you have read and completely understand all the following documents: - “safety rules”...
  • Page 40 Fig. 4-9-2: Installation - MIG/MAG wire welding with push torch Fig. 4-9-3: Installation - MIG/MAG welding with pull torch...
  • Page 41 Fig. 4-9-4: Installation – FCAW welding with wire push type torch Stick welding Fig. 4-9-5: Installation – stick welding Lift TIG welding...

  • Page 42: Technical Data

    Note! Please use the machine under the allowed power supply voltage range marked in the nameplate. The technical data with the basic input voltage are listed as the Table 4-10-1. Model PoWer MIG 210 Pulse Rated input voltage/frequency(1 phase) AC220/230V±15%, 50/60Hz Rated input power (KVA) 11.5...

  • Page 43: Dimension

    2-Step/4-Step/Special 4-step Protection class IP21S Insulation grade Cooling way Air cooled Wire spool diameter (mm) 200,300 Wire feeding system type Built-in Dimension (W×D×H) (mm3) 530×220×440 Weight (Kg) Table 4-10-1: PoWer MIG 210 Pulse technical data 4-11 Dimension Fig. 4-11-1: Dimension...

  • Page 44: Disassembly And Reassembly

    Item unit length 530mm Width 220mm Height 440mm Table. 4-11-1: Dimension 4-12 Disassembly and reassembly...
  • Page 45 Fig. 4-12-1: PoWer MIG 210 Pulse Item Stock no. Remarks Circuit breaker 745011-00068 Thermostor 720022-00013 Rectifier 735004-00006 746002-00049...
  • Page 46 Varistor 720021-00020 Polypropylene capacitor 722001-00023 Polypropylene capacitor 722001-00011 Aluminum electrolytic capacitor 722004-00105 IGBT tube 735003-00013 Temperature relay 745008-00032 Main transformer 763002-00026 Diode 730001-00007 Output reactor 763005-00023 Main control drive board 210580-01256 Display board 220503-00318 Power transformer 220179-01025 Wirefeeder 321017-00037 Quick socket 740002-00080 Solenoid valve 752001-00045...

  • Page 47: 5-Trouble Shooting

    Note: If no special remarks, the input voltage mentioned in above table is one phase. 5-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 48 3. Circuit failure -Short circuit of torch signal wire -Display control board failure Abnormal Start The torch trigger is normal closed when power on Over current 1. Welding specification is too large 2. Circuit failure -Welder output short circuit -Current sensor failure -Display control board failure Over heat/fan...
  • Page 49 -Temperature relay failure -Display control board failure Communication Display board communication circuit failure abnormal Table 5-1: Error code Important! If an error code excluded in above table is displayed, please supply the fault phenomenon, error code, together with machine serial no. and machine model to the manufacturer after-service department.
  • Page 50 Change Circuit breaker on Rated current of circuit breaker workplace, the switch board on the switch board is too small proper switch or power switch on board The following devices may be welding machine damaged: input rectifier bridge, trips while in Check electrolytic capacitor, IGBT welding...

  • Page 51: 6-Care And Maintenance

    -Incorrect adjustment of gas flow -The remaining amount of gas is insufficient -Air leak in trachea Abnormal gas Check and replace protection -The gas regulator is damaged -The solenoid valve is damaged -Display control board damaged Table 5-2: Trouble shooting 6-CARE AND MAINTENANCE l Before open the machine Warning! An electric shock can be fatal.

  • Page 52: Daily Maintenance

    compressed air by professional technician, not less than twice per year. Clean the components at a certain distance only - If a lot of dust has accumulated, clean the cooling-air ducts l Daily maintenance Fig. 6-1: Daily maintenance...
  • Page 53 Item Stock no. SAP KODU 6064100259 Circuit breaker 745011-00068 Thermostor 720022-00013 6064100393 Rectifier 735004-00006 6064100500 746002-00049 6064100351 Varistor 720021-00020 6064100353 Polypropylene capacitor 722001-00023 Polypropylene capacitor 722001-00011 6064100355 Aluminum electrolytic capacitor 722004-00105 6064200439 IGBT tube 735003-00013 6064100501 Temperature relay 745008-00032 6064100358 Main transformer 763002-00026...
  • Page 54 6064100359 Diode 730001-00007 6064100360 Output reactor 763005-00023 Main control drive board 210580-01451 6064000403 Display board 220503-00318 6064100503 Power transformer 220179-01025 Wire feeder 321017-00037 6064200217 Quick socket 740002-00080 6064100487 Solenoid valve 752001-00045 6064200495 European torch connector 766003-02545 Filter board 220900-00473 6064000404...

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