GYS TRIMIG 300-4S MIG or MAG Welding Machine Instruction Manual

GYS TRIMIG 300-4S MIG or MAG Welding Machine Instruction Manual

WARNING – SAFETY RULES

GENERAL INSTRUCTIONS

Read and understand the following safety recommendations before using or servicing the unit.
Any change or servicing that is not specified in the instruction manual must not be undertaken.

The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual.In the event of problems or uncertainty, please consult a qualified person to handle the inspection properly.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual.
The operator must respect the safety precautions that apply to this type of welding. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury.

This equipment must be used and stored in a place protected from dust, acid or any other corrosive agent. Operate the machine in an open, or well-ventilated area.

Operating temperature:
Use between -10 and +40°C (+14 and +104°F).
Store between -20 and +55°C (-4 and 131°F).
Air humidity:
Lower or equal to 50% at 40°C (104°F).
Lower or equal to 90% at 20°C (68°F).
Altitude:
Up to 1000 meters above sea level (3280 feet).

PROTECTION OF THE INDIVIDUALS

Arc welding can be dangerous and can cause serious and even fatal injuries.
Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device.
To protect oneself as well as the other, ensure the following safety precautions are taken:

In order to protect you from burns and radiations, wear clothing without cuffs. These clothes must be insulated, dry, fireproof and in good condition, and cover the whole body.

Wear protective gloves which guarantee electrical and thermal insulation.

Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/ operation). Protect the eyes during cleaning operations. Do not operate whilst wearing contact lenses.
It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatters and sparks.
Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective clothes.

Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any person in the welding area).

Stay away from moving parts (e.g. engine, fan…) with hands, hair, clothes etc…
Never remove the safety covers from the cooling unit when the machine is plugged in – The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions.

The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling unit must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns.
ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

WELDING FUMES AND GAS

The fumes, gases and dust produced during welding are hazardous. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gases away from the work area. An air fed helmet is recommended in cases of insufficient air supply in the workplace.
Check that the air intake is in compliance with safety standards

Care must be taken when welding in small areas, and the operator will need supervision from a safe distance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to decrease the work piece before welding.
Gas cylinders must be stored in an open or ventilated area. The cylinders must be in a vertical position secured to a support or trolley.
Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSIONS RISKS

Protect the entire welding area. Compressed gas containers and other inflammable material must be moved to a minimum safe distance of 11 meters.
A fire extinguisher must be readily available

Be careful of spatter and sparks, even through cracks. It can be the source of a fire or an explosion.
Keep people, flammable objects and containers under pressure at a safe distance.
Welding of sealed containers or closed pipes should not be undertaken, and if opened, the operator must remove any inflammable or explosive materials (oil, petrol, gas…).
Grinding operations should not be directed towards the device itself, the power supply or any flammable materials.

GAS BOTTLE

Gas leaking from the cylinder can lead to suffocation if present in high concentrations around the work area.
Transport must be done safely: Cylinders closed and product off. Always keep cylinders in an upright position securely chained to a fixed support or trolley.

Close the bottle after any welding operation. Be wary of temperature changes or exposure to sunlight.
Cylinders should be located away from areas where they may be struck or subjected to physical damage.
Always keep gas bottles at a safe distance from arc welding or cutting operations, and any source of heat, sparks or flames.

Be careful when opening the valve on the gas bottle, it is necessary to remove the tip of the valve and make sure the gas meets your welding requirements.

ELECTRIC SAFETY

The machine must be connected to an earthed electrical supply. Use the recommended fuse size.
An electrical discharge can directly or indirectly cause serious or deadly accidents .

Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit.
Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged.
Do not touch the torch or electrode holder and earth clamp at the same time.
Damaged cables and torches must be changed by a qualified and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions and welding cables). Always wear dry clothes in good condition, in order to be insulated from the electrical circuit. Wear insulating shoes, regardless of the environment in which you work in.

EMC CLASSIFICATION

 These Class A devices are not intended to be used on a residential site where the electric current is supplied by the public network, with a low voltage power supply. There may be potential difficulties in ensuring electromagnetic compatibility on these sites, because of the interferences, as well as radio frequencies.

This equipment complies with EN 61000-3-12, provided that the power of the short-circuit Ssc is equal to or greater than 3.9MVA at the interface between the machine and the mains power network. It is the responsibility of the installer or user of the equipment to ensure if necessary by consulting the operator of the mains electricity, that the equipment is only connected to a power supply where the power of short-circuit ssc is equal to or greater than 3.9 MVA.

This equipment complies with the CEI 61000-3-11 standard.

ELECTROMAGNETIC INTERFERENCE

The electric currents flowing through a conductor cause electrical and magnetic fields (EMF). The welding current generates an EMF field around the welding circuit and the welding equipment.

The EMF fields may disrupt some medical implants, such as pacemakers. Protection measures should be taken for people wearing medical implants.
For example, access restrictions for passers-by or an individual risk evaluation for the welders.

All welders should take the following precautions in order to minimise exposure to the electromagnetic fields (EMF) generated by the welding circuit::

• position the welding cables together – if possible, attach them;
  keep your head and torso as far as possible from the welding circuit;

• never enroll the cables around your body;

• never position your body between the welding cables. Hold both welding cables on the same side of your body;

• connect the earth clamp as close as possible to the area being welded;

• do not work too close to, do not lean and do not sit on the welding machine

• do not weld when you’re carrying the welding machine or its wire feeder.

 People wearing pacemakers are advised to consult their doctor before using this device.
Exposure to electromagnetic fields while welding may have other health effects which are not yet known.

RECOMMENDATIONS TO ASSES THE AREA AND WELDING INSTALLATION

Overview
The user is responsible for installing and using the arc welding equipment in accordance with the manufacturer’s instructions. If electromagnetic disturbances are detected, it is the responsibility of the user of the arc welding equipment to resolve the situation with the manufacturer’s technical assistance. In some cases, this remedial action may be as simple as earthing the welding circuit. In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by fitting input filters. In all cases, electromagnetic interferences must be reduced until they are no longer bothersome.

Welding area assessment

Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned.

In particular, it should consider the following:

• the presence of other power cables (power supply cables, telephone cables, command cable,  tc…)above, below and on the sides of the arc welding machine.

• television transmitters and receivers ;

• computers and other hardware;

• critical safety equipment such as industrial machine protections;

• the health and safety of the people in the area such as people with pacemakers or hearing aids;

• calibration and measuring equipment

• The isolation of the equipment from other machinery.
  The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This may require extra precautions;

• make sure of the exact hour when the welding and/or other operations will take place.

The surface of the area to be considered around the device depends on the the building’s structure and other activities that take place there. The area taken in consideration can be larger than the limits determined by the companies.

Welding area assessment
Besides the welding area, the assessment of the arc welding systems intallation itself can be used to identify and resolve cases of disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION

National power grid: The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the filtering of the power suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source.

Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine maintenance check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on.. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.

Welding cables: Cables must be as short as possible, close to each other and close to the ground, if not on the ground.
Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

Do not use the cables or torch to move the machine. The welding equipment must be moved in an upright position. Do not place/carry the unit over people or objects.Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item. The removal of the wire reel from the machine is recommended before undertaking any lifting operation.

Stray welding currents/voltages may destroy earth conductors, damage electrical equipment or cause components to warm up which may cause a fire.

• All welding connections must be firmly secured, check regularly !
• Check that the metal piece fixation is strong and without any electrical problems !
• Attach or hang all the electrically conductive elements,such as the trolley in order to insulate them
• Do not place any electrical equipment such as drills on top of the welding machine without insulating them !
• Always place welding torches or electrodes holders on an insulated surface when they’re not in use !

EQUIPMENT INSTALLATION

• Put the machine on the floor (maximum incline of 10°.)
• Ensure the work area has sufficient ventillation for welding, and that there is easy access to the control panel.
• The machine must not be used in an area with conductive metal dusts.
• The machine must be placed in a sheltered area away from rain or direct sunlight.
• The machine protection level is IP21, which means :
  • Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and,
  • Protection against vertically falling drops. The power cables, extensions and welding cables must be fully uncoiled to prevent overheating.

The manufacturer does not incur any responsability 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 machine is unplugged from the mains, and wait for two minutes before carrying out maintenance work. DANGER High Voltage and Currents inside the machine.
• Remove the casing 2 or 3 times a year to remove any excess dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufacturer, its after sales service or an equally qualified person.
• Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.
• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

INSTALLATION – PRODUCT OPERATION

It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings.

DESCRIPTION

The Trimig are «synergic» semi-automatic welding units on wheels, ventilated for welding (MIG or MAG). They are recommended to weld steel, stainless steel and aluminium. Their adjustment is quick and easy with their « synergic wire speed » function. They work on 3-phase 400V

POWER SUPPLY

The welders are fitted with a 16A socket type EN 60309-1 which must be connected to a three-phase 400V (50 – 60 Hz) with four wires and one earthed neutral.
The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current required by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings. The device must be positioned so that the socket is always accessible. Do not use an extension leads with a section below 4mm².
These products are supplied with a 16A plug type CEE 7/7. The Trimig msut be connected to a 3-phase 400V socket. WITH earth protected by a 16A circuit- breaker and a 30mA differential.

DEVICE PRESENTATION (FIG-II / 46)

1. On-Off switch
2. Voltage adjustment switch(please refer to page 3) – Welding parameter keyboard (manual or automatic mode)
3. Welding parameters keyboard (manual or automatic mode).
4. European standard torch connection.
5. Thermal protection light: Signals a thermal break following intensive use (machine will stop for several minutes) .
6. Front torch support.
7. Power supply cable.
8. Earth cable connection.
9. Gas bottle support
10. Fastening chain for bottles. Warning: fasten the bottles securely. cf.FIG- IV-1
11. Reel support Ø200mm/300mm.
12. Gas input 1.
13. Rear torch cable support.
14. Polarity resversal cable

SEMI-AUTOMATIC FOR STEEL/STAINLESS STEEL (MAG MODE) (FIG III)

The Trimig 300-4S can weld Ø0.8/1 and 1.2 steel and stainless steel wire. The product is supplied ready to weld with Ø1mm steel wire (roller Ø 1/1.2 ref. 046849). For Steel or Stainless Steel, you will need to use a specific welding gas: Argon + CO2 (Ar + CO2). The proportion of CO2 will vary depending on usage. For the specific requirements, seek advice from your gas distributor. The gas flow in steel is between10 and 20L / min depending on the environment and experience of the welder.

SEMI-AUTOMATIC WELDING FOR ALUMINIUM

The Trimig 300-4S can weld Ø1.0/1.2 aluminium wire. (FIG-III-B) To weld aluminium, neutral gas “pure argon” (AR) is required. For specific requirements, seek advice from your gas distributor. The gas flow in aluminium should be between 15 and 25 L / min depending on the environment and experience of the welder. Below, find the differences between steel welding and aluminium welding:

• The rollers pressure on the wire: put a minimum pressure in order not to flatten the wire.
• Capillary tube : remove the capillary tube before connecting the aluminium torch with a teflon torch liner.
• Torch : use an aluminium torch. This torch has a teflon torch liner in order to reduce frictions.
• DO NOT cut the sheath This torch liner guide the wire from the rollers. (FIG-III-B)
• Contact tip : use a SPECIAL aluminium contact tip which matches the wire diameter.
• Rollers Ø 1,0/1,2 : ref. 040915.

« NO GAS » WELDING

The Trimig 300-4S can weld « No Gas » by performing a polairty reversal (FIG VIII – maximum tightening torque of 5 Nm). Welding flux cored wire with a standard nozzle can cause overheating and damage the torch. Remove the standard nozzle (FIG-VII).

• Rollers Ø 0,9/1,2 : ref. 042407.

PROCESS OF REELS AND TORCHES ASSEMBLY (FIG IV / 47)

Open the door of the machine.

• Place the reel on the driving pin (3) of the reel support. To install a 200mm wire reel, fit an adaptor on the support (ref. 042889).
  • Adjust the reel brake (4) to avoid the reel inertia tangling the wire when welding stops. In general, do not tighten too much! Tighten the fixing screw (2).
• The electrical rollers (8) are double groove rollers (Ø 0.8/ Ø 1 or Ø 1/ Ø 1.2). The indication on the visible side of the roller is the diameter in use. For a Ø1 mm wire, use the Ø1 groove. • For the first use :
  • Release the fixing screw which guides the wire (5)
  • Put the rollers, then tighten the screw retainer (9).
  • put the wire guide in place (7) as close as possible to the roller with no contact, then tighten the fixing screw.
• To set the adjusting knob of the pressing rollers (6), proceed as follow:  Loosen the knob fully, start the motor by pressing the torch trigger, tightenthe adjustment knob whilst pressing the trigger. Bend the wire where it comes out of the nozzle. Put a finger on the bended wire to prevent any movement. The setting is correct when the guide roller slides over the wire even when it is blocked at the end of the torch.
• A common adjustment is the rollers command (6) on the scale 3-4 for steel and 2-3 for aluminium.

CHOICE OF REELS

Possible settings :

steel

| Ø 300| 15| 0.6 / 0.8 / 1.0 / 1.2| x|

argon

+ CO2

Ø 200| 5| 0.6 / 0.8 / 1.0| x
stainless steel| Ø 200| 5| 0.8| x
Alu

AG5

| Ø 300| 7| 1.0 / 1.2| x*|

Pure argon

Ø 200| 2| 0.8 / 1.0 / 1.2| x*

*Make sure to have a teflon torch liner/contact tip for alu. Remove the capillary tube.

GAS CONNECTION

Connect the manometer (flowmeter) to the gas bottle if needed, then connect the gos hose to the gas connector. To prevent gas leaks, use the hose clips supplied in the accessories box. Make sure the gas bottle hold in place respecting chain fastening cf. FIG-IV-1 Maximum gas pressure 0.5MPA (5 bars

COMMAND KEYBOARD (FIG-V)

Choice of the welding mode (2)

• NORMAL (2T) : standard welding 2T
• NORMAL (4T) : standard welding 4T
• DELAY : « chain stitch » function, with spot delay setting
• SPOT : spot function, with adjustment of the spot diameter Wire speed adjustment potentiometer. The speed varies from 1 to 15m/ minute

SPOT/DELAY potentiometer (5) Manual mode (1) In manual mode, the wire speed is determinated by the user

ting the potentiometer (4).  Synergic mode (3) Set the potentiometer (4) in the middle of the « OPTIMAL SYNERGIC » zone. In this mode, the device determines the optimal wire speed according to 3 parameters:

• Voltage
  Wire diameter

• Wire type

It is possible to adjust the wire speed +/- with the potentiometer (4).

«MANUAL» MODE (FIG-V)

To set your device, proceed as follow:

• Choose the welding voltage using the 7-10 or 12 positions switch (depending on the product)

  • Example:
    To weld 1 mm thick steel, set the switch to 1

• Adjust the wire speed with the potentiometer(4).

Recommendations:

The wire speed adjustment is often determined « with the assistance of sound »: the arc must be stable and have a low crackling. If the speed is too low, the arc is not continuous. If the speed is too high, the arc crackles and the wire pushes back the torch.

«SYNERGIC» MODE (FIG-V)

With this function, no need to adjust the wire speed anymore.

• Set the wire speed potentiometer (4) in the middle of the« Optimal synergic » zone.
•  Select:
  • The wire type (3)
  • The wire diameter (3)

Then to select the right position in accordance with the thickness of the workpiece, please refer to the table «Synergic mode» fig. VI. From this combination, the device determines the optimal wire speed and the device is ready to weld. It is also possible to adjust the wire speed if necessary by adjusting the potentiometer (4) + or – manually. Settings are saved and loaded each time the user switches the machine back on.

RISK OF BLESSING RELATED TO MOBILE COMPONENTS

The wire feeders contain moving parts that may catch hand, hair, clothes or tools which can lead to injuries! Take extra care.

• Do not place your hand on mobile/pivoting/wire feeding parts of the machine!
• Make sure that all panels remain closed when in use !

Do not wear gloves when setting up the wire and changing the wire reel.

RECOMMENDATIONS AND THERMAL PROTECTION

• Ensure the air intakes of the device are not blocked to allow adequate air circulation.
• Leave the device plugged after welding to allow its cooling.
• Thermal protection: The light turns on and the cooling duration is a couple of minute according to the area temperature

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