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GeKaMac PoWer TIG Series User Manual

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PoWer TIG 4000
DC Pulse-HW
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-HW 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 Keep these as short as possible Connect the work cable to the work piece as close as possible to the area being welded. Lay term well away from other cables. Do not place your body between your electrode and work cables. Equipotential bonding Workpiece grounding (earthing) Shielding...
  • Page 5 • 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. Hot parts can burn •...

  • 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 ............................7 1-4 Duty cycle ................................7 1-5 Applications ............................... 8 1-6 Warning label ..............................8 2-VERSIONS BRIEFS ............................. 8 3-BEFORE COMMISSIONING ..........................

  • Page 7: 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...

  • Page 8: 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.

  • Page 9: 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 -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 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 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. Correct When the excess cables are only be used by rolling up, coil the cables to two windings in reverse direction and overlap...

  • Page 12: 4- Power Tig 4000 Dc Pulse-Hw

    4- PoWer TIG 4000 DC Pulse-HW 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.

  • Page 13: Control Panel

    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. Fig.
  • Page 14 2-step operation mode Fig. 4-3-5: 2-step operation mode 4-step operation mode Fig. 4-3-6: 4-step operation mode Repeat mode Fig. 4-3-7: Repeat mode...
  • Page 15 Spot weld mode Fig. 4-3-8: Spot weld mode 5.Welding power parameters: Fig. 4-3-9:Welding power source parameter PARAMETER Description CODE Unit Setting Factory range setting PRE-GAS FLOW Time of gas flow before welding 0.1~9.99 0.05 START The initial current after the arc is started 5~400 UP-SLOPE Time of starting current is increased until it...

  • Page 16: Sub Menu

    6.Hot wire power parameters selection Fig. 4-3-9:Hot wire power source parameter Description CODE Unit Setting range Factory setting PARAMETER HW STITCH ON/OFF the hot wire power ON/OFF HW CURRENT Welding current while in the SMAW and DC TIG 10~200 mode AC FREQUENCY The frequency of hot wire power in AC mode.

  • Page 17: Switch Between Gas Cooling/Water Cooling

    Fig. 4-5-1: Sub menu operation Sub-menu parameter Code Description Factory Setting F00-Local control,F01-Analog remote Remote/Local control F00/F01 /F02/F03 Control,F02-Digital remote control,F03- Group Control Reserve F10/F11 F10/F11 Repeat,spot welding setting F20/F21/F22 F20-2T/4T only; F21-Repeat welding;F22-Spot welding F30/F31 F30-HF,F31-No HF F40 - not greater than the peak current, F41 Base current controlled state F40/F41 - not controlled by the peak current (Pulse mode) Tungsten diameter selection P0.8-6.0...

  • Page 18: Restore To Factory Setting

    4-6 Restore to factory setting Press and hold the Parameter adjustment knob and 2/4 step button at same time for 5 seconds to restore to factory setting (Fig. 4-6-1). Fig. 4-6-1: Restore to factory setting 4-7 Interface Note! You may find that your machine has certain functions or some parameters that are not described in this operating manual.
  • Page 19 Connect work piece when processing SMAW; connect with TIG torch when processing TIG welding. 5.Gas outlet Connect gas hose of TIG torch. 6.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 20 Power signal 10V, to connect external analog potentiometer high potential side. Hot wire remote control current input given signal (0-10V). Hot wire remote control current Gnd. Hot wire remote control switch signal, short circuit with No.19 pin can start hot wire power. Common GND.

  • Page 21: Technical Data

    4-8 Technical data Note! For machines designed for special voltages, below is the technical data on the name plate. Model PoWer TIG 4000 DC Pulse-HW Input voltage/frequency 3 phase, AC380V/400V, 50Hz Rated input capacity (KW) Rated input current (A) Output current adjustment range (A) 5～410A Duty Cycle (%) OCV (V)

  • Page 22: 5-Hw 200

    5-HW 200 5-1 features This machine is a device that provides heating energy for the welding wire and is used in conjunction with the PoWer TIG 4000 DC Pulse-HW hotwire welding machine. Features and benefits: -MCU controlled technology -Self-diagnostic function with error code display -AC or DC current output 5-2 Functional principle Hot wire power source apply IGBT HF inverter technology.

  • Page 23: Interface

    Fig. 5-3-1: Duty cycle 5-4 Interface Fig. 4-5-1 Front Panel Fig. 4-5-2 Rear Panel 1.Hot wire power supply fast socket (+). This socket is connected to the heating ground cable. 2.Hot wire power supply fast socket (-). This socket is connected to the heating cable in the welding cables assembly. 3.Nameplate 4.Fan Cooling the heating device in the machine.

  • Page 24: Dimension

    5-6 Dimension Item Unit(mm) Unit(inches) length Width Height Fig. 5-6-1: Dimension Table. 5-6-1: Dimension 6-INSTALLATION AND OPERATION ● Installation environment requirements 1. It should be placed indoors without direct sunlight, rainproof, low humidity and less dust. The ambient air temperature range is -10℃~+40℃.
  • Page 25 Circuit breaker power cord ≥4 Cable size (mm²) Output cable Protective GND wire ≥4 Table6-1: Power supply and cable requirement Note! Welding machine must be taken special design if it is powered by generator, please contact with manufacturer if you have such needs. ●...
  • Page 26 TIG welding 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 machine into service Warning! If the machine is plugged into the mains supply and the mains switch is in "O" position during preparation, there is a high risk of very serious injury and damage.

  • Page 27: 7-Disassembly And Reassembly

    7-DISASSEMBLY AND REASSEMBLY Fig.7-1: DISASSEMBLY AND REASSEMBLY...
  • Page 28 Item Stock No.for 400 Stock No.for 500 Remarks Circuit breaker 745011-00021 745011-00022 Three phase rectifier 735005-00002 735005-00002 746001-00087(220V) 746001-00087(220V) 746001-00017(380V) 746001-00017(380V) Varistor 720021-00017 720021-00017 Polypropylene capacitor 722001-00070 722001-00070 Electrolytic capacitor 722004-00101 722004-00101 Polypropylene capacitor 722001-00073 722001-00073 IGBT Module 735007-00048 735007-00038 IGBT protection board 220005-00138 220005-00136...
  • Page 29 Fig.7-2: HW 200 Item Stock No. Remarks Three phase rectifier 735005-00009 746001-00109 746001-00106 746001-00109 Resistor 720003-00002 Polypropylene capacitor 722001-00024 Resistor 720003-00002 Polypropylene capacitor 722001-00070 Polypropylene capacitor 722001-00067 Polypropylene capacitor 722001-00070 Secondary IGBT module 220221-00001 IGBT module 735007-00046 Temperature relay 745008-00008 Fast rfecovery diode 735006-00056 Fast rfecovery diode...
  • Page 30 Commutation inductor 220287-00001 Given anti-jamming inductor 220269-00027 Main control board(HW) 210580-01182 Drive board(HW) 210310-00124 763001-00033 Power transformer 763001-00326 745007-00012 Fuse 745007-00011 Filter 752004-00017 Table7-2:Spare parts...

  • Page 31: 8-Trouble Shooting

    8-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 32 ● Error code display This series of machines have automatic protection and error code display function. Relevant Cause & Remedy can be found according to below Error codes, as shown in Table 8-2 code Trouble Cause Remedy No current output after pressing Torch trigger fault Release torch trigger torch trigger for 2s...
  • Page 33 ①Power internal overheating ①Check the fan, (beyond the rated load sustained waiting for the welding power supply rate use, the vents are blocked)； internal cooling; ②Check the Overheat protection--E19 ②Temperature relay fault； temperature relay connection; ③Replace the Signal line failure； temperature relay;...

  • Page 34: 9-Care And Maintenance

    9-CARE AND MAINTENANCE 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 inadvertently switching it back on again.
  • Page 35 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-hw

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