GYSARC 80 Welding Machine Instruction Manual

80 Welding Machine
**Instruction Manual

GYSARC 80 / 100 / 120 / 160 / 200
MMA (Arc) welding machine
C51369 _V12_16/01/2023
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manuals on our website
www.gys.fr
**

WARNING – SAFETY RULES

GENERAL INSTRUCTIONS

Read and understand the following safety instructions before use.
Any modification and maintenance not specified in the instructions manual should 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 uncertainties, please consult a qualified person to handle the installation 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. Safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held liable.
This equipment must be used and stored in a room free from dust, acid, flammable gas 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).
Storage 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).

INDIVIDUAL PROTECTION AND PROTECTION FOR OTHERS

Arc welding can be dangerous and can cause serious injury or even death.
Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, risk of electric shock, noise and gas fumes. People wearing pacemakers are advised to consult a doctor before using the welding machine.
To protect oneself as well otherS, ensure the following safety precautions are taken:

In order to protect yourself from burns and radiation, wear clothing without turn-up or cuffs. These clothes must be insulated, dry, fireproof, in good condition and cover the whole body.
Wear protective gloves to guarantee electrical and thermal insulation.
Wear sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Contact lenses are prohibited during use.
It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatter 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).
Keep hands, hair and clothes away from moving parts such as fans, and engines.
Never remove the safety covers from the cooling unit when the machine is plugged in. The manufacturer is not liable for any injury or damage caused due to non-compliance with the safety precautions.”
Parts that have previously been welded will be hot and may cause burns if 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.
When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns that could potentially be caused by the liquid.
It is important to secure the working area before leaving to ensure the protection of property and the safety of others.

WELDING FUMES AND GAS

Fumes, gas and dust produced during welding are hazardous to health. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gas away from the work area. Using an air fed welding helmet is recommended in case of insufficient ventilation in the workplace. Check that the air supply is effective by referring to the recommended safety regulations. Precautions 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 degrease the workpiece before welding. Gas cylinders must be stored in an open or ventilated area. They must be stored vertically and held by a support or trolley to limit the risk of falling. Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION HAZARDS

Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters.
A fire extinguisher must be readily available near the welding operations.
Be careful of weld spatter and sparks, even through cracks. If not careful then this could potentially lead to a fire or an explosion.
Keep people, flammable materials/objects and containers that are under pressure at a safe distance.
Welding in closed containers or pipes should be avoided and , if they are opened, they must be emptied of any flammable or explosive material (oil, fuel, gas …).
Grinding operations should not be carried out close to the power supply or any flammable materials.

GAS CYLINDERS

Gas leaking from the cylinders can lead to suffocation if present in high concentration around the work area (ventilation required).
Transport must be done safely: cylinders closed and welding machine switched off. They must be stored vertically and held by a support to limit the risk of falling.
Close the cylinder between two uses. Beware of temperature variations and sun exposure.
The cylinder must not be in contact with a flame, electric arc, torch, earth clamp or all other sources of heat.
Always keep gas cylinders away from electrical circuits, and therefore never weld a cylinder under pressure.
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.

ELECTRICAL SAFETY

The electrical mains used must have an earth terminal. Use the recommended fuse size.
An electric shock could cause serious injuries or potentially even 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 the 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 which are in good condition in order to be isolated from the welding circuit. Wear insulated shoes, regardless of the workplace/environment in which you work in.

EMC CLASSIFICATION

This Class A machine is not intended to be used on a residential site where the electric current is supplied by the domestic low-voltage power grid. There may be potential difficulties in ensuring electromagnetic compatibility at these sites, due to conducted interferences as well as radiation.
GYSARC 80 / 100 / 120: This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage systems interfacing with the public power grid only at the medium- or high-voltage level. If it is connected to a public low-voltage power grid, the installer or user of the machine has to ensure, by checking with the network operator, that the device can be connected.
GYSARC 160 / 200: This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage systems interfacing with the public supply only at the medium- or high-voltage level. On a public low- voltage power grid, it is the responsibility of the installer or user of the device to ensure, by checking with the operator of the distribution network, which device can be connected.
GYSARC 80 / 100/120: This equipment complies with the IEC 61000-3-11 standard.
GYSARC 160 : Provided that the impedance of the low-voltage public electrical network at the common coupling point is less than Zmax = 0.427 Ohms, this equipment complies with IEC 61000-3-11 and can be connected to public low- voltage electrical mains. It is the responsibility of the installer or user of the equipment to ensure, in consultation with the distribution netwtork operator if necessary, that the network impedance complies with the impedance restrictions.
GYSARC 200: Provided that the impedance of the low-voltage public electrical network at the common coupling point is less than Zmax = 0.270 Ohms, this equipment complies with IEC 61000-3-11 and can be connected to public low- voltage electrical mains. It is the responsibility of the installer or user of the equipment to ensure, in consultation with the distribution netwtork operator if necessary, that the network impedance complies with the impedance restrictions.

ELECTROMAGNETIC EMISSIONS

The electric current flowing through any conductor causes electrical and magnetic fields (EMF). The welding current generates an EMF around the welding circuit and the welding equipment.
The EMF electromagnetic fields can interfere with certain medical implants, such as pacemakers. Protection measures must be taken for people with medical implants. For example, by restricting access to passers-by or conducting 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 wrap 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, 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 identified.

RECOMMENDATIONS TO ASSESS THE WELDING AREA AND WELDING INSTALLATION
Overview
The user is responsible for the installation and use of the arc welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, the user is responsible for resolving the situation with the manufacturer’s technical assistance. In some cases, this corrective 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 inconvenient.
Welding area assessment
Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the areawhere the installation is planned. The following elements should be taken into account:
a) the presence (above, below and next to the arc welding machine) of other power cables, remote cables and telephone cables;
b) television transmitters and receivers;
c) computers and other hardware;
d) critical safety equipment such as industrial machine protections;
e) the health and safety of the people in the area such as people with pacemakers or hearing aids;
f) calibration and measuring equipment;
g) the isolation of other pieces of equipment which are in the same area.
The user has to ensure that the devices and pieces of equipment used in the same area are compatible with each other.
This may require extra precautions;
h) the time of day during the welding or other activities have to be performed.
The surface of the area to be considered around the device depends on the building’s structure and other activities that take place there. The area taken into consideration can be larger than the limits of the installations.
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
a. National power grid: the arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. In case of interferences, it may be necessary to take additional precautions such as the filtering of the power supply network. Consideration should be given to shielding the power supply cable in a metal conduit or equivalent of permanently installed arc welding equipment. It is necessary to ensure the electrical continuity of the shielding along its 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.
b. Maintenance of the arc welding equipment: The arc welding machine should be subject to a routine maintenance check according to the recommendations of the manufacturer. 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.
c. Welding cables: Cables must be as short as possible, close to each other and close to the ground, if not on the ground.
d. Equipotential bonding: consideration should be given to bonding all metal objects in the surrounding area.
However, metal objects connected to the workpiece increase the risk of electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.
e. Earthing of the welded part: When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.
f. Protection and shielding: The selective protection and shielding of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

The machine is equipped with a top strap for easy transportation. Be careful not to underestimate the weight of the machine. The strap is not design to be use to hang the machine to something else.
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.

INSTALLATION

• Put the machine on the floor (maximum incline of 10°).
• Provide an adequate area to ventilate the machine and access the controls.
• Do not use in an area with conductive metal dust.
• 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 manufacturer does not accept any liability in relation to damages caused to objects or harm caused to people as the result of incorrect and/or dangerous use of the machine.

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. A yearly maintenance is recommended.
• Ensure the machine is unplugged from the mains, and then wait 2 minutes before carrying out maintenance work. Inside, voltages and currents are high and dangerous.
• Remove regularly the casing and any excess of 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 to prevent danger.
• Ensure the vents 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

Only qualified personnel authorised by the manufacturer should perform the installation of the welding equipment.
During the installation, the operator must ensure that the machine is disconnected from the mains. Connecting generators in serial or in parallel are forbidden.

PRODUCT DESCRIPTION

The GYSARC are Inverter technology based welding machines, portable, single phase, fan cooled, for electrode welding (MMA) in direct current (DC). These machines can weld all types of electrodes : rutile, basic/low hydrogen, stainless and cast iron. It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings.

POWER SWITCH

• This machine is fitted with a 16A socket type CEE7/7 which must be connected to a single-phase 230V (50 – 60 Hz) power supply fitted with three wires and one earthed neutral. The absorbed effective current (I1eff) is indicated on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings.
• For the GYSARC 160 and 200, preferably use a 32A socket protected by a 32A circuit breaker for use intensive. The appliance must be placed in such a way that the power plug is accessible.
• The GYSARC 200 is equipped with the Protec 400 (P400) function: the unit goes into protection (protection light flashes) if the supply voltage is higher than 265 V. Normal operation is resumed as soon as the supply voltage returns to its nominal range.
• To start the unit, press the on/off button located on the backof the device.

CONNECTION TO A GENERATOR

These products are not protected against the regurlarly overvoltage provided by the power generator. It is therefore not recommended to connect them on this type of power supply.
COATED ELECTRODE WELDING (MMA)

CONNECTIONS AND RECOMMENDATIONS

• Connect the cables, electrode holder and earth clamp to the connectors,
• Follow the welding polarities and power recommendations indicated on the electrode boxes.
• Remove the electrode from the electrode holder when the machine is not in use.
• The machine has 3 features exclusive to Inverters:

*  The Hot Start creates an overcurrent at the beginning of the welding.

• The Arc Force creates an overcurrent which prevents the electrode from sticking to the weld pool.
• The Anti-Sticking technology makes it easier to unstick the electrode from the metal.

TROUBLESHOOTING

switch), then turn it on.
The green indicator is on, but the machine does not weld.| Fault with earth clamp/cable connection.| Check the connections
The product is under voltage, you are feeling tingling when touching the machine’s body.| The earth contact is faulty.| Check the plug and the earth of your installation.
machine welds poorly.| Polarity error (+/-).| Check the polarity (+/-) recommended on the electrode box. mended

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment related failures (pollution, rust, dust).
  In case of failure, return the unit to your distributor together with:
  – The proof of purchase (receipt etc …)
  – A description of the fault reported

SPARE PARTS

| 80| 100| 120| 160| 200
---|---|---|---|---|---
1| Potentiometer button| 73099
2| Warning Indicator| C13203
3| Power Indicator| C13201
4| Sockets| C31312
5| Electonic board| 64121| 64124| 53543| 53545| 64152
6|  On/off switch| C51504| 52460| 53546| C51524
7|  Power supply cable| 21468| 21480
8|  Fan / Later| 53544| 51032| C16545
9| Main transformer| C32576IND2| C32545| C32556| C32588
10| Panel PCB| 64120| | 64120

INTERFACE

1. Current setting potentiometer
2. Yellow indicator for thermal protection and overcurrent
3. Green indicator (operation)
4. Earth clamp and electrode holder connectors
5. Switch

CIRCUIT DIAGRAM

TECHNICAL SPECIFICATIONS

| 80| 100| 120| 160| 200
---|---|---|---|---|---
 Primary| |
Power supply voltage| 230 V +/- 15%
 Mains frequency| 50 / 60 Hz
 Number of phases| 1
 Fuse| 10 A| 16 A| 16 A| 16 A| 32 A
Maximum effective supply current I1eff| 7 A| 7 A| 10 A| 14.5 A| 15 A
 Maximum supply current I1max| 16 A| 19 A| 23 A| 34 A| 44 A
 Mains cable section| 3 x 1.5 mm²| 3 x 1.5 mm²| 3 x 1.5 mm²| 3 x 1.5 mm²| 3 x 2.5 mm²
 Maximum active power consumed| 2192 W| 2747 W| 3506 W| 5053 W| 6531 W
 Idle consumption| 30 W| 35 W| 50 W| 48 W| 49 W
Efficiency at I2max| 84.6 %| 87.3 %| 84.8 %| 83.5 %| 84.73 %
 Power factor at I2max (λ)| 0.62| 0.62| 0.63| 0.63| 0.64
 EMC class| A
Secondary| |
 No load voltage| 63 V| 63 V| 63 V| 63 V| 64 V
 Type of welding current| DC| DC| DC| DC| DC
 Welding modes| MMA| MMA| MMA| MMA| MMA
Minimum welding current| 10| 10| 10| 10| 20
 Normal current output (I2)| 10 → 80 A| 10 →100 A| 10 → 120 A| 10 → 160 A| 20→ 200 A
Conventional voltage output (U2)| 20.4 → 23.2 V| 20.4→ 24 V| 20.4→ 24.8 V| 20.4 → 26.4 V| 20.8 → 28 V
Duty cycle at 40°C (10 min) Standard EN60974-1.| Inschakelduur bij 40°C (10 min) Norm EN60974-1.| Imax| 20 %| 14 %| 20 %| 10 %| 10 %
60%| 50 A| 50 A| 70 A| 85 A| 90 A
100%| 35 A| 35 A| 55 A| 70 A| 80 A
Functionning temperature| -10°C → +40°C
 Storage temperature| -20°C → +55°C
 Protection level| IP21| IP21| IP21| IP21| IP21
 Minimum coil insulation class| F| F| F| F| F
 Dimensions (Lxlxh)| 21 × 13 × 10 cm| 23 x 15 x 10 cm| 27 x 11 x 16.5 cm
Weight| 2 kg| 2.7 kg| 2.9 kg| 3.6 kg

*The duty cycles are measured according to standard EN60974-1 à 40°C and on a 10 min cycle.
While under intensive use (> to duty cycle) the thermal protection can turn on, in that case, the arc swictes off and the indicator switches on.
Keep the machine’s power supply on to enable cooling until thermal protection cancellation.
The welding power source describes an external drooping characteristic.

SYMBOLS

| Caution ! Read the user manual.
---|---
|  Single phase inverter, converter-rectifier
| Electrode welding (MMA – Manual Metal Arc)
|  Adapted for welding in environments with increased risk of electrical shock. However, the welding machine should not be placed in such places.
| Welding direct current
U0|  Rated no-load voltage
X(40°C)| X : duty cycle at …%
I2| I2 : corresponding conventional welding current
A| Amps
U2|  U2 : conventional voltages in corresponding load
V| Volt
Hz| Hertz
| Single phase power supply 50 or 60Hz
U1|  rated supply voltage
---|---
I1max|  Rated maximum supply current (effective value)
I1eff| Maximum effective supply current
| The device complies with European Directive. The certificate of compliance is available on our website.
EN60974-1 EN60974-10 Class A| The device complies with EN60974-1, EN60974-10, Class A standard relative to welding units
| Ne pas jeter dans une poubelle domestique ! – Separate collection required
| Conformity mark EAC (Eurasian Economic Commission)
|  Thermal protection information
|  This product should be recycled appropriately
| – Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website (see cover page).
| – Material complies with British requirements. The British Declaration of Conformity is available on our website (see cover page).
|  Number of standard electrodes that can be welded continuously in 1 hour, with a 20s stop time between each electrode, divided by the number of weldable electrodes under the same conditions without any thermal protection activating.
| Number of standard electrodes that can be welded in 1 hour, at 20°C, with a 20s stop time between each electrode.

53941 SAINT-BERTHEVIN Cedex
FRANCE

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| GYS GYSARC 80 Welding Machine [pdf] Instruction Manual
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