GYS SMARTFEED M-4 Robotic Wire Feeder User Manual

GYS SMARTFEED M-4 Robotic Wire Feeder

GENERAL INSTRUCTIONS

These instructions must be read and fully understood before use.
Do not carry out any alterations or maintenance work that is not directly specified in this manual.

The manufacturer shall not be liable for any damage to persons or property resulting from use not in accordance with the instructions in this manual. In the event of problems or uncertainties, please consult a qualified person to handle the installation properly. Read the welding machine’s instruction manual before using the wire feeder.

ENVIRONMENT

This equipment should only be used for welding operations performed within the limits indicated on the information panel and/or in this manual. These safety guidelines must be observed. The manufacturer cannot be held responsible in the event of improper or dangerous use.
The equipment must be operated and stored in a location that is free of dust, acid, flammable gases or any other corrosive substances. Operate the machine in an open, or well-ventilated area.
Temperature range:

• Use between -10 and +40°C (+14 and +104°F).
• Store between -20 and +55°C (-4 and 131°F).

Air humidity:

• Lower than or equal to 50% at 40°C (104°F).
• Lower than or equal to 90% at 20°C (68°F).

Altitude:
Up to 1,000 m above sea level (3280 feet).

PROTECTING YOURSELF AND OTHERS

Arc welding can be dangerous and cause serious injury or death.
Welding exposes people to a dangerous source of heat, light radiation from the arc, electromagnetic fields (caution to those using pacemakers) and risk of electrocution, as well as noise and fumes.
To protect yourself and others, please observe the following safety instructions:

• To protect yourself from burns and radiation, wear insulating, dry and fireproof clothing without lapels. Ensure the clothing is in good condition and that covers the whole body.

• Wear protective gloves which provide electrical and thermal insulation.

• Use welding protection and/or a welding helmet with a sufficient level of protection (depending on the specific use). Protect your eyes during cleaning procedures. Contact lenses are specifically forbidden.

• It may be necessary to section off the welding area with fireproof curtains to protect the area from arc radiation and hot spatter. Inform people in the welding area not to stare at the arc rays or molten parts and to wear appropriate clothing for protection.

• Wear noise protection headphones if the welding process becomes louder than the permissible limit (this is also applicable to anyone else in the welding area).

• Keep hands, hair and clothing away from moving parts (the ventilation fan, for example).
  Never remove the cooling unit housing protections when the welding power source is live, the manufacturer cannot be held responsible inthe event of an accident.

• Newly welded parts are hot and can cause burns when handled. When maintenance work is carried out on the torch or electrode holder, ensure that it is sufficiently cold by waiting at least 10 minutes before carrying out any work. The cooling unit must be switched on when using a water-cooled torch to ensure that the liquid cannot cause burns. It is important to secure the working area before leaving it, in order to protect people and property.

WELDING FUMES AND GAS

The fumes, gases and dusts emitted by welding are harmful to health. Sufficient ventilation must be provided and an additional air supply may be required. An air-fed mask could be a solution in situations where there is inadequate ventilation.
Check the extraction system’s performance against the relevant safety standards.

Caution: Welding in confined spaces requires safety monitoring from a safe distance. In addition, the welding of certain materials containing lead, cadmium, zinc, mercury or even beryllium can be particularly harmful. Remove any grease from the parts before welding.
Cylinders should be stored in open or well-ventilated areas. They should be stored in an upright position and kept on a stand or trolley.
Welding should not be carried out near grease or paint.

RISK OF FIRES AND EXPLOSIONS

Fully shield the welding area, flammable materials should be kept at least 11 metres away.
Fire fighting equipment should be kept close to wherever the welding activities are being undertaken.

Beware the expulsion of hot spatter or sparks, even through cracks, which can cause fires or explosions.
Keep people, flammable objects and pressurised containers at a safe distance.
Welding in closed containers or tubes is to be avoided. If the containers or tubes are open, they must be emptied of all flammable or explosive materials (oil, fuel, gas residues, etc.).
Grinding work must not be directed towards the source of the welding current or towards any flammable materials.

GAS CYLINDERS

Gas escaping from cylinders can cause suffocation if there is too high a concentration of it in the welding area (ensure good ventilation).
The machine must be transported in complete safety: gas cylinders must be closed and the welding power source turned off. They should be stored upright and supported to limit the risk of falling.

Close the cylinder between uses. Beware of temperature variations and exposure to the sun.
The cylinder must not come into contact with flames, arcs, torches, earth clamps or any other sources of heat or ignition.
Be sure to keep it away from electrical and welding circuits. Never weld a pressurised cylinder.
When opening the cylinder valve, keep your head away from the valve and ensure that the gas being used is suitable for the welding process.

ELECTRICAL SAFETY

The electrical network used must be earthed. Use the recommended fuse size from the rating plate. An electric shock can be the source of a serious accident, whether directly or indirectly, or even death.

Never touch live parts connected to the live current, either inside or outside the power source casing unit (torches, clamps, cables, electrodes), as these items are connected to the welding circuit.
Before opening the welding machine’s power source, disconnect it from the mains and wait two minutes to ensure that all the capacitors have fully discharged.
Do not touch the torch or the electrode holder and the earth clamp at the same time.
If the cables or torches become damaged, they must be replaced by a qualified and authorised person.
Measure the cable cross-section according to the intended application. Always use dry and in-fact clothing to insulate yourself from the welding circuit. Alongside this, wear well-insulated footwear in all working environments.

INSTALLATION OF THE REEL AND LOADING OF THE WIRE

Isolation of the welder at the arc in relation to the welding voltage !
Not all the different parts involved in the welding current can be protected against direct human contact. The welder must therefore avoid the risks by following the relevant safety regulations. Even a contact at low current may take the operator by surprise and cause an incident.

• Wear dry and intact protective equipment (shoes with rubber soles/baked welder’s protective gloves without rivets or staples)!
• Avoid direct contact with non-insulated or connecting sockets!
• Always place the welding torch or electrode holder on an insulated support!

Risk of burning at the welding power connection!
If the connectors are not safely locked in place, the connectors and the cables can become hot and cause burns !
Check the welding connectors daily and lock them in place if needed by turning them to the right.

Risk of electrocution !
If the weld is performed using different processes while the torch and the electrode holder are connected to material, a no-load voltage or welding voltage is applied to the circuits !
At the beginning of a job and during interruptions, always isolate the torch and the electrode holder !

ELECTRO-MAGNETIC EMISSIONS

An electric current passing through any conductor produces localised electric and magnetic fields (EMF). The welding current produces an electromagnetic field around the welding circuit and the welding equipment.

Electromagnetic fields (EMFs) can interfere with some medical devices, for example pacemakers. Protective measures must be taken for people with medical implants. For example, restricted access for onlookers or an individual risk assessment for welders.
All welders should use the following guidelines to minimise exposure to the welding circuit’s electromagnetic fields:

• position the welding cables together – securing them with a clamp if possible;
• position yourself (head and body) as far away from the welding circuit as possible;
• never wrap the welding cables around your body;
• do not position yourself between the welding cables. and keep both welding cables on your same side;
• connect the return cable to the workpiece, as close as possible to the area to be welded,
• do not work next to, sit on, or lean against the source of the welding current;
• do not weld while the current source or wire feeder is being carried.
• Pacemaker users should consult a doctor before using this equipment.
  Exposure to electromagnetic fields during welding may have other health effects that are not yet known.

TRANSPORT AND TRANSIT OF THE WIRE FEEDER

Stray welding currents can destroy earthing conductors, damage electrical equipment and devices and cause component parts to overheat leading to fires.

• All welding connections must be firmly secured and regularly checked!
• Make sure that the item’s attachment is firm and secure, without any electrical problems!
• Join together or suspend any electrically conductive parts of the welding source such as the frame, trolley and lifting systems so that they are insulated!
• Do not place other equipment such as drills or grinding devices etc. on the welding source, trolley, or lifting systems unless they are insulated!
• Always place welding torches or electrode holders on an insulated surface when not in use!

SETTING UP THE EQUIPMENT

• Put the wire feeder on a floor with a maximum incline of 10°.
• The dispenser must be protected from driving rain and not exposed to sunlight.
• The machine benefits from an IP21 protection index, which means:
• its dangerous parts are protected from being entered by objects greater than 12.5 mm and,
• Protection against vertically falling drops
  This machine is designed for indoor use.
  The power cables, extensions and welding cables must be fully uncoiled to prevent overheating.
  GYS does not incur any responsibility regarding damages to both objects and persons that result from an incorrect and/or dangerous use of the machine.

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
• Ensure the wire feeder is disconnected from the welding machine, and wait for two minutes before carrying out maintenance work.
• Regularly remove the cover and blow out any dust. Take this opportunity to have the electrical connections checked by a qualified person, using an insulated tool.
• Regularly check the condition of the connection cable between the wire feeder and the machine. If found damaged, the interconnection cable must be replaced.
• Warning ! If the welding machine is transported/handled by another solution than the one recommended by the manufacturer; the wire feeder casing must be insulated from the transporting/handling solution.
  Rules to follow :• The wire feeder must be switched on with all access panels closed.

INSTALLATION – USING THE PRODUCT
Only experienced personnel, authorised by the manufacturer, may carry out the machine’s set-up. During set-up, ensure that the power source is unplugged from the mains. It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings.

DESCRIPTION OF THE EQUIPMENT (I)

1. Euro connector
2. Power relay connector
3. Air outlet connector
4. Collision sensor connector (M-4) 24- pin connector for Push-Pull torch and collision sensor (MB-PP)
5. Optional input/output connectors
6. Connector for the welding power source
7. Connector for wire end sensor
8. Air inlet connector
9. Gas inlet connector
10. Manual motor control (wire inching)
11. Manual motor control (wire retraction)
12. Manual gas valve control (purge)
13. Manual air valve control (cleaning)
14. Access panel for wire connector fitting
15. Power supply indication LED
16. Wire-feed motor

PRODUCT OVERVIEW

The SMARTFEED robotic wire feeders (M-4 and MB-PP) have been designed to work exclusively with GYS power sources from the NEOPULSE range:

• NEOPULSE 500 G (ref. 014503)

• NEOPULSE 400 G (ref. 014497)

• NEOPULSE 400 CW (ref. 062061)

• NEOPULSE 320 C (ref. 062474)
  + remote HMI option available (ref. 062122)

• The SMARTFEED M-4 is equipped with a 115W DC motor.

• The SMARTFEED MB-PP wire feeder is equipped with a 100W BRUSHLESS motor.

• The connection between the power source (NEOPULSE) and the wire feeder (SMARTFEED) is made via a dedicated interconnection cable. These wire feeders can be used with both manual and robotic MIG-MAG torches.

• The SMARTFEED MB-PP wire feeder is compatible with Push-Pull robotic torches (see specifications on the following pages).

PRECAUTIONS

Make sure the main welding power source switched off when connecting or disconnecting the wire feeder.

WIRE LOADING

• To change the rollers, do the following:

  • Loosen the knobs (a) to the maximum and lower them.

  • Unlock the rollers by turning the retaining rings (b) by a quarter turn.

  • Fit the correct drive rollers for your use and lock the retaining rings in place. The rollers supplied are double steel groove rollers (1.0 and 1.2).

  • Check the inscription on the roller to ensure that the rollers are suitable for the wire diameter and the wire material (for a Ø 1.2 wire, use the Ø 1.2 groove).

  • Use V-grooved rollers for steel and other hard wires.

  • Use U-grooved rollers for aluminium and other soft, alloyed wires.

  • : visible inscription on the roller (example: 1.2 VT)

  • : groove to be used

• To install the wire, follow the steps below:

  • Loosen the dials to the maximum and lower them.
  • Insert the wire, then close the motor reel and tighten the dials as shown.
  • Activate the motor by pressing the manual wire inching button (I-10).

CONNECTOR SPECIFICATION FOR WIRE-END SENSOR

SMARTFEEDs are equipped with a connector for a wire end sensor on the rear panel (I-7). The plug is an M8 / 3-pole connector.
Voltage: 24 VDC
Max current: 250mA

CONNECTOR SPECIFICATION FOR COLLISION SENSOR

SMARTFEED M-4 :
The SMARTFEED M-4 is equipped with a collision sensor connector on the front panel (I-4). The plug is an M8 / 3-pole connector.
Voltage: 24 VDC
Max current: 250mA

SMARTFEED MB-PP :
The SMARTFEED MB-PP is equipped with a collision sensor connector on the front panel (I-4). The connector is a 24-pin plug.
The collision input operates on 24V.

Collision sensor

(dry contact between 24 Vdc and signal)

14| 24 VDC
15| Collision or Signal

TORCH COMPATIBILITY

• The SMARTFEED M-4 is compatible with all standard robotic torches (excluding Push-Pull) with a EURO connection.
• The SMARTFEED MB-PP can accommodate 3 types of torches:
  • Standard robotic torches without Push-Pull (EURO connection), all brands.
  • Push-Pull DC robotic torches (EURO connection / max. permissible voltage 42V / without encoder), all brands.
  • Push-Pull BRUSHLESS robotic torches (EURO connection / max voltage 42V / 500pts encoder).
  • Compatible with the BINZEL MPP OA PUSH PULL torch.
  • Other brands or references, please consult us before use.
• The configuration of the torch type can be done in 2 different ways (see the following pages):
  • Changing the configuration of a DIP SWITCH on the circuit board (requires opening the product, see page 59-60).
  • Pin grounding in the torch connector during wiring by the customer.

TORCH TYPE CONFIGURATION AND TORCH WIRING

WIRING OF THE TORCH

Pin| Name| Function

BRUSHLESS                                                    DC

---|---|---
 |
1| Phase 3| Phase 3 (motor supply)|
2| Phase 2| Phase 2 (motor supply)| (-) Motor (motor supply)
3| Phase 1| Phase 1 (motor supply)| (+) Motor (motor supply)
4| GND| ****

Hall Effect Sensor

5| 5Vdc
6| HALL_A
7| HALL_B
8| HALL_C
9| GND| ****

Encoder

500pts

10| 5Vdc
11| A
12| B
13| GND| Collision sensor

Dry contact between 24vdc and collision signal

14| 24Vdc
15| Collision signal
16| Reverse signal Wire| Dry contact between GND and Reverse wire signal
17| Advance signal Wire| Dry contact between GND and wire feed signal
18| Signal EV GAZ| Dry contact between GND and EV GAZ signal
19| GND| ****

Torch selection

20| 10Vdc
21| IN 4
22| Detect_PP
23| Type_Mot
24| Signal EV AIR| Dry contact between GND and EV AIR signal

DETERMINING THE FEEDER NUMBER

SMARTFEED wire feeders can be configured in «MASTER» or «SLAVE» mode.
In the case of two feeders, feeder no. 1 will be «MASTER» and feeder no. 2 will be «SLAVE». The configuration is done via a DIP SWITCH (requires opening the product, see page 61-62).

If the configuration is not followed, the display of the HMI will show the following error.

OPTIONAL CONNECTIVITY

The SMARTFEED M-4 / MB-PP wire feeders are equipped with a hatch on the front panel (I-5) that provides access to a 10-pin connector. This connector allows the user to have additional inputs/outputs for automation functions.

The outputs are to be connected between terminals 1 to 5 and are arranged as follows:

• Terminal 1: 24 VDC power supply common to all outputs
• Terminal 2: Output no. 1
• Terminal 3: Output no. 2
• Terminal 4: Output no. 3
• Terminal 5: Output no. 4

The inputs are to be connected on terminals 6 to 10 and are arranged as follows:

• Terminal 6: Input no. 1 24VDC
• Terminal 7: Input no. 2 24VDC
• Terminal 8: Input no. 3 24VDC
• Terminal 9: Input no. 4 24VDC
• Terminal 10 : Ground 0 VDC common to all inputs
  It is recommended to make the connection between the safety module and terminal block using a shielded cable. Maximum wire cross-section will be 28-16AWG – 1.5mm².

Summary and technical characteristics of inputs and outputs

Type of insulation

| Contact SEC 24V DC 1 – 24VDC

2-5 – DO1 – DO4 (NO)

| Photocoupler insulation 500 VDC 6-9 – DI1 – DI4 (NO)

10 – Ground (0V)

ON Voltage Vmin/Vmax| +20V to +30 V| 15VDC – 28VDC
OFF Voltage Vmin/Vmax|  | 0VDC – 5 VDC
Input impédance|  | 800 KOhm
Rated current at +24 V| Max 2A| 10 mA

RISK OF INJURY FROM MOVING COMPONENTS

The motorised wire-feed rollers have moving parts that can catch on hands, hair, clothing or tools and may result in injuries!

• Do not touch pivoting or mobile parts or parts used for the feeding parts !
• Ensure that the housing covers or protective covers remain fully closed when in operation.
• Do not wear gloves when threading the filler wire or changing the filler-wire’s spool.

WARRANTY CONDITIONS

The warranty covers any defects or manufacturing faults for two years from the date of purchase (parts and labour). The warranty does not cover:

• Any other damage caused during transport.
• The general wear and tear of parts (i.e. : cables, clamps, etc.).
• Incidents caused by misuse (incorrect power supply, dropping or dismantling).
• Environment-related faults (such as pollution, rust and dust).
• In the event of a breakdown, please return the appliance to your distributor, along with:
  • a dated proof of purchase (receipt or invoice etc.). a note explaining the malfunction.
  • A description of the fault reported
  • une note explicative de la panne.

CONTROL CIRCUIT

CIRCUIT DIAGRAM

TECHNICAL SPECIFICATIONS

U11 = 48 V – 2 A U12 = 24 V – 1 A

Motor speed| 1  25 m/min

(39  984 IPM)

Motor power| 115 W| 100 W
Torch connector| EURO
 |  |  | Acier / Steel| ø 0.6  1.6 mm

(.023  .039”)

 |  |  | Inox / Stainless steel| ø 0.6  1.6 mm

(.023  .039”)

Supported wires|  | ****

Aluminium

| ø 0.8  1.6 mm

(.031  .039”)

 |  |  | CuSi / CuAl| ø 0.8  1.2 mm

(.031  .047”)

 |  |  | Flux Cored Wire| ø 0.9  2.4 mm

(.035  .094”)

Facteur de marche à 40°C (10 min)*

Norme EN60974-1.

Duty cycle at 40°C (10 min)*

Standard EN60974-1. Einschaltdauer @ 40°C (10 min)* EN60974-1 -Norm.

ПВ% при 40°C (10 мин)* Норма EN60974-1.

| Inschakelduur bij 40°C (10 min)*

Norm EN60974-1.

Ciclo di lavoro a 40°C (10 min)*

Norma EN60974-1.

40摄氏度时候的暂载率

（10分钟）

标准EN60974-1

|  | 60%| 500 A
 | ****

100%

| ****

460 A

Maximum gas pressure (Pmax)| 5 bar

(0.5 MPa)

Drive roller type| F|
Functionning temperature| -10°C  +40°C (14°F  +104°F)
Storage temperature| -20°C  +55°C (-4°F  +131°F)
Protection level| IP21
Dimensions (LxWxH)| 244 x 207 x 152 mm

(9.6 x 8.15 x 5.98”)

/ Weight|  |  | 4.5 kg

(9.92 lb)

SYMBOLS

• Warning ! Read the user manual before use.
• Direct welding current
• Rated welding current(s) at 100% and/or 60% duty cycle.
• Amperes
• Volt
• Rated input voltage(s).
• Rated input current(s) at maximum load.
• Device complies with europeans directives, The EU declaration of conformity is available on our website (see cover page).
• Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
• Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website (see cover page).
• This product is compliant with standard EN 60974-5.
• This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin !
• This product should be recycled appropriately
• EAEC Conformity marking (Eurasian Economic Community).
• Remote control
• Wire unwinding
• Cooling liquid input.
• Cooling liquid output.
• Gas input
• Gas output
• Warning, hot surface

GYS SAS
1, rue de la Croix des Landes CS 54159
53941 SAINT-BERTHEVIN Cedex France

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