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GeKaMac PoWer MIG Series User Manual

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Gedik Welding Inc.
Ankara Caddesi No: 306 Seyhli 34906 Pendik - Istanbul / Turkey
P +90 216 378 50 00 F +90 216 378 20 44
www.gedikwelding.com

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  • Page 1 Gedik Welding Inc. Ankara Caddesi No: 306 Seyhli 34906 Pendik - Istanbul / Turkey P +90 216 378 50 00 F +90 216 378 20 44 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

    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 5: Safety Rules

    Safety Rules “Danger” indicates an imminently hazardous situation which, if not avoided, Danger! will result in death or serious injury. “Warning!” indicates a possible hazardous situation which, if not avoided, Warning! could result in death or serious injury. The possible hazards are explained in the text.
  • Page 6 or stop machine before installing or maintenance. • 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;...
  • Page 7 is not good, wear an approved air-supplied respirator. • Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. • Welding fumes and gases can displace air and lower the oxygen level causing injury or death.
  • Page 8 source of heat, sparks, or flame. • No touching cylinder by welding electrode, electrode holder or any other electrically “hot” parts. Do not drape welding cables or welding torches over a gas cylinder. • Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the process used;...
  • Page 9 Equipment with CCC markings meets the requirements of implementations rules for China compulsory certification.

  • Page 10: Table Of Contents

    Contents 1 - GENERAL REMARKS ....................9 1-1Power source features ..........9 1-2 Functional principle ..........9 1-3 Output characteristics ..........9 1-4 Duty cycle ............ 10 1-5Applications ........... 10 1-6Warning label ..........11 2 –VERSIONS BRIEFS ....................12 3 -BEFORE COMMISSIONING ................... 12 3-1Utilization for intended purpose only ........
  • Page 11 4-9 STICK (MMA) welding process and operating ....... 42 4-10 TIG welding process and operating ........ 44 4-11 Gouging process and operating ........46 4-12 Technical data ..........47 4-13 Disassembly and reassembly ........49 5-TROUBLE SHOOTING ..................... 52 6 –CARE AND MAINTENANCE ................54 7 - BASIC WELDING TECHNIQUE ................

  • Page 12: General Remarks

    1 - GENERAL REMARKS This series of power sources apply IGBT soft switch inverter technology. Its internal control system applies digital signal processor which ensures quick response to any change during the welding process so as to achieve precise control of welding process and ensure optimal welding results. 1-1Power source features This series of power sources are microprocessor controlled and apply MCU + DSP control technology to improve the control precision.

  • Page 13: Duty Cycle

    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 14: 1-6Warning Label

    - Shipbuilding and offshore engineering - Electric power construction - Vehicle manufacturing - Mechanical industry - Other industries 1-6Warning label The warning label is affixed on the top of machine. Fig. 1-6-1: Warning label...

  • Page 15: -Versions Briefs

    2 –VERSIONS BRIEFS Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different weldings. 3 -BEFORE COMMISSIONING Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the...

  • Page 16: 3-1Utilization For Intended Purpose Only

    functions described here until you have read and completely understood “safety rules”. 3-1Utilization for intended purpose only The power source may only be used for MIG, P-MIG, STICK, TIG and Gouging. Utilization for other purposes, or in any other manner, shall be deemed to be "not in accordance with the intended purpose". The manufacturer shall not be liable for any damage resulting from such improper use.
  • Page 17 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 them.

  • Page 18: Power Mig Gs 5000

    4 - POWER MIG GS 5000 4-1 System components PoWer MIG GS 5000 can be equipped with many different accessories and can be used in different special sites with different configurations. System components Fig. 4-1-1: 4-2 Basic equipments for welding Only be equipped with the necessary accessories, can the power source POWER MIG GS 5000 operate well.

  • Page 19: Control Panel

    Electrode Gouging Power source Ground cable Carbon arc gouging torch Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas) Carbon rod 4-3 Control panel The functions on the control panels are all arranged in a very logical way. The various modes and parameters needed for welding are easy to select by pressing the appropriate button;...

  • Page 20: Creating A Job

    Important! Values increase in clockwise direction while values decrease in anti-clockwise rotation. To turn the knob left or right while pressing it will achieve quick adjustment. (2) Parameters selection button F2 Press this button, one parameter indicator light is on, the corresponding parameter is chosen; keep pressing this button can switch among the following parameters: - Temperature indicator for the mains - Arc length adjustment...
  • Page 21 “Job” (2) Briefly press the Store button (5) to change to the job menu. The first vacant program location for the job is now indicated (3) Select the program location with the adjustment dial (1), or else leave the suggested program location unchanged. (4) Press and hold the Store button (5).
  • Page 22 For selecting the operating mode of the torch. (9) Process button (s) For select welding process. (10) F2 selection button indicator When the indicator lights up, F2 works (11) “JOB” No. For receiving parameter records/job numbers that were previously saved with “Store” button. (12) Welding speed indicator When the light is on, the right-hand displayer shows the preset welding speed (cm/min) , and the wire speed and welding current &...

  • Page 23: Interface

    For synergic MIG, the inductance value when changing short circuiting transfer (-5.0-+5.0). - harder, stable arc 0 neutral arc + soft, low spatter arc In electrode (MMA) welding mode, for influencing the short-circuiting amperage at the instant of droplet transfer 0 soft, low-spatter arc 100 harder, more stable arc (17) Wire feeding speed indicator...

  • Page 24: 4-5Wire Feeder

    - Connect ground cable in P-MIG/MAG welding process - Connect the torch cable in TIG welding - Connect ground cable or electrode holder in MMA welding - Connect ground cable in gouging Wire feeder control socket X7 For connecting with the control cable of wire feeder, please refer to “Table 4-4-1” in detail: Description AC31V RS485 communication interface...
  • Page 25 Fig. 4-5-1: Connector and control panel of analog wire feeder 1. Current regulation button For preset welding current on analog adjustment mode (set sub-menu parameter P09 as OFF). 2. Voltage regulation button For preset welding voltage on analog adjustment mode (set sub-menu parameter P09 as OFF). 3.
  • Page 26 19, 20 AC current 31V Table 4-5-1: Digital communication socket 6. Water inlet For connecting water outlet of water cooled torch (red). 7. Control cable connector of digital welding torch (KC3) For connecting the control plug of digital torch, please refer to Table 4-5-2 in detail. Description Welding torch switching signal Welding torch right-hand button signal...
  • Page 27 ● Connector and control panel of digital wire feeder Fig. 4-5-2: Connector and control panel of digital wire feeder 1. Torch connector For connecting with welding torch of European connection. 2. Water outlet For connecting water flow out tube of torch (red). 3.
  • Page 28 12. Gas test button Click the gas test button will open the gas valve, the wire feeder and welding machine will not work. The gas test will last for 30 seconds, and re-click the gas test button will stop gas flow ahead of time. ●...

  • Page 29: Water Cooling System

    0 neutral arc + soft, low spatter arc 7. Wire feeding speed indicator When the indicator lights up, the left-hand displayer shows the wire feeding speed (M/min). 8. Welding current indicator When the indicator lights up, the left-hand displayer shows the preset or actual welding current values. 9.

  • Page 30: Installation

    Fig. 4-6-1: Cooling unit connections Note! Please check the volume and purity of the coolant before using. Please take freeze-proofing measures when the temperature is too low. Important! Factory setting of welding machine is water cooled mode (sub-menu parameter P10 is ON). When short water, error code E0A displays, welding machine stops working.
  • Page 31 Please note the size of fuse and circuit breaker in the table below are for reference only. Single voltage Model AMIG500P Input power supply Three phase, AC380V/400V/415V Electricity grid min. Power grid power (KVA) Generator Fuse Input protection(A) Circuit breaker ≥4 Input cable...
  • Page 32 Fig. 4-7-2: Connections for input cable and distribution box ● Welding cable components assembly Assembly method of welding cable components please refer to Fig. 4-7-3: Fig. 4-7-3: Welding cable components assembly ● 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 33 ● Making an earth connection (1) Plug one end of the ground cable to the output socket (-) of power source and turn it to fasten it; (2) Connect the other end of the ground cable to the work piece. ●...
  • Page 34 Fig. 4-7-6: Installation for steel wire feed tube Note! If the wire hose is too tight or too loose, it will increase resistance for wire feeding and cause wire feeding instable. ●Normal welding torch assembly 1. Switch off the power source; 2.
  • Page 35 Switch off the power source Check whether the torch is correctly and completely tooled up. If yes, firstly install wire feed hose, then plug the torch’s connector into the torch connector (a) of the wire feeder; Screw up to make the torch well in place; Plug the control plug of the welding torch into the torch control connector (b);...
  • Page 36 In order to get ideal wire feeding result, the proper wire feed rolls must be chosen according to the size and material of the wire. Specific step as follows: Fig. 4-7-12: Wire feeder structure 1. Switch off the power source; 2.

  • Page 37: Mig/P-Mig Welding Process And Operating

    3. Screw the end-cover of the shaft; 4. Fix the wire spool into the shaft and make sure of the correct direction; 5. Twist the end-cover of the shaft Warning! The drop of wire spool will cause danger! Ensure the wire spool is fixed in the bracket firmly.
  • Page 38 manual. ● Sub-menu parameter In order to achieve an optimum welding result, it is necessary in some cases to make corrections of the arc-length, arc force as well as parameters like pre-gas time, post-gas time and slow wire feeding. For details of how to set the Sub-menu parameters, please refer to “Sub-menu parameter set”.
  • Page 39 - 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; if too short time, the wire will stick with the work piece. - P02 Slow wire feeding With too quick feeding speed, the wire will be easily exploding with failed arc-starting;...
  • Page 40 Fig. 4-8-1: Double pulse reference wave form Choose OFF mode, there is no double pulse, but single pulse mode. If ON, it is double pulse mode, at the same time, you can set low frequency pulse rate. The density and depth of ripple pattern in welding seam can be changed by adjusting low frequency pulse frequency, which is similar to adjustment of T value in Fig.
  • Page 41 - P21 Twin wire master-slave control When use twin wire welding, ONL means master machine, ONT means slave machine; both ON means non-cooperative control, both OFF means it does not work. ● Sub-menu parameters set Enter and exit from the sub-menu and parameters adjustment as Fig. 4-8-2: 1.
  • Page 42 Only where a cooling unit and water-cooled torch are used, plug the water hoses of the welding torch to the correct plug-type connectors on the wire feeder Plug in the mains plug Fix the selected wire; Switch on the power source Caution! Risk of injury and damage from electric shock.
  • Page 43 12. Specify the desired welding power with reference to any of the following parameters: - a-dimension - Sheet thickness - Welding current - Wire feed speed Important! The parameters “a”-dimension, sheet thickness, welding current and wire feed speed are directly interlinked.

  • Page 44: Retrieving A Job

    Important! If the selected program location already has a job stored in it, then this existing job will be replaced by the new job. (11) “PrG” appears on the left-hand displayer to indicate that the job is now stored. Release the Store button (5) (12) Briefly press the Store button (5) to exitfrom the job menu Retrieving a job...

  • Page 45: Stick (Mma) Welding Process And Operating

    Fig. 4-8-4: Restore the factory setting 4-9 STICK (MMA) welding process and operating Warning! Operating the equipment incorrectly can cause serious injury and damage. Please read the following chapters before the first starting use the power source: - Safety rules - before using Warning! An electric shock can be fatal.
  • Page 46 detail. Press the “Parameter selection” button (3) and select “Welding current” (18), (indicator on this button must light up) Set the desired amperage, using the adjustment dial (1) (value can be read from the left-hand indicator) Press the “Parameter selection” button (3) to set the “Arc force” (16), (indicator on the button must light up) Set the desired arc-force dynamic, using the adjustment dial (1) (value can be read from the light-hand indicator) Start welding...

  • Page 47: Anti-Stick Function

    Fig. 4-9-1: Graphic symbol As shown in Fig. 4-9-1, welding current is set as 100A. Hot arc-starting current (H01) is 50%. During the hot arc-starting time (H02, such as 0.5s), the actual welding current is 100A+ (50% of 100A)=150A. Anti-stick function In ON mode, power source has anti-stick function automatically.

  • Page 48: Tig Welding

    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 all of the following guides: - Safety rules - Before commissioning Warning!Electric shock can be fatal. If the machine is plugged into the mains supply during installation, there is a high risk of very serious injury and damage.

  • Page 49: Gouging Process And Operating

    Start arc by making the tungsten electrode touch with work piece surface. 1. Put the nozzle on the ignition location so that there is a gap of 2-3mm (0.8-0.12in.) between the tungsten electrode and the work piece Fig. 4-10-1: Put nozzle on work piece 2.

  • Page 50: Technical Data

    (1) Unplug the machine from mains (2) Switch off the mains switch (3) Dismount the MIG/MAG welding torch (4) Plug the ground cable into output socket (-), and latch it in firmly (5) Connect the other end of the ground cable to the work piece (6) Plug the carbon arc gouging torch into output socket (+) (7) Connect air tube to outlet of air compressor or other air supply tube (8) Plug in the mains plug...
  • Page 51 Duty cycle(%) ≥87 Full-load efficiency (%) ≥0.95 Power factor Ф0.8、Ф1.0、Ф1.2、Ф1.6 Wire diameter (mm) CO2 Gas flow(L/min) 15～20 655×322×558 Dimension (mm Weight (Kg) output reactor Isolation degree Main transformer/ Table 4-9-1: POWER MIG GS 5000 technical data - single voltage Multi voltage POWER MIG GS 5000 Model Three Phase, AC 220/440V, 60Hz...

  • Page 52: Disassembly And Reassembly

    4-13 Disassembly and reassembly Disassemble and reassembly Fig. 4-13-1: Item Stock No Left plate 262017-00038 380V/50Hz Top plate 262029-00029 380V/50Hz Handle 766003-00138 380V/50Hz Resonance capacitor 722001-00074 380V/50Hz Main transformer 220629-00088 380V/50Hz Resonance inductor 220521-00004 380V/50Hz Main control board components 210580-00258 380V/50Hz Power transformer I 220179-00207 380V/50Hz 220179-00279 415V/50Hz...
  • Page 53 220179-00495 CE model Solid state relay 715004-00003 380V/50Hz Circuit breaker pressing plate 766003-00188 380V/50Hz Circuit breaker 745011-00022 380V/50Hz 746001-00017 380V/50Hz 746001-00019 415V/50Hz 746001-00034 CE model Rear plate 262011-00399 380V/50Hz Cable 769001-00027 380V/50Hz 769001-00027 415V/50Hz 769001-00028 CE model Rubber circuit breaker cover 766003-01522 380V/50Hz Circuit breaker cover pressing plate 766003-01523 380V/50Hz...
  • Page 54 IGBT radiator 264005-00090 380V/50Hz Radiator support 766002-00090 380V/50Hz Output diode radiator 264011-00025 380V/50Hz Current exchange inductor 220281-00008 380V/50Hz Fast recovery diode module 735006-00029 380V/50Hz Diode protection board 220455-00002 380V/50Hz Radiator junction plate 775004-00027 380V/50Hz Radiator support frame 766002-00078 380V/50Hz Main components list Table 4-13-1: Note: This table is for reference only, and the detail of actual product shall prevail.

  • Page 55: 5-Trouble Shooting

    5-TROUBLE SHOOTING 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 on again -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.
  • Page 56 Note! The flowing troubles and causes are uncertain. However, during the process of MIG Pulse and the normal using conditions, that might happen. Trouble Remedy • Check the mains supply lead, make sure that the mains plug is plugged in •...

  • Page 57: -Care And Maintenance

    6 –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 inadvertentlyswitching it on again -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.

  • Page 58: Basic Welding Technique

    7 - 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. 7-1 MIG (GMAW/FCAW) 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 59 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 60 Fig. 7-1-4: Butt & horizontal welds Fig. 7-1-5: Horizontal fillet weld...
  • Page 61 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 62 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. These variables are: • Type of electrode wire • Size of electrode wire •...
  • Page 63 to the direction of travel. Fig. 7-1-9: Transverse and Longitudinal Fig. 7-1-10: Nozzle Angle Right Handed Operator Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece.

  • Page 64: Tig Welding Technique

    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. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter.
  • Page 65 Fig. 7-2-2: TIG ARC DC TIG welding is a process in which an arc is struck between a TUNGSTEN electrode and the metal work piece. The weld area is shielded by an inert gas flow to prevent contamination of the tungsten, molten pool and weld area.
  • Page 66 Fig. 7-2-7: Arc Ignition Fig. 7-2-8: Established TIG Arc TIG Welding Fusion Technique Fig. 7-2-9: 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 67 Fig. 7-2-13: Add TIG Filler Wire 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 68: Smaw (Stick) Welding Technique

    Follow are common used tungsten types: Thoriated, Ceriated, Lanthanated, Zirconiated Table 7-2-1: Tungsten Electrodes Rating for Welding Currents Tungsten DC Current Diameter Amps 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...
  • Page 69 weld area from atmospheric contamination. The electrode core itself acts as filler material the residue from the flux that forms a slag covering over the weld metal must be chipped away after welding. Fig. 7-3-1: Stick ARC Fig. 7-3-2: ARC Ignition Fig.
  • Page 70 ● establishing arc characteristics ● adding alloying elements Covered electrodes serve many purposes in addition to adding filler metal to the molten pool. These additional functions are provided mainly by the covering on the electrode. MMA (Stick) Welding Fundamentals Electrode Selection As a general rule, the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal.

  • Page 71: Gouging Technique Guide

    Electrode Angle The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal. When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel.
  • Page 72 CAC-A usually choose DC reversed polarity (work piece connect to negative electrode). So the arc is stable, melting metal mobility is better, freezing point is lower, so reversed polarity ensure stable gouging process, arc sends out continuous swish sound, width of dadoing is equal, smooth and bright. If it is wrongly connected, arc is not stable and sends out inconsistently blare sound.
  • Page 73 Extension length is carbon length from tip to end of carbon rod. In manual CAC-A, extension length is long, tip of compressed air is far from arc, cause lack of wind power, can not blow off slag, and carbon rod is easy to break. Usually extension length is better 80~100mm, along with carbon rod burn, extension length becomes shorter, when extension length decreases to 20~30mm, should adjust it back to 80~100mm.
  • Page 75 SAP KODU SAP KODU Item Stock No.for 3500 Stock No.for 5000 Stock No.for Stock No.for 3500 5000 6064000403 6064000403 Power transformer II 763001-00048 763001-00048 6064100514 6064100514 Power transformer I 763001-00049 763001-00049 Main control board 210580-01609 210580-01609 6064100227 6064100227 Current exchange inductor 220281-00008 220281-00008 6064100154...

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