GYS NEOPULSE 320 C MMA Welding Machine Instructions

NEOPULSE 320 C MMA Welding Machine

Product Specifications

• Model: NEOPULSE 320 C
• Functions: MIG/MAG, TIG, MMA welding
• Version: 73502 V3.1
• Release Date: 23/12/2023

Installation

1. Ensure the power supply is compatible (400 V).
2. Install the wire spool by following the provided instructions, ensuring proper positioning and securing.

Wire Loading

1. Remove the nozzle and contact tube from your MIG/MAG torch.
2. Position the wire spool on its support, considering the drive lug on the spool holder.
3. Secure the plastic spool holder for a 200 mm spool tightly to prevent motor overheating.

Welding Modes

• Semi-automatic steel/stainless steel welding (MAG mode)
• Semi-automatic aluminum welding (MIG mode)
• Semi-automatic CuSi and CuAl brazing welding (braze mode)

Gas Connection
Ensure proper gas connection as per the welding mode being used.

Welding Settings
Refer to the provided table for wire size, current range, and other welding parameters based on the welding mode selected.

Frequently Asked Questions (FAQ)
Q: How do I troubleshoot if the machine does not power on?
A: Check the power supply connection and ensure it is providing the correct voltage. Also, verify that the emergency stop button is not engaged.

MIG/MAG – TIG – MMA welding machin

Before using your device for the first time, please check for new updates

Before using the machine for the first time, calibrate the welding cables

WARNINGS – SAFETY INSTRUCTIONS

GENERAL INSTRUCTIONS

These instructions must be read and understood before using the machine.
Any modification or maintenance that is not specified in the manual must not be carried out.
The manufacturer will not be held responsible for any damage to persons or property caused by the failure to follow this product’s user manual instructions.
In case of problems or queries, please consult a qualified tradesperson to correctly install the product.

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 cases of improper or dangerous use.
The machine must be set up somewhere free from dust, acid, flammable gases or any other corrosive substances. This also applies to the machine’s storage. Operate the machine in an open or well-ventilated area.

Temperature range
Operate between -10 and +40°C (+14 and +104°F).
Store between -20 and +55°C (-4 and 131°F).

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

Altitude
Up to 1,000m above sea level (3,280 feet).

PROTECTING YOURSELF AND OTHERS

Arc welding can be dangerous and cause serious injury or death.
Welding exposes people to a dangerous heat source, arc light, electromagnetic fields (be aware of those wearing pacemakers), risk of electrocution, loud noises 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 gloves that ensure 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 operations. 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. Advise people in the welding area not to stare at the arc rays or molten material and to wear appropriate protective clothing.
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 your hands, hair and clothing away from moving parts (for example, the fans).
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.
The 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.
To protect people and property, it is important to properly secure the work area before leaving.

WELDING FUMES AND GAS

The fumes, gases and dusts emitted during welding are harmful to health. Sufficient ventilation must be provided and an additional air supply may be required. A n air-fed mask could be a solution in cases where there is insufficient ventilation.
Check that the suction is functioning effectively by checking it against safety standards.

Caution: when welding in small areas requires supervision 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.
Gas cylinders should be stored in open or well-ventilated areas. They should be kept in an upright position and kept on a cart or trolley. Welding should not be undertaken near grease or paint.

FIRE AND EXPLOSION RISKS

Fully protect the welding area, flammable materials should be kept at least 11 metres away. Fire fighting equipment should be present in the vicinity of welding operations.

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.
Do not weld in closed containers or tubes. If they are open, remove any flammable or explosive materials (oil, fuel, etc.) before welding. Grinding work must not be directed towards the source of the welding current or towards any flammable materials.

GAS CYLINDERS
Gas escaping from the cylinders can cause suffocation if it becomes concentrated in the welding area (ventilate well). Transporting the machine must be done safely: gas cylinders must be closed and the welding power source turned off. They should be stored upright and supported to reduce the risk of falling.

• Tightly close the bottle between uses. Beware of temperature changes and sun exposure.
• The bottle should not come into contact with flames, electric arcs, torches, earth clamps or any other sources of heat.
• Keep away from electrical and welding circuits and 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 chosen from the information table. Electric shocks can cause serious direct and indirect accidents 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 length of cable according to its use. Always wear dry, good quality clothing to insulate yourself from the welding circuit. Alongside this, wear well-insulated footwear in all working environments.

EMC CLASSIFICATION

This Class A equipment is not intended for domestic use where electrical power is supplied from the low-voltage mains system. Ensuring electromagnetic compatibilty may be difficult at these sites due to conducted, as well as radiated, radio frequency interference.
This equipment complies with IEC 61000-3-11.
This equipment does not comply with IEC 61000-3-12 and is designed to be plugged into private, low voltage, power supply networks. It is intended to be connected to the public mains supply only at medium or high voltage level. If connected to a public, low voltage, power supply network, it is the installer or user’s responsibilty to ensure that the equipment can be properly connected by checking with the mains grid operator.

ELECTROMAGNETIC INTERFERENCES

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 should be taken for those with medical, implanted devices. 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 – if possible, securing them with a clamp,
• 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 or lean on the source of the welding current,
• do not weld while transporting the source of the welding current or wire feeder.

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.

RECOMMENDATIONS FOR ASSESSING THE WELDING AREA AND EQUIPMENT

General Information
It is the user’s responsibilit to install and use the arc welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, it is the user’s responsiblity to resolve the situation using the manufacturer’s technical support. 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 current source and around the entire workpiece by setting up input filters. In any case, electromagnetic interference should be reduced until it is no longer an inconvenience.

Assessing the welding area
Before installing arc welding equipment, the user should assess the potential electromagnetic problems in the surrounding area.

The following should be taken into account:

• the presence of power, control, signal and telephone cables above, below and next to the arc welding equipment,

• radio and television receivers and transmitters,

• computers and other control equipment,

• critical safety equipment, e.g. the protection of industrial equipment,

• the health of nearby persons, e.g. those using of pacemakers or hearing aids,

• the equipment used for calibrating or measuring,

• the protection of other surrounding equipment.
  The operator has to ensure that the devices and equipment used in the same area are compatible with each other. This may require further protective measures;

• the time of day when welding or other activities are to take place.

The size of the surrounding area to be taken into account will depend on the building’s structure and the other activities taking place there. The surrounding area may extend beyond the boundaries of the premises.

Assessment of the welding equipment
In addition to the assessment of the surrounding area, the arc welding equipment’s assessment can be used to identify and resolve cases of interference. It is appropriate that the assessment of any emissions should include in situ procedures as specified in Article 10 of CISPR 11. In situ procedures can also be used to confirm the effectiveness of mitigation measures.

GUIDELINES ON HOW TO REDUCE ELECTROMAGNETIC EMISSIONS

• The mains power grid: Arc welding equipment should be connected to the mains power grid according to the manufacturer’s recommendations. If any interference occurs, it may be necessary to take additional precautionary measures such as filtering the mains power supply. Consider protecting the power cables of permanently installed, arc welding equipment within a metal pipe or a similar casing. The power cable should be protected along its entire length. The protective casing should be connected to the welding machine’s power source to ensure good electrical contact between the protective pipeline and the welding machine’s power source housing.
• The maintenance of arc welding equipment: Arc welding equipment should be subject to routine maintenance as recommended by the manufacturer. All access points, service openings and bonnets should be closed and properly locked when the arc welding equipment is in use. The arc welding equipment should not be modified in any way, except for those modifications and adjustments mentioned in the manufacturer’s instructions. The spark gap of arc starters and stabilisers should be adjusted and maintained according to the manufacturer’s recommendations.
• Welding cables: Cables should be as short as possible, placed close together either near or on the ground.
• Equipotential bonding: Consideration should be given to the joining of all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of electric shocks to the user if they touch both these metal parts and the electrode. The user should be isolated from such metal objects.
• Earthing the workpiece: In cases where the part to be welded is unearthed for electrical safety reasons or due to its size and location, such as ship hulls or structural steel buildings, an earthed connection can reduce emissions in some cases, although not always. Care should be taken to avoid the earthing of parts which could increase the risk of injury to users or damage to other electrical equipment. If necessary, the workpiece’s connection should be earthed directly, but in some countries where a direct connection is not allowed, the connection should be made with a suitable capacitor chosen according to national regulations.
• Protection and protective casing: The selective protection and encasing of other cables and equipment in the surrounding area may limit interference problems. The safeguarding of the entire welding area may be considered for special applications.

THE TRANSPORTING AND MOVING OF THE MACHINE’S POWER SOURCE

The machine is fitted with handle(s) to facilitate transportation. Be careful not to underestimate the machine’s weight. The handle(s) cannot be used for slinging.
Do not use the cables or torch to move the welding power source. It should be transported in an upright position.
Do not carry or transport the power source overhead of people or objects.

Never lift a gas cylinder and the welding power source at the same time. Their transport requirements are different. It is advisable to remove the wire spool before lifting or transporting the welding power source.

SETTING UP THE EQUIPMENT

• Place the welding power source on a floor with a maximum inclination of 10°.

• Provide sufficient space to ventilate the welding power source and access the controls.

• Do not use in an area with conductive metal dust.

• The welding power source should be protected from heavy rain and not exposed to direct sunlight.

• The equipment has an IP23 protection rating which means:

  • its dangerous parts are protected from being entered by objects greater than 12.5 mm and,

  • it is protected against rain falling up to 60° from the vertical.
    The equipment can be used outside in accordance with the IP23 protection certification.

  • 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 securFully protect the welding area, flammable materials should be kept at least 11 metres away. Fire fighting equipment should be present in the vicinity of welding operations.ed 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!

Power cables, extension cables and welding cables should be fully unwound to avoid overheating.
The manufacturer assumes no responsibility for damage to persons or objects caused by improper and dangerous use of this equipment.

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
• Switch off the power supply by pulling the plug and wait two minutes before working on the equipment.. Inside the macine, the voltages and currents are high and dangerous.
• Regularly remove the cover and blow out any dust. Take advantage of the opportunity to have the electrical connections checked with an insulated tool by a qualified professional.
• Regularly check the condition of the power cord. If the power cable is damaged, it must be replaced by the manufacturer, the after sales service team or an equally qualified person to avoid any danger.
• Leave the welding power source vents free for air intake and outflow.
• Do not use this welding power source for thawing pipes, recharging batteries/storage batteries or starter motors.

INSTALLATION – USING THE PRODUCT
Only experienced persons, authorised by the manufacturer, may carry out the installation. During installation, ensure that the power source is disconnected from the mains. Series or parallel power source connections are not allowed. It is recommended to use the welding cables supplied with the unit in order to obtain the best performance.

DESCRIPTION

This machine is a three-phase power source for semi-automatic, software- supported welding (MIG or MAG), coated electrode welding (MMA) and refractory electrode welding (TIG). It accepts 200 and 300 mm diameter wire spools.

DESCRIPTION OF THE EQUIPMENT (I)

1. ON / OFF switch
2. Gas connector
3. Cable gland (mains cable)
4. External grids
5. Reel support
6. USB connector
7. Rocker switch wire feed / gas purge
8. Wirefeed motor
9. Interface (MMI)
10. Digital RC connector (option ref. 063938)
11. Analogue connector
12. Euro connector
13.  polarity plug
14. + polarity plug
15. Polarity reversal cable
16. SMC connection system (optional)

HUMAN- MACHINE INTERFACE (HMI)
Please read the Human Machine Interface (HMI) which forms part of the equipment’s user literature.

POWER SWITCH

• This equipment is supplied with a 32 A EN 60309-1 socket and should only be used on a three phase, 400 V (50-60 Hz), four wire, earthed electrical system. The actual absorbed current (I1eff) for optimal operating conditions is indicated on the equipment. Check that the power supply and its safe-guards (fuses and/or circuit breakers) are compatible with the current required to use the machine. For optimum functionality in certain countries, it may be necessary to change the plug.
• The power source is designed to operate at 400 V +/- 15%. • The machine will go into protection mode if the supply voltage falls below 330 Veff (rated insulation voltage) or goes above 490 Veff, (an error code will appear on the display screen).
• To switch the machine on, turn the on/off switch (I-1) to position I, whereas switching it off is done by turning the switch to position 0. Caution! Never disconnect the machine from the power supply while the machine is charging.
• Ventilation fan performance: This equipment is fitted with smart ventilation management system in order to minimise the noise made by the machine. The fans will adjust their speed according to useage and the surrounding temperature. They can be switched off in MIG or TIG mode.

CONNECTING TO A POWER SOURCE

This equipment can be operated with electric generators provided that the auxiliary power supply meets the following requirements: – The voltage must be alternating with an RMS value of 400 V +/- 15% and a peak voltage of less than 700 V.
The frequency must be between 50 and 60 Hz.
It is vital to check these conditions as many generators produce high voltage peaks that can damage equipment.

USING EXTENSION LEADS

All extension leads must be of a suitable length and width that is appropriate to the equipment’s voltage. Use an extension lead that complies with national safety regulations.

SETTING UP THE REEL

• Remove the nozzle (a) and contact tube (b) from your MIG/MAG torch.
• Position the reel on its holder.
• Take into consideration the reel stands’s drive lug (c). To fit a 200 mm reel, tighten the plastic reel holder (a) to the maximum.
• Adjust the brake wheel (b) to prevent the non-moving spool from tangling the wire when the welding stops. In general, do not overtighten, as this will cause the motor to overheat.

LOADING THE FILLER WIRE

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 groove steel 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)

Do the following to install the filler wire

• Loosen the dials to the maximum and lower them.
• Insert the wire, then close the motor reel and tighten the dials as shown.
• Operate the motor using the torch trigger or the manual wire feed button (I-6).

Notes:

• Too narrow a sheath can lead to unreeling issues and can lead to the overheating of the motor.
• The torch connection must also be properly tightened to prevent it from overheating.
• Ensure that neither the wire, nor the reel, touches the device’s mechanism, otherwise, there is a danger of short-circuiting the ma-chine.

RISK OF INJURY FROM MOVING COMPONENTS

The reels have moving parts that can trap hands, hair, clothing or tools causing injuries!

• Do not touch rotating, moving or driving parts of the machine!
• 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 reel.

SEMI-AUTOMATIC STEEL/STAINLESS STEEL WELDING (MAG MODE)

• This machine can weld steel wire from Ø 0.6 to 1.2 mm and stainless steel wire from Ø 0.8 to 1.2 mm (II-A).
• The machine is designed for use with Ø 1.0 mm steel wire (Ø 1.0/1.2 roller) as standard. The contact tip, the sheave groove and the welding torch sheath are designed for this use. Use a torch no longer than 3 m to weld 0.6 diameter wire. The contact tip as well as the spools of the motorised wire feed roller should be replaced by a 0.6 grooved model (ref. (réf. 061859). In this case, position it so that the marking 0.6 is visible.
• To do this using steel requires a specific welding gas (Ar+CO2). The amount of CO2 may vary depending on the type of gas used. Use 2% CO2 for stainless steel. It is necessary to connect a gas pre-heater to the gas cylinder when welding with pure CO2. For specific gas issues, please contact your gas distributor. The gas flow rate for steel is between 8 and 15 litres per minute depending on the surroundings.

SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE)

The equipment can weld aluminium wire from Ø 0.8 to 1.2 mm (II-B).
The use of aluminium requires a specific, pure, argon gas (Ar). Seek advice from a gas distributor for a wide selection of gases. he gas flow rate of aluminium is between 15 and 25 l/min depending on the surrounding environment and the welder’s experience.

The differences between steel and aluminium processing are as follows

• Use specific rollers for aluminium welding.
• Put minimum pressure on the motorised reel’s pressure rollers so as not to crush the thread.
• Use a capillary tube (to guide the wire between the motorised wire feeder rollers and the EURO connector) for steel/stainless steel welding only.
• Use a special aluminium torch. This aluminium torch has a Teflon coating to reduce friction. DO NOT cut away the coating at the tip of the connector!This coating is used to guide the wire from the rollers.
• Contact tips: use a SPECIAL aluminium contact tip that matches the wire’s diameter.

When using red or blue sheathing (aluminium welding), it is recommended to use the 91151 (II-C) accessory. This stainless steel sheath guide improves the centering of the sheath and facilitates the flow of the wire.

SEMI-AUTOMATIC WELDING IN CUSI AND CUAL (SOLDERING MODE)
The machine can weld CuSi and CuAl wire from Ø 0.8 to 1.2 mm.
In the same way as with steel, a capillary tube must be set up and a torch with a steel sheath must be used. When braze welding, pure argon (Ar) should be used.

SEMI-AUTOMATIC «NO GAS» WIRE WELDING
This equipment can weld wire without gas protection (No Gas) from Ø 0.9 to 1.6 mm. Welding flux-cored wire with a standard nozzle can lead to overheating and damage to the torch. Remove the original nozzle from your MIG-MAG torch.

CHOOSING A POLARITY

In any case, refer to the wire manufacturer’s recommendations for the choice of polarity for your MIG-MAG torch.

GAS SUPPLY

• Fit a suitable pressure regulator to the gas cylinder. Connect it to the welding station with the pipe supplied. Attach the two hose clamps to prevent leaks.
• Ensure that the gas cylinder is held securely in place with a chain attached to the power source.
  Set the gas flow rate by adjusting the dial on the pressure regulator.
  NB: To adjust the gas flow rate more easily, use the rollers on the motorised spool by pulling the trigger on the torch (loosen the brake wheel on the motorised reel so that no wire is drawn in). Maximum gas pressure: 0.5 MPa (5 bar).

This procedure does not apply to welding in «No Gas» mode.

| ****

(mm)

| Current (A)| Ø Wire (mm)| Ø Nozzle (mm)| Flow rate L/min
---|---|---|---|---|---
MIG| 0.8-2| 20-100| 0.8| 12| 10-12
2-4| 100-200| 1.0| 12-15| 12-15
4-8| 200-300| 1.0/1.2| 15-16| 15-18
8-15| 300-500| 1.2/1.6| 16| 18-25
MAG| 0.6-1.5| 15-80| 0.6| 12| 8-10
1.5-3| 80-150| 0.8| 12-15| 10-12
3-8| 150-300| 1.0/1.2| 15-16| 12-15
8-20| 300-500| 1.2/1.6| 16| 15-18

MIG / MAG (GMAW/FCAW) WELDING MODE

| Welding processes|
---|---|---

Settings

| ****

ADJUSTABLE SETTINGS

| MANUAL| STD DYNAMIC| STD IMPACT| STD ROOT| COLD PULSE| PULSE|
Couple material/gas| – Fe Ar 25% CO2

– …

| –| | | | | | Choice of the material to be welded. Pre-installed welding user settings
Wire diameter| Ø 0.6 > Ø 1.6 mm| | | | | | | Choice of wire diameter
ModulArc| OFF – ON| –| –| –| –| –| | Activating or deactivating the welding current’s modulation (Double Pulse)
USING THE TRIG- GER| 2T, 4T| | | | | | | Choice of trigger welding management mode.
Spot welding mode| SPOT, DELAY| | | | | ****| –| Selecting spot welding mode

First Setting

| Thickness Start-up Speed| ****

–

| | | | | ****| Choosing the main setting to be displayed (thickness of the workpiece, average welding current or wire speed).
Power| Hold

Thermal coefficient

| | | | | | | See «Power» section on the following pages.

Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual.

WELDING PROCESSES
For more information on GYS pre-installed user settings and welding processes, scan the QR code:

SPOT WELDING MODE

SPOT WELDING
This welding mode allows the pre-assembly of parts before welding. Spot welding can be done manually using the trigger or timed with a predefined spot welding period. This spot welding makes reproduction and execution of non- oxidised weld points easier (accessible in the advanced menu).

TIME LIMITS
This is a welding mode similar to SPOT welding but with predefined weld and dwell times, as long as the trigger is held down.

CONFIGURING THE SETTINGS

| Units|
---|---|---
Wire speed| m/min| Amount of filler metal deposited and consequently the welding intensity and penetration.
Voltage| V| Control over the cord’s width.
Self| –| Lessens the welding current more or less. To be set according to the welding position.
Pre-Gas| s| When the torch is bled and the gas shield is created before ignition.
Post-Gas| s| Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from

oxidation.

Thickness

| ****

mm

| The pre-installed user settings (syngergies) allow for a fully-automatic set-up. Working with different thicknesses

automatically sets the appropriate thread tension and speed.

Start-up| A| The welding current is set according to the type of wire used and the material to be welded.
Arc length| –| Used to adjust the distance between the end of the wire and the weld pool (tension adjustment).
Approach speed| %| Progressive yarn speed. Before priming, the wire moves slowly to create the first contact without jolting.
Hot Start| % & s| The Hot Start is an overcurrent used at the start that prevents the wire from sticking to the workpiece. The intensity (% of welding current) and the time (seconds) can be programmed.
Crater Filler| %| This idling bearing current is a phase after the current is lowered.

The intensity (% of welding current) and the time (seconds) can be programmed.

Soft Start| s| Gradual current increase. The current is controlled between the first contact and the welding process in order to avoid the possibility of violent ignitions or jolts.
Uplsope| s| Upslope current
Cold current| %| Second welding current known as a «cold» welding current.
Pulse frequency| Hz| Pulse frequency
Duty cycle| %| In pulsed mode, the hot current time is adjusted in relation to the cold current time.
Downslope| s| Downslope current.
Tack welding| s| Set duration.
Time between two points| s| Time between the end of a point (excluding Post- Gas) and the start of a new point (including Pre-Gas).
Burnback| s| Feature preventing the thread sticking to the bead. This is timed to coincide with the wire rising from the weld

pool.

Access to some welding settings depends on the welding process (Manual, Standard, etc.) and the selected display mode (Easy, Expert or Ad-vanced). Refer to the HMI manual.

MIG/MAG WELDING CYCLES Standard 2T process:

When the trigger is pulled, the pre-gas starts. When the wire touches the workpiece, a pulse initiates the arc and the welding cycle starts. When the trigger is released, the wire feeding stops and a curraent pulse cleanly cuts the wire, followed by the post-gas. As long as the post-gas has not finished, pressing the trigger will allow a quick restart of the weld (manual chain stitch) without going through the HotStart phase. A HotStart and/or a crater filler can be added to the cycle.

Standard 4T process

In a standard 4T process, the timing of pre-gas and post-gas is managed automatically. HotStart and crater filler are both controlled by the trigger.

When the trigger is pulled, the pre-gas starts. When the wire touches the workpiece, a pulse initiates the arc. Then, the machine starts with HotStart or upslope and finally, the welding cycle starts. When the trigger is released, the downslope initiates until it reaches crater fill. Then the STOP PEAK cuts the wire followed by the Post gas. Just as in Standard mode, the user can quickly restart the welding process during the post-gas phase without going through the HotStart phase.

In pulsed 4T mode, the timing of the pre-gas and post-gas is managed automatically. HotStart and crater fill are controlled by the trigger.

TIG (GTAW) WELDING MODE

INSTALLATION AND GUIDANCE

• DC TIG welding requires a protective gas shield (Argon).
• Connect the earth clamp to the positive (+) plug connector. Plug in the TIG torch (ref. 046108) iinto the power source’s EURO connector and the reverse cable into the negative (-) connector.
• Ensure that the torch is properly fitted and that the consumables (vice grip pliers, collet bodies, diffusers and nozzles) are not worn out.
• The choice of electrode will depend on the current of the DC TIG process.

ELECTRODE SHARPENING
For optimum results, it is advised to use an electrode sharpened in the following way:

ASSISTANCE FOR SETTING UP AND SELECTING CONSUMABLES

DC

| |

Current (A)

| ****

Electrode (mm)

| ****

Shroud (mm)

| ****

Argon flow rate (L/min)

---|---|---|---|---|---
0.3 – 3 mm| 5 – 75| 1| 6.5| 6 – 7
2.4 – 6 mm| 60 – 150| 1.6| 8| 6 – 7
4 – 8 mm| 100 – 200| 2| 9.5| 7 – 8
6.8 – 8.8 mm| 170 – 250| 2.4| 11| 8 – 9
9 – 12 mm| 225 – 300| 3.2| 12.5| 9 -10

PROCESS SETTINGS

| Welding processes|
---|---|---

Settings

| ADJUSTABLE SETTINGS| Synergies (pre-installed user settings)| ****

DC

|
–| Standard| –| | Smooth current
Pulsed| –| | Pulsed current
Spot welding| –| | Smooth tacking
Tack| –| | Pulsed tacking
Type of materials| Fe, Al, etc.| | –| Choice of the material to be welded
Tungsten elec- trode’s diameter| 1 – 4 mm| | | Choice of electrode diameter.
Trigger mode| 2T – 4T – 4T LOG| | | Choice of trigger welding management mode.
E.TIG| ON – OFF| | ****| Constant energy welding mode with arc length correction.
Power| Hold

Thermal coefficient

| –| ****| See «Power» section on the following pages.

Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced.

WELDING PROCESSES

• DC TIG welding
  Specifically designed for ferrous metals such as steel, stainless steel, copper and its alloys, as well as titanium.

• Synergic TIG welding
  No longer based on the selection of a DC current type and the welding cycle settings but intergrates welding rules/pre-installed settings based on real welding experiences. Therefore, this mode restricts the number of basic, adjustable settings to three: Type of material, welding thickness and welding position.

ADJUSTABLE SETTINGS

• STANDARD WELDING
  The standard DC TIG welding process allows high quality welding on most ferrous materials such as steel and stainless steel, but also copper and its alloys including titanium. The various current and gas management possibilities allow you to perfectly control your welding operation, from priming to the final cooling of your weld seam.

• PULSED WELDING
  This pulsed current welding mode combines high current pulses (I = welding pulses) with low current pulses (cold I, workpiece cooling pulses). The pulsed mode allows parts to be assembled while limiting temperature rises and warping. Ideal for on site use.

Example
The welding current (I) is set to 100 A and % (cold I) = 50%, i.e. cold current = 50% x 100 A = 50.
F(Hz) is set to 10 Hz, the signal period will be 1/10 Hz = 100 ms -> a 100 A pulse every 100 ms then followed by another at 50 A.

• SPOT WELDING
  This welding mode allows the pre-assembly of parts before welding. Spot welding can be done manually using the trigger or timed with a predefined spot welding period. Spot welding allows for better reproduction and non-oxidized weld points.

• TACK WELDING
  This welding mode also allows for the pre-assembly of parts before welding, but in two stages this time: the first stage uses a pulsed DC current which concentrates the arc for better penetration. This is then followed by the second stage where a standard DC current is used to widen the arc and the- refore the weld pool to secure the weld point.
  The variable times of the two welding stages allow for better reproduction and non-oxidized weld points.

• E-TIG WELDING
  This mode allows for constant power welding by measuring arc length variations in real time to ensure consistent bead width and penetration. In cases where the assembly requires careful control of the welding energy, the E-TIG mode guarantees that the welder will respect the welding power regardless of the torch’s position in relation to the workpiece.

CHOOSING THE ELECTRODE’S DIAMETER

Electrode Ø (mm)

| TIG DC
---|---
Pure tungsten| Tungsten with oxides
1| 10 > 75| 10 > 75
1.6| 60 > 150| 60 > 150
2| 75 > 180| 100 > 200
2.5| 130 > 230| 170 > 250
3.2| 160 > 310| 225 > 330
4| 275 > 450| 350 > 480
| Approx. = 80 A per mm Ø

USING THE TRIGGER

• T1 – The main button is pressed, the welding cycle starts (Pre-Gas, I_Start, upslope and welding).
• T2 – The main button is released, the welding cycle is stopped  (downslope, I_Stop, Post-Gas).

For two-button torches in T2 only, the secondary button is treated as the main button.

1. T1 – The main button is pressed, the cycle starts from Pre-Gas and stops at the I_Start phase.

2. T2 – The main button is released, the cycle continues to upslope and welding.

3. T3 – The main button is pressed, the cycle goes to downslope and stops in the I_Stop phase.

4. T4 – The main button is released, the cycle ends with the Post-Gas. NB: for torches, double buttons and double button + potentiometer => «up/weld current» button turns on the potentiometer, the «down» button turns it off.

5. T1 – The main button is pressed, the cycle starts from Pre-Gas and stops at the I_Start phase.

6. T2 – The main button is released, the cycle continues to upslope and welding.
   LOG: this operating mode is used during the welding phase:

   • a quick press of the main button (<0.5 s) switches the current from I_welding to I_cold and vice versa.
   • if the secondary button is pressed, the current switches from
     I_welding to I_cold.
     – if the secondary button is left unpressed, the current switches from I_cold to I_welding.

7. T3 – After holding down the main button (>0.5 s), the cycle goes into downslope and stops at the I_Stop phase.

8. T4 – The main button is released and the cycle ends with Post-Gas.

For dual button or dual trigger torches, the «high» trigger retains the same functionality as the single trigger torch . The «low» trigger is not active.

MANUAL GAS FLUSHING
The presence of oxygen in the torch can lead to a decrease in mechanical quality and can result in less corrosion resistance. To flush the gas from the torch, press and hold the button #1 and follow the on-screen procedure.

CONFIGURING THE SETTINGS

| Units|
---|---|---
Pre-Gas| s| When the torch is bled and the gas shield is created before ignition.
Start-up time| %| This start-up bearing current is a warm-up phase before the current is raised.
Starting time| s| Starting time before the current is raised.
Rising current| s| Allows a gradual increase in welding current.
Welding current| A| Welding current.
Crater-fill feature| s| Avoids cratering at the end of welding and the risk of cracking, particularly in light alloys.
End current| %| This idling bearing current is a phase after the current is lowered.
Stopping time| s| This idling time is a phase that comes after the current is lowered.
Thickness| mm| Thickness of the workpiece to be welded.
Position| –| Welding positioning
Post-Gas| s| Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from

oxidation during cooling.

Wave shape| –| Pulsed waveform.
Cold current| %| Second welding current known as a «cold» welding current.
Cold weather| %| Pulsed hot current (I) time balance
Pulse frequency| ****

Hz

| Pulse frequency SET-UP TIPS:

–  If welding with a manual, filler metal, then F(Hz) is synchronised to the inputting of the wire.

–  If the metal is thin and without filler (< 0.8 mm), F(Hz) > 10 Hz

–  If welding in position, then F(Hz) < 100 Hz

Spot welding| s| Either manual or a set time.
Timed pulsed| s| Manual or timed pulsed hase
Timed non-pulsed| s| Manual or timed smooth current phase

Access to certain welding settings depends on the welding process (Standard, Pulsed, etc.) and the selected display mode (Easy, Expert or Ad-vanced).

MMA (SMAW) WELDING MODE

INSTALLATION AND GUIDANCE

• Plug the cables, electrode holder and earth clamp into the plug connections.
  Respect the electrical polarities and the strength of the welding power indicated on the electrode boxes.

• Remove the coated electrode from the electrode holder when the welding power source is not in use.

• The equipment is fitted with 3 inverter-specific features:

  • Hot Start provides an overcurrent at the beginning of the welding process.
  • Arc Force creates an overcurrent which prevents the electrode from sticking to the weld pool.
  • The Anti-Stick technology makes it easier to unstick the electrode from the metal.

PROCESS SETTINGS

| Welding processes|
---|---|---
Settings| ADJUSTABLE SETTINGS| Standard| Pulsed|
Electrode type| Rutile Basic Cellulosic| | | The type of electrode determines the settings in order to optimise its weldability depending on the type of electrode used.
Anti-Sticking| ****

OFF – ON

| | | The anti-stick feature is recommended to safely remove the electrode in the event of it sticking to the workpiece (the current is cut off automati- cally).
Power| Hold

Thermal coefficient

| | | See «Power» section on the following pages.

Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual.

WELDING PROCESSES

• STANDARD WELDING
  This standard MMA welding mode is suitable for most welding applications. It enables welding with all types of coated, rutile, basic and cellulosic electrodes, as well as on all materials: steel, stainless steel and cast iron.

• PULSED WELDING
  The pulsed MMA welding mode is suitable for upright (PF) applications. The pulsed setting keeps the weld pool cold while promoting material transfer. Without pulsing, vertical upward welding requires a «Christmas tree» movement, i.e. a difficult triangular movement. Thanks to Pulsed MMA welding, it is no longer necessary to perform this movement. Depending on the thickness of your workpiece, a straight upward movement should suffice. However, if you want to enlarge your weld pool, a simple sideways movement similar to downheld welding is sufficient.. In this case, you can set the frequency of your pulsed current on the display monitor. This method offers greater control of the vertical welding operation.

CHOOSING COATED ELECTRODES

• Rutile electrodes: very easy to use in any position.
• Basic electrodes: it can be used in all positions and is suitable for safety work due to its increased mechanical properties.
• Cellulosic electrodes: a very powerful arc with a high melting speed, its ability to be used in all positions makes it especially suitable for pipeline work.

CONFIGURING THE SETTINGS

| Units|
---|---|---
Percentage Hot Start| %| ****

Hot Start is an overcurrent at the ignition stage which prevents the electrode from sticking to the workpiece. The intensity (% of welding current) and the time (seconds) can be programmed.

Duration of Hot Start| s
Welding current| A| The welding current is determined by the type of electrode chosen (see electrode packaging).
Arc Force| %| Arc Force is an overcurrent administered to prevent sticking when the electrode or weld bead touches the weld

pool.

Percentage I cold| %|
Cold weather| s|
Pulse frequency| Hz| PULSE mode’s PULSING frequency.

Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual.

ADJUSTING THE WELDING CURRENT
The following settings correspond to the applicable current range depending on the type and diameter of the electrode used. These ranges are quite large as they depend on the usage and the welding position.

ADJUSTING THE ARC FORCE

It is advisable to set the Arc Force to the middle position (0) to start welding and then adjust it according to the results obtained and individual welding preferences. Note: The adjustment range of the Arc Force is specific to the type of electrode chosen.

POWER

A method developed for welding with DMOS-regulated energy control. As well as displaying the energy of the weld bead after welding, this mode allows the setting of the thermal coefficient according to the standard used: One for ASME standards and 0.6 (TIG) or 0.8 (MMA/MIG-MAG) for European standards. The energy displayed is calculated taking into account this coefficient.

OPTIONAL PUSH-PULL TORCH

A push-pull torch can be connected to the power source via the socket (I-11). This type of torch allows the use of AlSi wire even in Ø 0.8 mm with a torch length of 8 m. This torch can be used in all MIG-MAG welding modes.
The Push-Pull torch is detected by simply pulling the trigger.
When using a push-pull torch with potentiometer, the highest control range setting can be set using the interface.
The potentiometer can then range anywhere between 50% and 100% within this setting.

OPTIONAL REMOTE CONTROL

• RC-HA2 Analogue remote control (ref. 047679):
  An analogue remote control can be connected to the power source via the socket (I-11).
  This controller acts on the voltage (first potentiometer) and the wire speed (second potentiometer). These settings are then inaccessible from the power source’s interface.

• RC-HD2 Digital remote control (ref. 062122):
  A digital remote control can be connected to the power source via the NUM-1 Kit (option ref. 063938).
  This remote control is designed for MIG/MAG, MMA and TIG welding processes. It enables the welding unit to be controlled remotely. An ON/OFF button is used to switch the digital remote control on or off. When the digital remote control is switched on, the HMI power source displays the cur-rent and voltage values. As soon as the HMI is switched off or disconnected, the HMI power source is reactivated.

OPTIONAL COOLING UNIT

The cooling unit is automatically detected by the machine. To deactivate the cooling unit (OFF), please refer to the interface manual. The protections supported by the cooling unit to ensure the protection of the torch and the user are:

• Minimum coolant level.
• Minimum flow rate of coolant flowing through the torch.
• Thermal protection of the coolant.

Make sure that the cooling unit is turned off before disconnecting the inlet and outlet hoses for torch liquid. The coolant is harmful and irritates the eyes, the mucous membranes and the skin. Hot liquid may cause burns.

DRIVE ROLLERS (F) OPTIONAL

If the drive rollers are found to be worn or if using a filler wire with a diameter > 1.6 mm, it is advisable to replace the plastic wire guide:

OPTIONAL FLOWMETER KIT

The flow meter kit (ref. 073395) is used to regulate and control the gas flow at the outlet of the torch when it is connec-ted to a gas supply (Ar and Ar/Co2). The gas pressure in the system must be stable and between 2 and 7 bar. The flow rate can be set between 3 and 30 L/min.

OPTIONAL FILTER KIT

Dust filter (PN. 063143) with a filter fineness of 270 µm (0.27 mm).
Please note that the use of this filter reduces the duty cycle of your machine’s power source.
To avoid the risk of overheating due to blocked air vents, the dust filter should be regularly cleaned. Unclip and clean with compressed air.

ADDITONAL FEATURES

The manufacturer, GYS, offers a wide range of features compatible with your product. To find out more, scan the QR code.

DEFECTS: CAUSES & SOLUTIONS

Clean the contact tube or replace it with non-

stick material.

The wire slips in the roller.| Reapply the non-stick product.
One of the rollers is spinning.| Check the tightness of the roller screw.
The torch cable is twisted.| The torch cable should be as straight as possible.
The reel motor is not working.| Reel brake or roller is too tight.| Loosen the brake and rollers.
Incorrect wire unwinding.| Dirty or damaged wire guide.| Clean or replace.
Roller pin key is missing.| Reposition the pin in its slot.
Reel brake is too tight.| Loosen the brake.
No current or wrong welding current.| Improper connection of mains plug.| Check the plug connection and verify that the

plug is connected to the power supply.

Poor earth connection.| Check the earthing cable (its connection and

the condition of the clamp).

No power.| Check the torch trigger.
The wire jams after passing through the

rollers.

| Crushed wire guide sheath.| Check the sheath and torch.
Wire jamming in the torch.| Replace or clean.
No capillary tube.| Check that the capillary tube is present.
Wire speed too high.| Reduce the wire speed.
The weld bead is porous.| The gas flow is insufficient.| Adjustment range from 15 to 20 L / min.

Clean the base metal.

---|---|---
Gas cylinder empty.| Replace it.
Unsatisfactory gas quality.| Replace it.
Air circulation or wind influence.| Avoid draughts and protect the welding area.
Gas nozzle is too clogged.| Clean or replace gas nozzle.
Bad wire quality.| Use a wire suitable for MIG/MAG welding.
Condition of the welding surface is too poor (rusted, etc.).| Clean the workpiece before welding.
The gas is not connected.| Check that the gas is connected to the power

source’s inlet.

Excessive sparks.| Arc voltage is too low or too high.| See welding settings.
Poor earth connection.| Check and position the earth clamp as close as possible to the area to be welded.
Insufficient gas protection.| Adjust the gas flow.

No gas coming from the torch.

| ****

Poor gas connection.

| Check the connections of gas inlets.
Check that the solenoid valve is working.
Error while downloading.| The data on the USB stick is incorrect or

corrupted.

| Check your data.
Backup error.| You have exceeded the maximum number of backups.| You need to delete some programs.

The number of backups is limited to 500.

Automatic deletion of JOBS.| Some of your JOBs have been deleted because they were incompatible with the new pre-installed user settings (synergies).|
Push Pull torch detection error.| –| Check Push Pull torch connection.
USB key error.| There is no JOB detected on the USB stick.| –
The product’s memory space is full.| Free up some space on the USB key.

File error.

| The file does not match the pre-installed user settings (synergies) downloaded to the product.| The file was created with pre-installed user settings (synergies) that are not present on the machine.

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 by transportation.
• General wear of parts (eg. : cables, clamps, etc.).
• Damage caused by misuse (incorrect power supply, the dropping or dismantling of equipment).
• Environmental failures (pollution, rust and dust).

In the event of a breakdown, return the appliance to your distributor, together with:

• dated proof of purchase (receipt, invoice, etc.),
• a note explaining the breakdown..

SPARE PARTS

beschermrooster

|

51010

9| Faisceau analogique 14 pts| 91424ST
10|  Lock /| 71003
11|  Wirefeeder opening| 56231
12|  Glass opening /| 56238
13| Charnière / Hinge /| 56239
14| Support bobine der| 71613
15| Moto| 51201
16|  Wire feeder circuit| 97708C
| | 71857
18| Small fan| 51018
19|  Reversing button| 52468
20| LED filaire /| 51990
21|  Current sensor /| 64460
22| Circuit filtre CEM| 97804C
---|---|---
23|  Output capacitor| 96143
24| Patin| 56120
25| Power module| 97548
26|  Power transformer| 63728
27|  Cooling unit circuit| 97767C
28|  Control circuit| 97706C
29| Circuit alimentation / Power supply circuit /| 97711C
30| On/of| 56044
31|  On/off switch /| 51069
32| Cordon secteur| 21470
33| Electrovanne| 71542
34|  Large fan| 50999
35| External protection grid|

56225

CIRCUIT DIAGRAM

DISTANCE ANALOGIQUE

WIRING THE PUSH-PULL TORCH

ANALOGUE CONNECTION CABLE SPECIFICATION (FRONT OF THE WIRE FEEDER)

• 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. The power supply shows a flat output pattern.. In some countries, U0 is called TCO.

GYS UK
Filiale / Subsidiary
Unit 3
Great Central Way
CV21 3XH – Rugby – Warwickshire United Kingdom
www.gys-welding.com+44 1926 338 609
[email protected]

References

• Arc Welding, Battery Chargers & Body Repair | GYS

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