GYS EXPERT 130 1 Phase Portable Welding Machine User Manual

: June 4, 2024
: GYS

GYS EXPERT 130 1 Phase Portable Welding Machine

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.
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The manufacturer is not liable for any injury or damage caused 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. 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.
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| 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.
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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 degrease the workpiece 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 EXPLOSION 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.
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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.
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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.
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This equipment complies with the IEC 61000-3-12 standard.
This equipment complies with the IEC 61000-3-11 standard.

ELECTROMAGNETIC INTERFERENCES

| 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.
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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
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RECOMMANDATIONS 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:
a) the presence of other power cables (power supply cables, telephone cables, command cable, etc…)above, below and on the sides of the arc welding machine.
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 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;
h) 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

a. 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.
b. 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.
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. 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.
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 connectionis made with a capacitor selected according to national regulations.
f. Protection and plating :
The selective protection and plating 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 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 machine. The welding equipment must be moved in an upright position. Do not place/carry the unit over people or objects
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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 be placed in a sheltered area away from rain or direct sunlight.
The machine must not be used in an area with conductive metal dusts.
The equipment has a protection degree of IP21S, meaning :
– protection against access to dangerous parts of solid bodies of diameter >12.5 mm and,
– protection against vertical drops of water when its moving parts (fan) are stationary.
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 .
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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.
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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

NOTICE

GENERAL DESCRIPTION

The EXPERT 130 and 220 DV are traditional welding units for MMA electrode welding with direct current (DC). They can weld rutile, cast-iron, basic and stainless steel electrodes. They work on a 230V or 400V (EXPERT 220 DV only) single-phase power supply

POWER SUPPLY – START UP

This machine is delivered with a 16A plug type EEC7/7. The machine must be plugged on a 230 V (50-60Hz) socket with earth. The absorbed effective current (I1eff) is shown on the machine, for maximal using conditions. Check that the power supply and its protection (fuse and/or circuit-breaker) is compatible with the necessary current during use. In some countries, the change of plug can be necessary to allow a use at maximal conditions. The charger must be installed so that the mains plug is accessible.
To start the equipment, turn on the potentiometer to the desired current position, the power indicator lights then. Put the potentiometer on «O» for standby mode.
Connect the earth clamp and electrode-holder cables in the quick-plugs. Respect the polarities indicated on the electrode packaging.
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply network. There may be potential issues in ensuring electromagnetic compatibility in those locations, due to driven as well as radiated disturbances.
Do not use the machine in an area containing metallic conducting dust.

USE

Plug the earth lead and the electrode holder in the welding machine and connect it to the mains supply (to use the EXPERT 220 DV on a 230V socket, install the plug supplied with the machine).
Ensure the earth lead is connected to the workpiece (as close as possible to the welding area).
Set the machine at its minimum then switch it on (switch ON for the EXPERT 130 / commutator 230-0-400V for the EXPERT 220 DV). A light indicates the unit is switched on.
Select the appropriate electrode which should approximately the same thickness as the piece to be welded. Then select the appropriate welding current according to the diameter of the electrode by turning the knob and observing the setting on the scale:
– To increase the power, turn the knob clockwise,
– To decrease the power, turn the knob anti-clockwise.
Thermal protection: After a long period of welding or an intensive use, it is necessary to wait until the transformer cools down. These machines are protected by a thermostat which will automatically cut out the power to the unit to prevent damage during an overload:
– Light switched off: you can weld.
– Light switched on: you must wait.
After using the welding unit, turn off the unit with the switch (EXPERT 130) or the commutator (EXPERT 220 DV) and unplug the machine.

MAINTENANCE

Refer all servicing to qualified personnel.
Disconnect the generator and wait until the ventilator stopped before working on the unit. Inside the device, voltages and current are dangerous.
Two or three times a year, remove the steel cover and blow off the dust with compressed air. Let check the electrical connections (with an insulated tool) and the insulations by qualified personnel.
Regularly control the state of the cord. If this supply cable is damaged, it must be replaced by the manufacturer, its after sales service or a similarly qualified technician to avoid any danger.

ADVICE

Respect welding polarities and currents indicated on the electrode packaging
Remove the electrode from the electrode holder when you do not use it.
Keep the ventilated louvre passages clean to allow in/out air circulation.

SECURITY

The arc welding can be dangerous and leads serious injury, may fatal. Protect yourself and protect the others. Respect the following warnings:

Arc rays| Protect yourself thanks to a welding helmet in compliance with EN175 equipped with filters in compliance with EN 169 or EN 379. Inform and protect by the same means any people in the welding environment.
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Rain, steam, humidity| The working environment must be clean (degree of pollution ≤ 3) and protected against rain. Put the appliance on an even place and at least at one meter from the parts to be welded. Do not use in rain or snow.
Electric shocks| This appliance may only be use with a 230V monophase supply and must be earthed.
Moving| Do not underestimate the weight of the apparatus. Do not carry it over people or things. Do not drop it. Do not set it down brutally
Burns| Wear protective or fire-proof clothing (overalls, jeans).
Fire risks| Use some welder gloves and a fire-proof apron.
Smokes| Protect the others by installing non flammable protection wall , or prevent the others to not look at the arc and to keep a sufficient distance
Extra precautions| Suppress all flammable products from the working area. Do not works near flammable gas. Do not inhale gas or welding smokes. If indoors ventilate the area well and/or use local extraction ventilation equipment to remove fumes and gases. Any welding operation : – in environments with increased risk of electric shock, – in confined spaces, – in the presence of flammable or explosive materials must be evaluated in advance by an “Expert supervisor” and must always be carried out in the presence of other people trained to intervene in case of emergency. Technical protection measures MUST BE taken as described in the TECHNICAL SPECIFICATION «IEC 62081». Welding in raised positions is forbidden unless safety platforms are used.

The persons carrying pacemaker have to consult a doctor before using these machines Do not use the unit to thaw tubing.
In TIG welding, manipulate the gas bottle carefully. Indeed, there are risks if the bottle or the bottle valve are damaged

TROUBLESHOOTING

Anomalies

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Causes

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Remedies

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Thermal protection light switched on, the welding unit do not supply current.| The thermal protection of the wel- ding unit is switched on.| Wait until the end of the cooling phase.
Only the green indicator is on but you cannot weld.| Connection failure of the earth clamp or electrode holder.| Check the connections.
If, when the unit is on and you put your hand on the welding unit’s body, you feel tingling connection.| The welding unit is not correctly connected to the earth.| Check the plug and the earth of your electrical network.
Your unit does not weld correctly.| Polarity error (+/-).| Check the polarity advised on the electrode packaging.
The green indicator is on but the fan does not work or not continuously, no power when welding.| Power supply other than 230 or 400V

(EXPERT 220 DV)

| Check if the plug delivers the correct voltage. Switch off the machine for 2-3 minutes and try again.

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

WIRING DIAGRAM

Expert 130

Expert 220 DV

SYMBOLS

A

| Amps
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V

| Volt

Hz

| Hertz
| Soudage à l’électrode enrobée (MMA – Manual Metal Arc / Schweißen mit umhüllter Elektrode (MMA) Schweißen mit umhüllter Elektrode (E-Handschweißen) / Soldadura con electrodo cubierto (MMA – Ma- nual Metal Arc) / Booglassen met beklede elektrode (MMA – Manual Metal Arc / Saldatura ad elettrodo rivestito (MMA – Manual Metal) /
| Adapted for welding in environ- ment with increased risks of electrical shock. However, the welding source must not be placed in such places.

IP21S

| Protected against rain and against fingers access to dangerous parts.
| Welding alternative current.

| Single phase power supply 50 or 60Hz.

U 0

| Rated no-load voltage.
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U 1

| rated supply voltage.

I 1 max

| Rated maximum supply current (effective value).

I 1 eff

| Maximum effective supply current.

**EN60 974-1**

| The device complies with EN60974-1 standard relative to welding units.
****| Single phase inverter, converter-rectifier.

X …% @40°C

| X : duty factor at …%

I2 …%

| I2 : corresponding conventional welding current.

U2 …%

| U2 : conventional voltages in correspon- ding load.
| Ventilated
| The device complies with European Directive
| The electric arc produces dangerous rays for eyes and skin (protect yourself !)
| Caution, welding can produce fire or ex- plosion.
| The mains dis- connection mean is the mains plug in combination with the house installation. Accessibility of the plug must be guaranteed by user.
| Non-ionizing radiation
| Caution ! Read the user manual
| Separate collection required – Do not throw in a domestic dustbin
| Class 2 device
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| 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 ourwebsite (see cover page).