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GeKaMac PoWer TIG 300 DC Pulse User Manual

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  • Page 2: Table Of Contents

    No. P10334 P. 1 / 69 TABLE OF CONTENTS 1. SAFETY INFORMATION… ................2 2. ARC WELDING SAFETY PRECAUTIONS… ............. 2 3. GENERAL NOTICE OF OPERATION… ............. 8 4. STANDARD COMPOSITION AND ACCESSORIES… ........9 5. FUNCTION OF EQUIPMENT…................. 10 6.

  • Page 3: Safety Information

    No. P10334 P. 2 / 69 1. SAFETY INFORMATION The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING gives information regarding possible personal injury WARNING or loss of life. CAUTION refers to minor personal injury or possible equipment CAUTION damage.

  • Page 4: Electric Shock Can Kill

    No. P10334 P. 3 / 69 2. ARC WELDING SAFETY PRECAUTIONS (continued) ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuits are electrically live whenever the output is on. The power line and internal circuits of this equipment are also live when the line disconnect switch is on.
  • Page 5 No. P10334 P. 4 / 69 2. ARC WELDING SAFETY PRECAUTIONS (continued) WELDING can cause fire and explosion. Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, spatter, hot base metal, and hot equipment can cause fire and explosion. Accidental contact of electrode or welding wire to metal object can cause sparks, overheating, or fire.
  • Page 6 No. P10334 P. 5 / 69 2. ARC WELDING SAFETY PRECAUTIONS (continued) CYLINDER can explode if damaged. A shielding gas cylinder contains high-pressure gas. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Use only correct shielding gas cylinders, gas regulator, hoses, and fittings designed for the specific application;...
  • Page 7 No. P10334 P. 6 / 69 2. ARC WELDING SAFETY PRECAUTIONS (continued) ARC WELDING work areas are potentially hazardous. FALLING or MOVING machine can cause serious injury. ◆ When hanging the welding power source by a crane, do not use the carrying handle. ◆...

  • Page 8: Principal Safety Standards

    No. P10334 P. 7 / 69 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electro technical Commission Arc welding equipment Part 1: Welding power sources IEC 60974-1, from International Electro technical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.

  • Page 9: General Notice Of Operation

    No. P10334 P. 8 / 69 3. GENERAL NOTICE OF OPERATION 3.1 Rated Duty Cycle CAUTION ● Use this welding power source at or under the rated duty cycle. Failure to do so may result in damage to the machine. •...

  • Page 10: Standard Composition And Accessories

    No. P10334 P. 9 / 69 4. STANDARD COMPOSITION AND ACCESSORIES 4.1 Standard Components • This welding power source is not included the accessories indicated in the boxes. Preparation of the Accessories for welding. Gas regulator 3φ 400V Input cables (2m) Argon Digital remote control Torch switch...
  • Page 11 Grommet with film （ ） For pulling out external connection cables Carrying handle Parameter adjusting knob J O B WARNING MEMORY Input terminals S e c LOAD NO . PULSE FREQ. SAVE UP SLOPE DOWN SLOPE WELDING CURR. （BASE CURR. ） ENTER INIT IAL CURR.

  • Page 12: Function Of Equipment

    No. P10334 P. 11 / 69 5. FUNCTION OF EQUIPMENT (continued) 5.2 Welding Torch Torch switch 2P Water hose (5/8-18UNF) Gas hose (9/16-18UNF) Water in hose (5/8-18UNF) Power cable connector Torch body Nozzle Tungsten electrode...

  • Page 13: Necessary Power Source Equipment

    No. P10334 P. 12 / 69 6. NECESSARY POWER SOURCE EQUIPMENT 6.1 Welding Power Source Equipment (for commercial use) CAUTION ● When the welding machine is used in such a humid environment as construction site, on the steel plate, or on steel structure, install a leakage breaker. CAUTION ●...

  • Page 14: Transport And Installation

    No. P10334 P. 13 / 69 7. TRANSPORT AND INSTALLATION 7.1 Transport WARNING Follow the instructions below to avoid trouble and product damage when carrying the welding machine. ● Do not touch the charging parts inside or outside the welding machine. ●...
  • Page 15 No. P10334 P. 14 / 69 7. TRANSPORT AND INSTALLATION (continued) 7.2 Installation (continued) CAUTION To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again. ● Change the installation place of the welding machine. ●...

  • Page 16: Connection Procedure And Ground For Safety Use

    No. P10334 P. 15 / 69 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE WARNING Follow the instructions below to avoid electric shock.  Do not touch the charging parts, as this will result in fatal shock and severe burn. ●...
  • Page 17 No. P10334 P. 16 / 69 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) 8.1.1 TIG WELDING (water-cooled torch) Torch switch Torch switch cable ○ － Torch power cable Torch Gas hose Water supply hose* ○ Condensate hose* Base metal Base metal cable (38 mm or more)

  • Page 18: Stick Welding

    No. P10334 P. 17 / 69 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) 8.1.2 STICK WELDING The following figure shows the cable connections for stick welding with DC electrode positive (welding stick positive, base metal negative). When using DC electrode negative, switch the holder cable with the base metal cable.
  • Page 19 No. P10334 P. 18 / 69 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) 8.3 Connecting of the Gas Hose WARNING ● You may suffer from danger of suffocation caused by lack of oxygen when shield gas keeps drifting in a closed place. Be sure to turn off the shield gas at the main when the welding power source is not in use.
  • Page 20 No. P10334 P. 19 / 69 CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) CAUTION To prevent electromagnetic troubles, read the following. Also, if electromagnetic troubles occur, check the following again. ● Add a noise filter to an input cable. ●...
  • Page 21 No. P10334 P. 20 / 69 8. CONNECTION PROCEDURE AND GROUND FOR SAFETY USE (continued) • Cooling Water (When using the circulation system PU-301(optionally available), refer to the documentation that came with PU-301.) • Connect a water-cooled hose as illustrated below. Using a faucet that a 1/2 gas Employing a stop valve Direct insertion of the...
  • Page 22 No. P10334 P. 21 / 69 9. WELDING PREPERATION 9.1 Preparing the Protective Equipment CAUTION Check the followings before welding. ● The whole doors and covers of the welding machine are surely closed and fixed. ● The welding cable is placed as closely on the floor or ground as possible. ●...

  • Page 23: Welding Preparation

    No. P10334 P. 22 / 69 WELDING PREPARATION (continued) 9.2 Operating the Switches and Controlling the Gas Flow Rate Regulator CAUTION ● Keep your face away from the outlet when turning on gas at the main of the gas cylinder, as burst of high-pressure gas may result in physical injuries.
  • Page 24 No. P10334 P. 23 / 69 WELDING PREPARATION (continued) 9.4 TIG Welding Condition for reference） （1） TIG Welding Condition PULSE “OFF” ） Plate Argon Gas Electrode Dia. Filler Wire Dia. No. of Bevel Current Material Thickness Flow Rate (mm) (mm) Layer Shape (mm)
  • Page 25 No. P10334 P. 24 / 69 WELDING PREPARATION (continued) ◆ Weld joints with different heat capacity Pulse condition Welding Filler wire No. of Feeding Pulse Base Pulse Pulse Speed Material Joint geometry Layer Current Current Freq. Width Speed (Hz) (cm/min.) (cm/min.) Copper ＋...
  • Page 26 No. P10334 P. 25 / 69 OPERATION Front panel [10] [1] [14] [13] J O B ARNING MEMORY LOAD J O B N O . PULSE FREQ. SAVE UP SLOPE DOWN SLOPE WELDI N G CURR. （ ） BASE CURR. ENTER T1 INITIAL CURR.
  • Page 27 No. P10334 P. 26 / 69 OPERATION (continued) WARNING Follow the instructions below to avoid trouble and product damage when carrying the welding machine. ● Do not touch the electrode while pressing the TORCH switch. ● Disconnect the welding power source form input power supply before replacing the electrode.
  • Page 28 No. P10334 P. 27 / 69 OPERATION (continued) The parameters listed below may be selected with the parameter selector key [2] and adjusted with the parameter adjusting knob [3]. The set value of the parameter selected appears on the digital display with the respective unit indicator LED turned Unit LED WARNIN Digital meter...

  • Page 29: Operation

    No. P10334 P. 28 / 69 OPERATION (continued) （6） Pulse frequency This parameter may be selected only if the pulse setting is “ON”. When this parameter is selected, the set value appears on the right digital display with the unit indicator LED for “hertz (Hz) ” turned ON. In this state, the pulse frequency may be adjusted in the range between 0.1 and 500 Hz by the use of the parameter adjusting knob [3].
  • Page 30 No. P10334 P. 29 / 69 OPERATION (continued) 10.1.3 Pulse setting ( Pulsing is a technique to cyclically vary the welding current for stabilized arcing, controlled penetration geometry and/or controlled heat input, where arcing may be rigidified during high current period for improved stability, and penetration geometry and heat input may be controlled with the high/low current period ratio varied.
  • Page 31 No. P10334 P. 30 / 69 no selection may be made with the SLOPE key. 10. OPERATION (continued) 10.1.5 Crater setting At the end of welding, there remains a dent called “crater”. This dent that might cause cracking or other welding defects Crater must be minimized in size;...
  • Page 32 No. P10334 P. 31 / 69 Initial Crater Timinnig Chart Current Torch Switch Welding Current ● The torch switch hold turned ON during weld. Torch Switch Welding Current Welding Current Crater Current Torch Switch Welding Current Crater Current Initial Current Welding Current ●...
  • Page 33 No. P10334 P. 32 / 69 10. OPERATION (continued) Initial Crater Timinnig Chart Current Torch Switch Welding Current Welding Current Crater Current （REPEAT） Torch Switch Welding Current Welding Current Initial Current Crater Current ● Even if the torch switch is turned OFF during welding, the welding current will be self- held.
  • Page 34 No. P10334 P. 33 / 69 10. OPERATION (continued) 10.1.6 ARC SPOT setting ( For arc spot processing, set the crater setting selector switch [4] to ARC SPOT. Then, upon depression of the SPOT TIME key [5], the indicator LED located on the upper left corner of the setting key turns ON and the set value appears on the right digital display with the unit indicator LED for “second (sec)”...
  • Page 35 No. P10334 P. 34 / 69 10. OPERATION (continued) 10.1.7 START setting (Lift start or High frequency start) Start mode may be selected with LIFT START key [9]. Start mode may be indicated with the indicator LED on the upper left of the mode selector key that turns ON or OFF for “Lift start”...
  • Page 36 No. P10334 P. 35 / 69 10. OPERATION (continued) 10.1.8 Gas check ( ) with gas-saving function. Used to adjust gas flow rate when the gas cylinder discharge valve is opened. When the GAS CHECK key [12] is depressed once, the gas is discharged with the indicator LED on the upper left corner of the key turned ON.
  • Page 37 No. P10334 P. 36 / 69 10. OPERATION (continued) 10.1.10 Internal Functions This welding machine has various special functions that may be used by setting with F-key (Function selector key) [6]. ● How to use internal functions Ⓒ When F-key [6] is depressed, the function No. starts blinking on the left display described below and the status assigned to that function No.
  • Page 38 No. P10334 P. 37 / 69 10. OPERATION (continued) With F-key [6], the status of the following functions may be changed: （1） Selecting start current level: Function No. 1 The factory setting of this function is [ON] that means [high] start current. If any holes are caused at the start of welding, the [low] start current should be selected by setting the status of Function No.
  • Page 39 No. P10334 P. 38 / 69 10. OPERATION (continued) （4） Selecting AUTO or MANUAL mode: Function No. 4 Selecting AUTO mode allows operation stop to be cancelled with operation stop terminal short-circuited. In addition, select AUTO mode to utilize external voltage supply to feed welding current (base current) or pulse current for the operation combined with robot etc..
  • Page 40 No. P10334 P. 39 / 69 10. OPERATION (continued) （5） External voltage (0-12V) control: Function No. 5 When used in AUTO mode combined with INVERTER ARGO, selecting [ON] status for this function allows to use the machine with almost same conditions by slightly adjusting external control voltage (pulse current and welding current or base current).
  • Page 41 Welding current setting The welding current may be set with the parameter adjusting knob [3] in the range specified in the table shown below: ● Current range PoWer TIG 300 DC Pulse Three phases 10A-250A Output current range Single phase 10A-180A 10.2.3...
  • Page 42 No. P10334 P. 41 / 69 10. OPERATION (continued) 10.2.4 Analog remote control (K5023B) (optional accessory) This machine automatically recognizes the analog remote control. When the analog remote control is connected to the machine, the only remote control is effective and the parameters “welding current (base current)”...
  • Page 43 No. P10334 P. 42 / 69 10. OPERATION (continued) ④ Errors Any error caused to the machine will be indicated with blinking numeral assigned to each error type. See Section 11.1, “How to Solve an Error” for further details including error numbers. Notes: The averaged values indicated on the digital display are the data that should be used as the target values and may not be guaranteed as the control data for...
  • Page 44 No. P10334 P. 43 / 69 10. OPERATION (continued) CAUTION ● The welding conditions (electronic information) stored by this function are susceptible to occurrence of static electricity, impact, repair, etc., and there is a possibility that the storage contents may be changed or lost. BE SURE TO MAKE A COPY FOR IMPORTANT INFORMATION.
  • Page 45 No. P10334 P. 44 / 69 10. OPERATION (continued) (2) When pressing the ENTER key [18] after setting the condition number, the ENTER lamp blinks (located at the upper left of the key). Under this condition, you are allowed to confirm the setting value of the parameter preset to the condition number by using the DISPLAY CHANGE key [7].
  • Page 46 No. P10334 P. 45 / 69 10. OPERATION (continued) Note: You are not allowed to change condition number or select a welding method, etc. To reset the condition number, press the LOAD key [16], then return to the step (1). To quit the setting and exit from the readout mode, press the SAVE key [17].
  • Page 47 No. P10334 P. 46 / 69 10. OPERATION (continued) ③ Erasing the Welding Conditions When you erase the welding conditions stored in memory, you can select either erasing all or erasing one. • Erasing the welding conditions (1) Turn off the power switch and turn on the power switch with both the LOAD key [16] and SAVE key [17] pressed.
  • Page 48 No. P10334 P. 47 / 69 10. OPERATION (continued) 10.3.5 Resetting to Initial Values When resetting to the welding conditions to initial values, the welding conditions that are currently used (including the welding condition currently used) are all reset to initial values. But, even when resetting to initial values, the welding conditions held in memory are not changed.

  • Page 49: Applied Function

    No. P10334 P. 48 / 69 11. APPLIED FUNCTION 11.1 How to Solve an Error WARNING Observe the following to prevent electrical shock. When touching charging parts, critical electric shock and burn may occur. ● Do not touch charging parts inside or outside the welding machine. ●...
  • Page 50 No. P10334 P. 49 / 69 11. APPLIED FUNCTION (continued) dAIHEn Display If “dAI” and “HEn” in the displays blink, it indicates the “Torch switch off state waiting“. When turning on the power switch, the displays on the front panel shows “dAI” and “Hen” for one second, then the welding power source becomes operable.
  • Page 51 No. P10334 P. 50 / 69 cooled torch, make sure that the TORCH lamp on the front panel is OFF (AIR). 11. APPLIED FUNCTION (continued) 7) E-600 Display If "E-“ and “600" in the displays blink, it indicates the "Replacement of batteries (warning)". This welding power source uses batteries so that it can hold the welding conditions in memory even when no operation is carried out for long time.

  • Page 52: Operation

    No. P10334 P. 51 / 69 11. APPLIED FUNCTION (continued) WARNING Observe the following to prevent electrical shock. ● Do not touch charging parts inside or outside the welding machine. ● Have a qualified electric engineer ground the case of the welding power source and the base metal or jig electrically connected, following a local law.

  • Page 53: Maintenance And Troubleshooting

    No. P10334 P. 56 / 69 11. MAINTENANCE AND TROUBLESHOOTING WARNING To avoid electric shock, follow the below instructions. ● Do not touch live electrical parts inside or outside the welding machine. ● Turn off all of the line disconnect switches before touching the parts inside the welding machine.
  • Page 54 No. P10334 P. 57 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.1 Carrying out Maintenance on the Welding Power Source (1) Periodical checking Periodically check the welding power source to ensure the safety of the equipment and the efficiency of work. •...
  • Page 55 No. P10334 P. 58 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.3 Insulation Resistance Test WARNING Observe the following to prevent an electrical shock. When touching charging parts, a critical electric shock and burn may occur. ● Have qualified operators or the persons familiar with this welding power source measure insulation resistance and test withstand voltage.

  • Page 56: Troubleshooting

    No. P10334 P. 59 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.5 Troubleshooting When an error code is displayed, refer to Section 11.1, “How to Solve an Error”. • Check the troubleshooting information listed below before contacting your dealer for service. Trouble Cause Solution...
  • Page 57 No. P10334 P. 60 / 69 between electrode The sound of The connectors on the high Check for proper and base metal. spark discharge frequency generating circuit insertion of the can not be heard. are not firmly inserted. connectors on PCB P10263X.
  • Page 58 No. P10334 P. 61 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) Trouble Cause Solution Electrode gets white. Polish electrode. When pressing When electrode the torch touches on the switch, high base metal, arc Electrode is too thick. Current Set to the proper frequency is is output.
  • Page 59 No. P10334 P. 62 / 69 "This page is intentionally left blank."...
  • Page 60 No. P10334 P. 61 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.6 Schematic Diagram...
  • Page 61 No. P10334 P. 62 / 69 12. MAINTENANCE AND TROUBLESHOOTING (continued) 12.7 Parts Layout SC1 - 4 P10327V00 Ⓒ Rear Side Chassis (Upper) Right Side Around DR DR2 - 5 P10263X00 Ⓒ Chassis (Lower) Right Side R1-4 R14,15 C2a,b C4,5 ⑩...

  • Page 62: Parts List

    No. P10334 P. 63 / 69 13. PARTS LIST • Please contact your dealer to order parts. (See the back cover for telephone and fax numbers, and mailing addresses.) Q’ty Symbol Part No. Description Specifications Remarks 4614-101 Circuit protector CB3-X0-10-072-42D-C 4519-022 Line filter CF3030C-DJ...
  • Page 63 No. P10334 P. 64 / 69 13. PARTS LIST (continued) Q’ty Symbol Part No. Description Specifications Remarks PCB1 P10332U00 Printed circuit board P10332U00 PCB2 P10263P00 Printed circuit board P10263P00 PCB3 P10263Q00 Printed circuit board P10263Q00 PCB4 P10327V00 Printed circuit board P10327V00 PCB5 P10332T00 Printed circuit board...

  • Page 64: Specifications

    No. P10334 P. 65 / 69 14. SPECIFICATIONS （1）Welding power source Model PoWer TIG 300 DC Pulse Specificaitons Model PoWer TIG 300 DC Pulse Number of phase Three Single STICK STICK Rated frequency 50 / 60 Hz Rated input voltage...
  • Page 65 No. P10334 P. 66 / 69 14. SPECIFICATIONS (continued) 14.2 External View...
  • Page 66 No. P10334 P. 67/ 69 14. SPECIFICATIONS (continued) [1] [14] [13] [10] ● Initial Values and Setting Range of Parameters Initial value Setting range J O B 0 – 20 seconds Pre-flow time 0.3 second ARNING MEMORY 4 – 250 A Single Initial current 10 A...
  • Page 67 No. P10334 P. 68 / 69 14. SPECIFICATIONS (continued) QUICK MANUAL Refer to Section 10.1, “Basic Settings”and Section 10.2, “Applied Settings”. Ⓒ Ⓒ Before Using the Welding Power Source Settings of Parameter Settings of Welding Method Presetting the Welding Conditions Press the LOAD key.

  • Page 68: Service And Support

    • Name • Telephone number • Product model • Manufacture year • Serial number • Software version number • Details of troubles · MODEL: PoWer TIG 300 DC Pulse · DATE: 20XX · SERIAL NO.: P10334YXXXXXXXXXXX P10263 Ver ###.###.000 K8174...

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