GYS 200-4S TRIMIG Synergic Mig Welder Instruction Manual

: June 17, 2024
: GYS

Table of Contents

INSTALLATION INSTRUCTION
DESCRIPTION
TROUBLESHOOTING
References
Read User Manual Online (PDF format)
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**GYS 200-4S TRIMIG Synergic Mig Welder Instruction Manual

**

INSTALLATION INSTRUCTION

TRIMIG

Trimig 300 G/350-4S DUO DV/350 G DV
Trimig 300 G / 350 G

DESCRIPTION

Thank you for choosing this product; please read this instruction manual carefully before installing and using the product and keep in a safe place for future reference.
The Trimig are semi-automatic welding units; they are ventilated for semi automatic welding (MIG or MAG) and are capable of welding steel, stainless steel and aluminium. Adjustment is quick and easy with their «synergic wire speed» function. They work on a 400V three-phase power supply, and /or 230V three-phase for the DV models.

electricity supply

The absorbed current (I1eff) is indicated on the device for use at maximum settings. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed during use. The device must be placed in such way that the power socket is always accessible. Do not use an extension cable which has a wire section smaller than 4 mm². These products are supplied with a 16A or 32A plug type EEC RS/015. They should be plugged in to a 400V (3PH) power socket WITH earth and protected by a 16A circuit breaker and 1 differential 30mA.

230V 3-phase power supply, for Trimig 250-4S DV, 350 G DV and 350-4S DUO DV:
WARNING: This device is pre-built in 400V three-phase. If your electrical installation is 230V three-phase, you must modify the connection on the terminal board. This modification must be undertaken by qualified personnel. In order to do so, please refer to the technical diagram inside the product. The plug must be protected by a 16A or 25A (for models 350) circuit breaker and 1 differential 30mA.

device presentation (fig ii)

On / Off switch
Power Settings – 2 switches with 7 positions: for adjustment of the welding voltage output. The adjustment of the output voltage is proportional to the thickness of the work piece.
Control panel – Welding settings (manual or automatic mode).
European standard torch connection.
Thermal Protection light: Indicates when a cool-down period is necessary following intensive use.
Torch support.
Power Cable (5m).
Earth cable connector
Gas bottle support (max 1 bottle of 10m3).
Fastening chain for bottles. Warning: fasten the chain securely (see IV-1)
Reel support Ø 200 mm/ 300mm.
Gas connector (350-4S DUO DV)
Torch Cable support
Wire feeder solenoid valve 2
Wire feeder gas connection for torch 2
Wire feeder control cable connector
Wire feeder power cable connector
Selection switch potentiometer (only on 300G and 350 G DV)

SEMI-AUTOMATIC WELDING FOR STEEL / STAINLESS STEEL (MAG MODE) (fig iii)

The Trimig 200-4S can weld 0.6/0.8/1mm steel and stainless steel wires (fig. III-A).
The device is capable of working with Ø 1.0 mm steel wire (roller Ø 0.8/1.0, contact tip of 01.0).
If using lower diameter wire, you should use change the contact tip, and ensure that the reversible rollers in the wire
feeder are positioned correctly (so that required diameter is visible when in place). The Trimig 250-4S DV 230-400V can weld 0.8/1/1.2mm steel and stainless steel wires. The device is capable of working with Ø 1mm steel wire (roller Ø 0.8/1.0, contact tip of 1). The Trimig 300-4S, 300 G, 350-4S DUO DV and 350 G DV can weld 0.8/1/1.2mm steel and stainless steel wires. The device is capable of working with Ø 1mm steel wire (roller Ø 1.0/1.2, contact tip of 1).
For Steel or Stainless Steel, you will need to use specific gas – Argon + CO2 (Ar + CO2). The proportion of CO2 will vary depending on usage. The gas flow for steel is between 10 and 20L / min depending on the environment and experience of the welder.

SEMI-AUTOMATIC WELDING FOR ALUMINIUM (MIG MODE) (fig iii)

The Trimig 200-4S can weld 0.8mm and 1mm aluminium wires. (fig. III-B).
The Trimig 250, 300 and 350 can weld 1mm and 1.2mm aluminium wires. (fig. III-B).
To weld aluminium, neutral gas “pure Argon” (AR) is required. For specific gas requirements seek advice from your gas distributor. The gas flow in aluminium should be between 15 and 25 L / min depending on the environment and experience of the welder. Things to note when welding with Aluminium

Set the pressure of the rollers to a minimum so as not to crush the wire
Remove the capillary tube before connecting the aluminium torch
When welding aluminium use a special aluminium torch with Teflon sheath to reduce friction
Do not cut the sheath near the connector! It is used to guide the wire from the rollers (fig III-B).
Contact Tip: Use the specific Aluminium contact tip corresponding to the diameter of the wire.

SEMI-AUTOMATIC BRAZING FOR HIGH-TENSILE STRENGTH STEELS

The Trimig 200-4S can braze-weld high-tensile strength plates with Cuprosilicium CusI3 wire or Cuproaluminium CuAl8 wire (Ø 0.8 mm and Ø 1 mm). The welder must use a neutral gas: pure argon (Ar). For specific gas requirements seek advice from your gas distributor. The required gas flow is between 15 and 25L / min.

REEL AND TORCH ASSEMBLY (fig iv)

Open the door of the machine.

Position the reel on to the support (3). To place a 200mm wire reel, first install the adapter (ref. 042889) on the
support.
Adjust the reel brake (4) to avoid the reel movement tangling the wire when welding stops. Be careful not to tighten
too much! Then tighten the plastic screw (2) firmly.
The wire feeder uses double groove rollers (8) (Ø 0.8/ Ø 1 or Ø 1/ Ø 1.2). The visible diameter on the roller when fitted is the one currently in use. For Ø 1 mm wire, use the Ø 1 groove.
For first use:
- Release the fixing screw of the wire guide (5).
- Place the rollers, and tighten the screws (9).
- Place the wire guide (7) as close as possible to the roller but without touching it, then tighten the fixing screw.
To select the adjustment of the drive rollers (6) : loosen the knob fully, Start the motor by pressing the trigger of the torch, tighten the knob whilst pressing the trigger until the wire starts to move. Bend the wire where it comes out of the nozzle and hold it in place to stop its progress. The setting is correct when the guide roller slides over the wire, even when it is blocked at the end of the torch.
Common adjustment of knob (6): scale 3-4 for steel, and scale 2-3 for aluminium.

CHOICE OF REELS

Possible settings:

Wire type	Torch	Gas
Steel	Ø 300	x
Ø 200	x
Stainless	Ø 200	x
AluAG5	Ø 300	x*
Ø 200	x*

Consider Teflon sheath and special aluminium contact tip

GAS COUPLING

Fit the regulator/flowmeter to the gas bottle and then fit the gas pipe to the connector. To avoid gas leaks use the collars provided in the accessories box. Ensure proper maintenance of the gas cylinder in accordance with the attachment of the chain cf. IV-1.

CONTROL PANEL (fig v)

Welding mode selection (2)
2T: two-stage welding
4T: 4-stage welding
SPOT : Spot welding with adjustable spot diameter Wire speed selection (4) Wire speed regulator The speed varies from 1 to 15 m/minute. SPOT/DELAY setting potentiometer (5) Manual Mode (1)
In manual mode, the wire speed is determined by the user by adjusting the potentiometer (4)

Synergic Mode (3)
Position the potentiometer (4) in the middle of the « OPTIMAL SYNERGIC » zone
In this mode, the device determines the optimum wire speed according to 3 parameters:

Voltage
Wire diameter
The power mode
It is possible to adjust the speed wire + / -.

“manual” mode (fig v)

To set your device, proceed as follows:
Choose the welding voltage using the 2 power switches (2 and 7 positions)
Example:
For welding Steel – 1 mm with a Ø 0.8 wire, set the switch to «1» Adjust the wire speed with potentiometer (4).

Advice:
The wire speed adjustment is often determined by « the noise »: the arc must be stable and emit low crackling.
If the speed is too low, the arc will not be continuous.
If the speed is too high, the arc crackles and the wire will push back the torch.

“synergic” mode (fig v)

This function automatically controls the wire speed. There is no need to set the wire speed manually.

Position the wire speed potentiometer (4) in the middle of the « Optimal synergic » zone.
• Select:
Wire type (3)
Wire diameter (3)
Power setting (switch on the front)
To select the right position in accordance with the thickness of the work piece, please refer to the “synergic mode” table on the previous page.

From the settings chosen, the Trimig determines the optimum wire speed and the device is ready to weld. It is also possible to adjust the wire speed if necessary by adjusting potentiometer + or – manually (4). The last welding configuration is saved in the memory automatically (wire diameter, wire type, mode).

ADVICE and THERMAL PROTECTION

Trimig should not be lifted by its handles, torch support, or the top of the machine. When lifting the Trimig, ensure the weight is fully supported at the bottom of the machine. There must be no gas bottle connected during this operation.
Always respect the basic rules of welding.
Do not block/cover the ventilation holes of the machine.
Leave the device plugged in after welding to allow proper cooling down.
Thermal protection: If the machine becomes too hot, the warning light will illuminate and the machine will stop. Cooling will take a few minutes, the length of time will also depend on the external temperature.

DUTY CYCLE and WELDING ENVIRONMENT IN USE

The welding unit describes an output characteristic of “constant current” type. The duty cycles following the standard EN60974-1 (at 40°C on a 10mn cycle) are indicated in the table below:

x/60974-1 @ 40°C	I max	60%	100%
Trimig 200-4S	200A @ 30%	140A	120A
Trimig 250-4S	250A @ 30%	180A	140A
Trimig 300-4S et G	300A @ 35%	240A	180A
Trimig 350-4S DUO et G DV	350A @ 35%	270A	220A

Note : The machines’ duty cycle has been tested at room temperature (40°C) and has been determined by simulation.

These are Class-A devices. They are designed to be used in an industrial or professional environment. In a different environment, it can be difficult to ensure electromagnetic compatibility, due to conducted disturbances as well as radiation.
These devices comply with IEC 61000-3-12, provided that the power of the short-circuit Ssc is equal to or greater than 3.9MVA (2.8MVA for the Trimig 200-4S) at the interface between the machine and the mains power network. It is the responsibility of the installer or user of the equipment to ensure if necessary by consulting the operator of the mains electricity, that the equipment is only connected to a power supply where the power of short-circuit ssc is equal to or greater than 3,9MVA (2.8MVA for the Trimig 200-4S)

Maintenance

Maintenance should only be carried out by a qualified person.
Ensure the machine is unplugged, and that the ventilator inside has stopped before carrying out maintenance work. (DANGER High Voltage and Currents).
GYS recommends removing the steel cover 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 cord. If damaged, it will need to be replaced by the manufacturer, its’ after sales service or a qualified person.
Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.
Before each use, check the state of welding cables of the torch and earth clamp (The conductive metal should not be exposed).

SAFETY

Arc welding can be dangerous and can cause serious and even fatal injuries. Protect yourself and others. Ensure the following safety precautions are taken:
Arc radiation: Protect yourself with a helmet fitted with filters in compliance with EN169 or EN 379. Rain, steam, damp: Use your welding unit in a clean/dry environment (pollution factor ≤ 3), on a flat surface, and more than one meter from the welding work-piece. Do not use in rain or snow.
Electric choc: This device must only be used with an earthed power supply. Do not touch the parts under high voltage. Check that the power supply is suitable for this unit.
Falls: Do not place/carry the unit over people or objects.
Burns: Wear protective (fire-proof) clothing (cotton, overalls or jeans).
Wear protective gloves and a fire-proof apron. Ensure other people keep a safe distance from the work area and do not look directly at the welding arc. Protect others by installing fire-proof protection walls.
Fire risks: Remove all flammable products from the work area. Do not work in presence of flammable gases.
Fumes: Do not inhale welding gases and fumes. Use the device in a well ventilated environment, with artificial extraction if welding indoors.

Additional Precautions: Any welding operation undertaken in…..

rooms where there is an increased risk of electric shocks,
Poorly ventilated rooms,
In the presence of flammable or explosive material,
Use should always be approved by a “responsible expert”, and made in presence of people trained to intervene in case of emergency.
Technical protection as described in the Technical Specification CEI/IEC 62081 must be implemented. Welding in raised positions should not be undertaken, except in case of safety platforms use.

People wearing Pacemakers are advised to see their doctor before using this device. Do not use the welding unit to unfreeze pipes. Handle gas bottles with care – there is increased danger if the bottle or its valve are damaged.

TROUBLESHOOTING

Symptoms	Reasons	Solutions
******** The welding wire speed is not constant.	**** Cracklings block
up the opening.	Clean out the contact batch or change it and replace the

anti-adherence product. Ref.041806
**** The wire skids in the rollers.| Control the roller pressure or replace it.Wire diameter non-consonant with roller.Covering Wire guide in the torch non- consonant.
The unwinding motor doesn’t operate.| Reel or roller brake too tight.| Release the brake and rollers.
Electrical supply problem.| Check that the running button is on the position on.
Bad wire unwinding.| Covering wire guide dirty or damaged.| Clean or replace
Reel brake too tight| Release the brake
**** No welding current| Bad connection to the main supply.| See the branch connection and look if the plug is fed by 3 phases.
Bad earth connection.| Control the earth cable (connection and clamp condition).
Power contactor inoperative.| Control the torch trigger.
**** The wire rubs down after the rollers.| Covering wire guide crushed.| Check the covering and torch body.
Locking of the wire in the torch| Clean or replace.
No capillary tube.| Check the presence of capillary tube.
Wire speed too fast| Reduce the wire speed
**** The welding cord is porous| The gas flow rate is not sufficient.| Adjusting flow range 15 to 20 L / min. Clean the working metal.
Gas bottle empty.| Replace it.
Gas quality non-satisfying.| Replace it.
Air flow or wind influence.| Avert air blast, protect welding area.
Gas nozzle too full.| Clean or replace the gas nozzle.
Bad wire quality.| Use adapted WIRE for MIG-MAG welding.
Surface to weld in bad condtion. (rust, etc, …)| Clean the working parts before welding.
Very important flashing particules.| Arc voltage too low or too high.| See welding settings.
Bad earth connection.| Check and place the earth cable to have a better connection.
Protecting gas insufficient.| Adjust the gas flow.
No gas at the torch output.| **** Bad gas connection.| See if the gas coupling beside the engine is well connected. Check the flowmeter and the solenoid valves.