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GeKaMac PoWer TIG 2000 AC/DC Pulse User Manual

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Summary of Contents for GeKaMac PoWer TIG 2000 AC/DC Pulse

  • 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

    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 4: 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 thetext. Caution “...

  • Page 5: Safety Signs

    Safety signs • All the safety instructions and danger warnings on the machine must be kept in legible condition, not removed, not be covered, pasted or painted cover. Safety inspection • The owner/operator is obliged to perform safety inspection at regular intervals. •...
  • Page 6 Equipotential bonding Workpiece grounding (earthing) Shielding Shield the entire welding equipment and other equipment nearby. ARC rays can burn • Visible and invisible rays can burn eyes and skin. • Wear an approved welding helmet or suitable clothing made from durable flame-resistantmaterial (leather, heavy cotton, or wool) to protect your eyes and skin from arc rays and sparks when welding or watching.
  • Page 7 Cylinder can explode if damaged • Pressure gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. • Cylinders should be located away from areas where they may be struck or subjected to physical damage.
  • Page 8 Overuse can cause overheating • Use machine follow duty cycle. Reduce current or reduce duty cycle before starting to weld again. • Allow cooling period. • Do not block or filter airflow to unit. Safety markings • Equipment with CE-markings fulfils the basic requirements of the Low-Voltage and Electromagnetic Compatibility Guideline (e.g.

  • Page 9: Table Of Contents

    Contents 1-GENERAL REMARKS .............................9 1-1 Power source features ........................9 1-2 Functional principle .......................... 10 1-3 Output characteristics ........................10 1-4 Duty cycle ............................11 1-5 Applications ............................11 1-6 Warning label ............................11 2- VERSIONS BRIEFS ............................. 12 3-BEFORE COMMISSIONING .........................13 3-1 Utilization for intended purpose only ....................
  • Page 10 4-10 Disassembly and reassembly ......................31 6 –TROUBLE SHOOTING............................. 35 7–CARE AND MAINTENANCE............................37...

  • Page 11: 1-General Remarks

    1-GENERAL REMARKS 1-1 Power source features The power source is controlled by microcomputer, has DC MMA, AC MMA, DC TIG, DC pulse TIG, AC TIG, AC pulse TIG, mixed waveform TIG welding process, which are used for carbon steel, stainless steel, copper, titanium, aluminum and Al-Mg alloy welding.

  • Page 12: Functional Principle

    1-2 Functional principle This welding machine applies HF inverter technology. 1- phase 230V input volt is rectifified, fifiltered, and voltage stabilized by PFC circuit, inverted into HF AC by IGBT single tube, reduced by HF transformer, rectifified by HF rectififier, then output DC power suitable for welding.

  • Page 13: 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 14: Warning Label

    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 2- VERSIONS BRIEFS Professional welding of special materials requires special welding parameters. Different models of the power sources are matched to different welding.

  • Page 15: 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 STICK and TIG welding. Utilization for other purposes, or in any other manner, shall be deemed to be "not in accordance with the intended purpose".

  • Page 16: Welding Cables Instruction

    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. If extended cable is used, please do as shown in Fig. 3-4-1. Wrong Coil the excess ground cable and weldingcable in same direction respectively.

  • Page 17: 4-Power Tig 2000Ac Dc Pulse

    4-POWER TIG 2000 AC DC Pulse 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 Basic equipments are needed for normal welding.

  • Page 18: Interface

    4-3 Interface 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. Front panel 1.

  • Page 19: Control Panel

    4-4 Control panel The functions on the control panel are all arranged in a very logical way. The various parameters needed for welding are easy to select, by pressing the appropriate button. Note! Your machine has certain functions that are not in accordance with this operating manual, or vice versa. Also, certain illustrations may be slightly different from the actual controls on your machine.
  • Page 20 Fig. 4-4-2: Press torch trigger Fig. 4-4-3: Hold torch trigger Fig. 4-4-4: Release torch trigger 2-step operation mode a. Press and hold torch trigger to start welding ● Open solenoid valve, shielding gas will flow out to expel air from torch hose (pre-gas time depends on the hose length).
  • Page 21 ● Welding current will continuously decrease at a certain rate until it reaches to crater-filler current and the time is called downslope time. ● Time of crater-filler current depends on the time that the torch trigger is pressed and heldagain. d.
  • Page 22 heat input during arc starting 3～140A AC110V 5～210A AC220V AC TIG AC110V 5～140A Time elapse of welding current up 0～10S Up slope 0.2S slopes from arc starting current. 3～210A AC220V DC TIG 3～140A AC110V 5～210A AC220V Current Welding current at CC welding or peak AC TIG 100A current at pulse welding...

  • Page 23: Submenu

    Time of gas flflow after welding 0.1～60S Post gas 5.0S finished 0～100A Arc force arc force current on STICK mode time ratio of current for cleaning in AC -40～40% Clean ratio -10% TIG welding. *1 10～250Hz 60Hz Frequency of AC TIG/AC pulse TIG frequency Table.

  • Page 24: Save/Call Function

    TIG: 2-step and 4-step TIG: repeat mode (2-step and 4-step indicator Welding mode lights simultaneously) TIG:spot welding mode (2/4 step indicators do not light up) DC TIG: reversed polarity (DCEP) Arc start polarity selection on TIG mode DC TIG: straight polarity (DCEN) STICK VRD ON VRD ON/OFF STICK VRD OFF...

  • Page 25: Other Functions

    program, save/call indicator lights up, exit from submenu, start welding. At this stage, only can check parameter, can not advise parameter. Exit from call mode: enter sub-menu,select needed channel no. LXX, press parameter selection knob and AC/DC selection button for 3s, save/call indicator lights off, exit from callmode. Fig.

  • Page 26: Installation

    Gas test: press parameter selection knob and pulse selection button at the same time for 3s, enter into gas test mode. Fig. 4-7-2:Gas test function 4-8 Installation Warning! Electric shock is very dangerous. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage.
  • Page 27 The connection between input cable and distributor box Warning! - Never connection when equipment is power on! - The connection must be carried out by a qualified electrician! - Do not connect two units of power sources to the same circuit breaker! Fig.
  • Page 28 TIG installation 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 29: Technical Data

    4-9 Technical data Note! Please use the machine under the allowed power supply voltage range marked in the nameplate. PoWer TIG 2000 AC DC Pulse Model Single input Input voltage(V) AC220±15% Frequency(Hz) 50/60 Rated input capacity(KVA) Rated max. input current Rated duty cycle(@40℃) 10～170...

  • Page 30: Disassembly And Reassembly

    4-10 Disassembly and reassembly Fig. 4-10-1: Disassembly and reassembly NO. Item Stock NO. Remarks Control socket 740001-00247 Knob 780999-07776 Anti common mode inductance 210250-00003 Inductor 763004-00213 Current sensor 753001-00024 Over voltage protection board 220900-00319...
  • Page 31 HF board 220900-00318 Power transformer 763001-00310 Diode 730001-00027 Valve 752001-00045 Gas connecotr 740012-00184 water-proof clamp for cable 773002-00025 Plastic rear panel 262011-00700 746002-00025 PFC inductor 763005-00145 Aluminum electrolytic capacitors 722004-00146 Main transformer 763002-00031 Rectifier 735004-00006 Main control board&drive board 210580-00972 Bottom plate 261065-00353 Quick sokcet（-）...
  • Page 32 5-REMOTE CONTROL KITS The control interface of the welding machine can be connected to a foot pedal, with a current-regulated button-type torch, a current-regulated potentiometer-type torch, etc. Control socket Definition of pin 1、2 Torch trigger Judge whether there is current, and there is a sh 3、8 ort circuit between 3 and 8 when there is current output...
  • Page 33 Current-regulated type torch There are two types of current adjustable torch: button-type torch, potentiometer-type torch Plug pin NO. button-type potentiometer-type Red (trigger cord) trigger ( Red) Black (trigger cord) Trigger (Black) Green (power cord) potentiometer power cord(White)+5V Brown (digital signal cord 1) potentiometer center tap (Green) White (digital signal cord 2) potentiometer ground (Brown)

  • Page 34: Troubleshooting

    6 –TROUBLE SHOOTING Warning! An electric shock can be fatal. Before opening themachine: -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 35 Machine problem, cause and remedy Note! The following troubles and causes are uncertain. However, during the normal welding, that might happen. TROUBLE CAUSE 1. The automatic air switch of the switchboard or welding machine power supply is damaged Indicator light does not light 2.Poor contact of input cable on and welding machine 3.The grid voltage connected to the input cable is not within the...
  • Page 36 and replace it after confirmation. 5. Check whether the high frequency board is damaged or not, and replace it after confirmation. 6, check whether the spacing between the spark arresters on the high frequency board is too large or not, and confirm that the adjustment interval is 1mm.

  • Page 37: Care And Maintenance

    7 –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 -Check to make sure the electrically charged components (e.g.capacitors) have been discharged.

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