GeKaMac Power MIG Series User Manual
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Summary of Contents for GeKaMac Power MIG Series
- Page 1 Power MIG 500/630 Users Manual Please Read and Understand This Manual Before Operating The Welding Machine www.gedikwelding.com...
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Page 2: 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. If you treat your product carefully, this definitely helps to prolong its enduring quality and reliability–things which are both essential prerequisites for getting outstanding results. -
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 Hot parts can burn • Do not touch hot parts with bare hand or skin. • Ensure equipment is cooled down before perform any work. • If touching hot parts is needed, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
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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 ..........................6 1-4 Duty cycle ..............................7 1-5 Applications ..............................7 1-6 Warning label ............................... 8 2- VERSIONS BRIEFS ............................8 3- BEFORE COMMISSIONING ......................... -
Page 7: 1- General Remarks
1- GENERAL REMARKS This series of power sources apply IGBT soft switch inverter technology. Its internal control system applies 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. 1-1 Power source features Highlights as follows: - Enjoy reasonable static characteristic and sound dynamic characteristic. -
Page 8: Duty Cycle
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: Warning Label
1-6 Warning label The warning label is affixed on the top of machine. 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. ●... -
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 CO2/MAG, Utilization for any other purpose, 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...
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Page 12: 4-Power Mig 500/630
4-PoWer MIG 500/630 4-1 System 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 4-2 Basic equipments for welding Only be equipped with the necessary accessories, can the power source operate well. The following is the needed accessories list. - Page 13 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 content of this manual. Fig. 4-3-1: Control panel 1.BURN BACK knob Adjusting the burn-back time can improve the size of the molten ball at the end of the wire; it can prevent the wire sticking to the workpiece.
- Page 14 7.Torch control switch Operating mode of torch trigger Graphic symbol Fig. 4-3-2 Press torch trigger Fig. 4-3-3 Hold torch trigger Fig.4-3-4 Release torch trigger P03……Pre-gas time I………..Welding current: Uniform thermal input for the preheated base metals. P06……Crater-filler parameter: Prevent burn-through caused by too much heat at the welding ends. P04……Post-gas time P01……Burn back time - 2-step mode...
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Page 15: Interface
In 4-step mode, it is used to preset the crater filler voltage. Important! The digital meter does not display the crater filler voltage value when presetting. When in crater filler status, it will display the real crater filler voltage value. 4-4 Interface Fig. -
Page 16: Installation
4-5 Installation Warning! An electric shock can be fatal. If the machine is plugged into the mains electricity supply during installation, there is high risk of very serious injury and damage. Do not use the functions described here until you have read and completely understood “safety rules” in the beginning.Only carry out work on the machine when - the mains switch is on turn-off position, - the machine is unplugged from the mains... -
Page 17: Welding Process
●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. 2. Take the protective cap off the gas cylinder. 3. -
Page 18: Dimension
Open circuit voltage(V) Range of welding current (A) 60~500 60~630 Range of welding voltage (V) 15~50 Rated duty cycle (%) Full-load efficiency (%) ≥87 Wire size (mm) Ф1.0~Ф1.6 CO2 gas flow (L/min) 10~25 Dimension (mm) 636×322×584 686×322×584 Weight (Kg) Insulation class Table. -
Page 19: Disassembly And Reassembly
4-9 Disassembly and reassembly Fig. 4-9-1: Disassemble and reassembly... - Page 20 Item Stock No.500 Stock No.630 REMARKS Potentiometer knob 720031-00138 720031-00138 Digital display 755001-00023 755001-00023 Light(red) 715002-00026 715002-00026 Potentiometer 720031-00158 Burn back Potentiometer 720031-00041 720031-00041 Inductance Rocker switch 745002-00003 745002-00003 Gas test Left plate 262017-00579 262017-00629 262029-00412 262029-00467 Top plate Handle 766003-00138 766003-00138 Resonance capacitor...
- Page 21 Potentiometer 720031-00042 720031-00042 Crater filling Light(yellow) 715002-00025 715002-00025 Dust cover 745090-00002 745090-00002 Varistor 720021-00017 720021-00017 Screw 779001-00440 779001-00440 Spring washer 779007-00017 779007-00023 Flat washer 779007-00018 779007-00018 Three phase rectifier modules 735005-00003 735005-00003 Polypropylene capacitor 722001-00067 722001-00014 IGBT protection board 220005-00135 220005-00008 IGBT module 735007-00038...
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Page 22: 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. -
Page 23: 6-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 inadvertently switching it on again. - Page 24 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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