GYS 400 AC-DC Titanium TIG Welder Instruction Manual

: June 1, 2024
: GYS

GYS 400 AC-DC Titanium TIG Welder

GYS-400 AC-DC-Titanium-TIG-Welder-product

Product Specifications

Model: TITANIUM 400 AC/DC, TITANIUM 230 AC/DC FV
Product Type: TIG AC/DC – MMA Welding Machine
Model Number: 73502 V2
Release Date: 08/03/2024

Interface Homme Machine (IHM)
The Interface Homme Machine (IHM) includes various components such as:

Trappe for connector kit NUM TIG-1 (option ref. 037960)
Trappe for connector kit NUM-1 (option ref. 063938) – for 230 AC/DC only
Commutateur ON / OFF
Connecteur USB
Connecteur analogique
Connecteur d’alimentation et pilotage du groupe de refroidissement

Raccordement Gaz
Connect the gas supply according to the following specifications:

TITANIUM 400 AC/DC: 400 V
TITANIUM 230 AC/DV FV: 110 V or 230 V

Mode de Soudage TIG (GTAW)
Adjust the welding parameters based on the material and thickness being welded. Follow the guidelines below:

TIG DC:
- Wire Diameter (mm): 0.3 – 10
- Current Range (A): 3 – 400
TIG AC:
- Amperage Range: 15 – 480 A

Post Gaz
Configure the post-gas settings based on the welding requirements. Adjust parameters such as Step, Mode, Pulse frequency, etc.

Frequently Asked Questions (FAQ):
Q: How do I activate the VRD function?
A: To activate the Voltage Reduction Device (VRD) function, refer to the user manual for specific instructions based on your model.

$GYS-400 AC-DC-Titanium-TIG-Welder- $2$$ $GYS-400 AC- DC-Titanium-TIG-Welder- $2$$

WARNINGS – SAFETY REGULATIONS

GENERAL INFORMATION

These instructions must be fully read and understood before operating the machine.
Do not carry out any modifications or maintenance work that is not included in the user manual.

Any personal injury or material damage due to use that does not comply with the instructions in this manual cannot be held at the expense of the manufacturer.
If you have a problem or query, please consult a qualified technician to set up the device correctly.

THE ENVIRONMENT

This equipment should only be used for welding operations within the limits indicated on the rating plate and/or in the user manual. The safety regulations must be observed. In the event of improper or dangerous use, the manufacturer shall not be held liable.
The device must be set up and operated in a location that is free of dust, acids, flammable gases and other corrosive substances. The same applies to the device’s storage. Make sure there is sufficient air circulation when in use.

Temperature ranges:
Use 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).
Less than or equal to 90% at 20°C (68°F).

Altitude :
Up to 1,000 m 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 source of heat, light and radiation from the arc as well as electromagnetic fields (caution to those with pacemakers), risk of electrocution, noise and gaseous fumes.

To protect yourself and others, follow these safety instructions:

To protect yourself from burns and radiation, wear insulating, dry, fireproof clothing in good condition without lapels; the clothing must cover the whole body.
Wear gloves that provide electrical and thermal insulation.
Use welding PPE and/or a welding helmet with a sufficient protection level (depending on the application). Protect your eyes during cleaning operations. Wearing contact lenses is strictly forbidden.
It is sometimes necessary to enclose the welding area with fireproof curtains to protect it from arc radiation, spatter and incandescent waste.
Inform people in the welding area not to look at the arc rays or the molten parts and to wear the appropriate clothing to protect themselves.
Wear noise-cancelling headphones if the welding process reaches a noise level above the permissible limit (these must be worn by anyone in the welding area).
Keep hands, hair and clothing away from moving parts (the fan).
Never remove the cooling unit’s protective casing when the welding power source is on; the manufacturer cannot be held responsible in the event of an accident.
Newly welded parts are hot and can cause burns when handled. When carrying out maintenance on the torch or electrode holder, make sure that it has sufficiently cooled by waiting at least 10 minutes before starting any work. The
cooling unit must be switched on when using a water-cooled torch to make sure that the liquid does not cause burns.
It is important to secure the work area before leaving it, this is to protect people and property.

WELDING FUMES AND GASES

The fumes, gases and dusts emitted by welding are health hazards. Sufficient ventilation must be provided and an air supply may be required. An air-fed mask could be a possible solution if there is inadequate ventilation.
Check that the extraction system is operating effectively by checking it against relevant safety standards.

Caution: welding in confined environments requires remote monitoring for safety reasons. Furthermore, welding certain materials that contain lead, cadmium, zinc, mercury or even beryllium, can be particularly harmful; it is important to thoroughly degrease the parts before welding them.
Gas cylinders must be stored in an open or well-ventilated area. They must be in an upright position and held on a support or on a trolley.
Do not weld near grease or paint.

FIRE AND EXPLOSION RISK
Fully shield the welding area; flammable materials should be kept at least 11 metres away. Fire fighting equipment must be nearby during welding operations.

Beware of hot material or sparks being projected, even through cracks; they can cause a fire or explosion.
Keep people, flammable objects, and pressurised containers at a safe distance.
Welding in closed containers or tubes should be avoided and if they are open they should be emptied of any flammable or explosive material (oils, fuels and gas residues, etc.).
Grinding operations must not be directed towards the welding power source or towards any flammable materials.

GAS CYLINDERS

The gas coming out of the gas cylinders can cause suffocation if it becomes concentrated in the welding area (ventilate well). Transportation must be done carefully and safely: gas cylinders must be shut off and the welding power source must be switched off. They must be stored vertically and supported to limit the risk of falling.
Close the gas cylinder between uses. Beware of temperature variations and sun exposure.
The gas cylinder must not come into contact with flames, electric arcs, torches, earth clamps or any other heat or incandescent sources.
Be sure to keep it away from electrical and welding circuits and, therefore, never weld a pressurised cylinder.
Be careful when opening the gas cylinder’s valve, keep your head away from the valve and make sure that the gas used is suitable for the welding process.

ELECTRICAL SAFETY

The electrical power supply must be earthed. Use the fuse size recommended on the information panel. Electric shocks can cause serious direct or indirect accidents and even death.
Never touch live parts inside or outside the live power source (torches, clamps, cables and electrodes) as these parts are directly connected to the welding circuit.
Before opening the welding current source, it must be disconnected from the mains and wait 2 minutes. so that all the capacitors are discharged. Do not touch the torch or electrode holder and the earth clamp at the same time.
Make sure to have the cables and torches replaced by a qualified and authorised technician if they become damaged. Select the cable’s cross-section size according to the intended application. Always wear dry, undamaged clothing to insulate yourself from the welding circuit. Wear insulated footwear in all work environments.

THE EQUIPMENT’S EMC CLASSIFICATION

This Class A equipment is not suitable for use in a residential setting where power is supplied from the public, low voltage, supply network. There may be difficulties in ensuring electromagnetic compatibility at these sites, this is due to both conducted and radiated radio frequency interference.

TITANIUM 230 AC/DC FV:
Provided that the public, low-voltage, supply-network impedance at the point of common coupling is less than Zmax = 0.173 Ohms, this equipment complies with standard IEC 61000-3-11 and can be connected to public, low-voltage supply networks. The installer or user of the equipment is responsible for ensuring that the network impedance complies with the impedance restrictions, this may involve consulting with the distribution network operator if necessary.

TITANIUM 400 AC/DC:
This material complies with IEC 61000-3-11.

TITANIUM 230 AC/DC FV:
This material complies with IEC 61000-3-12.

TITANIUM 400 AC/DC:
This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private, low-voltage networks that are connected to the public supply network only at medium- and high-voltage levels. If connected to a public, low voltage supply network, it is the installer’s or user’s responsibility to ensure that the equipment can be connected to the power supply by consulting with the distribution network operator.

ELECTRO-MAGNETIC EMISSIONS

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 (EMF) can interfere with some medical implants, such as pacemakers. Protective measures must be taken for people with medical implants. For example, restricted access for passers-by or an individual risk assessment for welding professionals.
All welders must carry out the following procedures to minimise exposure to electromagnetic fields from the welding circuit:

position the welding cables together and secure them with a clamp, if possible
position yourself (head and torso) as far away from the welding circuit as possible
never wrap the welding cables around your body
do not position your body between the welding cables • keep both welding cables on the same side of your body
connect the return cable to the workpiece as close as possible to the area to be welded
do not work next to, sit on or lean against the welding power source
do not weld when transporting the welding power source or the wire-feed reel

Those with pacemakers should consult a physician before using this equipment.
Exposure to electromagnetic fields during the welding process may have other health effects that are not yet known.

RECOMMENDATIONS FOR EVALUATING THE WELDING AREA AND SET UP

General Information
The user is responsible for setting up and using the arc-welding equipment according to the manufacturer’s instructions. If electromagnetic interference is detected, it is the arc-welding equipment user’s responsibility to resolve the situation with the manufacturer’s technical assistance. In some cases, this corrective action may be as simple as earthing the welding circuit. In other cases, an electromagnetic shield may need to be constructed around the welding power source as well as the entire workpiece with input filters installed. In all instances, electromagnetic interference should be reduced until it is no longer a concern.

Assessing the Welding Area
Before setting up arc welding equipment, the user must assess the potential electromagnetic issues in the surrounding area. The following should be taken into account:

the presence of other power, control, signal and telephone cables either above, below or next to the arc-welding equipment
radio and television receivers and transmitters
computers and other control equipment
safety-critical equipment, such as industrial equipment safeguarding
the health of people nearby, for example, those with pacemakers or hearing aids
the calibration or measurement equipment used
the immunity of other equipment located nearby
The user must verify that the other equipment used in the surrounding environment is compatible. This may require additional protective measures:(h) the time of day when welding or other activities are to be carried out
The size of the surrounding area to be taken into account depends on the structure of the building and other activities taking place there. The surrounding area may extend beyond the facility’s boundaries.

Assessing the Welding Equipment
In addition to assessing the surrounding area, the arc-welding equipment can also be assessed to identify and resolve instances of disturbance. The emissions assessment should include in situ readings as specified in Article 10 of CISPR 11. In situ readings can also be used to confirm whether the mitigation measures are effective.

RECOMMENDATIONS ON METHODS FOR REDUCING ELECTROMAGNETIC EMISSIONS

Public power supply network: Arc-welding equipment should be connected to the public power supply following the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional preventive measures such as filtering the public power supply. Consider shielding the power cable within a metal conduit or equivalent for permanently set up arc-welding equipment. The shielding must be electrically continuous along its entire length. The shielding should be connected to the welding power source to ensure good electrical contact between the conduit and the welding power source’s casing.
Maintaining arc-welding equipment: Arc-welding equipment must undergo routine maintenance according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc-welding equipment is in use. The arc-welding equipment must not be modified in any way, except for those modifications and adjustments specified in the manufacturer’s instructions. In particular, the arc ignition and stabiliser’s spark gap must be adjusted and maintained according to the manufacturer’s recommendations.
Welding cables: The welding cables should be as short as possible and placed close together near or on the ground.
Equipotential bonding: Consider linking together all metal objects in the surrounding area. However, metal objects connected to the workpiece will increase the risk of electric shocks to the user if they touch both the metal objects and the electrode. Therefore, the operator must be isolated from such metal objects.
Earthing the workpiece: Where the part to be welded is not earthed for electrical safety reasons or because of its size and location, e.g. a ship’s hulls or a building’s structural steel framework, an earthed connection can, in some cases but not always, reduce emissions. Care should be taken to avoid earthing parts which could increase the risk of injury to users or damage to other electrical equipment. If necessary, the workpiece’s earth connection should be made directly. However, in certain countries where this direct connection is prohibited, the connection should be made with a suitable capacitor chosen in accordance with national regulations.
Protective and shielding measures: Selectively protecting and shielding other cables and equipment in the surrounding area can limit interference issues. Protecting the entire welding area could be an option for special applications.

TRANSPORTING AND MOVING THE WELDING MACHINE
The welding power source is equipped with a top handle allowing it to be carried by hand. Be careful not to underestimate the weight of the machine. The handle is not intended as a means of hoisting or suspending the machine.

Do not use the cables or torch to move the welding current source. It must be moved in an upright position.
Do not carry the welding machine over people or objects.
Never lift a gas cylinder and the welding current source at the same time. They have different transportation requirements.

SETTING UP THE EQUIPMENT

Place the welding power source on a floor with a maximum inclination of 10°.
Provide a sufficient area to properly ventilate the source of the welding current and access the machine’s controls.
Do not use in an environment with conductive metal dust.
The welding power source must be protected from heavy rain and out of direct sunlight.
The equipment has an IP23 protection rating, meaning:
it is protected against dangerous access by solid bodies with a diameter >12.5 mm
it is protected against rain falling at 60° to the vertical
This equipment is, therefore, suitable for outdoor use in accordance with its IP23 protection rating.

Power, extension and welding cables must be fully unwound to avoid overheating.

The manufacturer assumes no responsibility for damage to persons and objects caused by improper or dangerous use of this equipment.

MAINTENANCE / ADVICE

$GYS-400 AC-DC-Titanium-TIG-Welder- $9$$ Maintenance should only be carried out by a qualified technician. Annual maintenance is recommended.
Switch off the power supply by disconnecting the plug and waiting for two minutes before carrying out work on the equipment. Inside, the voltages and intensities are high and dangerous.
- Regularly remove the cover and blow out the dust Take the opportunity to have the electrical connections checked by a qualified technician using an insulated tool.
Check the power cable’s condition regularly. If the power cable is damaged, it must be replaced by the manufacturer, their after-sales service department or a similarly qualified technician to avoid hazards.
Leave the welding power source’s vents free to allow air to enter and exit the machine.
Do not use this welding power source for thawing pipes, recharging batteries/accumulators or starting motors.

SETUP – OPERATING THE PRODUCT

Only experienced persons, authorised by the manufacturer, may set up the device. During setup, ensure that the power source is disconnected from the mains system. Serial or parallel power source connections are not allowed. It is recommended to use the welding cables supplied with the unit in order to achieve the product’s optimum settings’ configuration.

DESCRIPTION

This equipment is a power source for TIG welding with a direct current (DC TIG) or an alternating current (AC TIG) as well as for coated-electrode welding (MMA).

EQUIPMENT DESCRIPTION (I)

Human Machine Interface (HMI)
Positive polarity socket
Torch gas connection
Torch button connection
Negative polarity socket
Cylinder gas connection
Digital TIG-1 kit connection (optional extra, P.N. 037960) NUM-1 kit connection (option ref. 063938) = 230 AC/DC FV only
ON/OFF Switch
Power supply cable
USB connection
Analogue connection
Reel or remote HMI connection = 400 AC/DC only
Power supply connection and cooling unit management connection $GYS-400 AC-DC-Titanium-TIG-Welder- $2$$

HUMAN-MACHINE INTERFACE (HMI)
Please read the Human Machine Interface (HMI) user manual which forms part of the complete hardware documentation.

POWER SUPPLY-START-UP

TITANIUM 230 AC/DC FV:
This equipment is delivered with a single-phase, three-pin (E/N/L), 230 V/16 A, CEE17 socket. It comes equipped with «Flexible Voltage» technology and can be supplied from an earthed electrical installation between 110 – 240 V (50 – 60 Hz).

TITANIUM 400 AC/DC:
This equipment is fitted with a 32 A, EN 60309-1 socket and should only be used on a three-phase, 400 V (50 – 60 Hz), four-wire electrical network with an earthed neutral pin.

The effective absorbed current (I1eff) for the ideal operating conditions is indicated on the equipment. Check that the power supply and its safeguards (the fuse and/or circuit breaker) are compatible with the required current. It may be necessary to change the plug in some countries to allow the pro-duct to operate at its optimum conditions.

The welding current source will go into a protective mode if the supply voltage goes below or above 15% of the specified voltage(s) (a fault code will appear on the display).
Switching the device on is done by turning the ON/OFF switch (I-8) to the I position; conversely, switching it off is done by turning it to the 0 position. Warning! Never turn off the power supply when the machine is charging.
Fan performance: This equipment is fitted with an intelligent ventilation management system to minimise the machine’s noise level. The fans will adapt their speed to match the device’s current application and the ambient temperature. The fan will run continuously in MMA mode. In TIG mode, the fan will only run during the welding phase and then stop after cooling.
Warning: increasing the length of the torch or return cables beyond the maximum length specified by the manufacturer will increase the risk of electric shock.
Arc ignition and arc stabilising are both designed for manual and mechanically guided operations.

CONNECTING TO THE POWER SOURCE
This equipment can be operated using battery-based power sources provided that the auxiliary power meets the following requirements:

The voltage must be alternating, set as specified and with a peak voltage of less than 700 V for the TITANIUM 400 AC/DC and 400 V for the TITANIUM 230 AC/DC FV
The frequency must be between 50 – 60 Hz
Checking these conditions is crucial as many power sources produce high voltage spikes that can damage equipment.

USING ELECTRICAL EXTENSION CABLES

All extension cables must be of an appropriate length and cross-section for the equipment’s voltage. Use an extension cable that complies with na-tional regulations. $GYS-400 AC-DC-Titanium-TIG-Welder- $10$$

GAS CONNECTION

This equipment is equipped with two couplings. A cylinder coupling for putting gas into the device and a torch gas coupling for releasing gas from the end of the torch. We recommend that you use the adaptors supplied with the welding machine to ensure optimum connections.

ACTIVATING THE VRD FEATURE (VOLTAGE REDUCTION DEVICE)

The voltage reducing device (or VRD) is only available for the TITANIUM 230 AC/DC.
This device protects the welder. The welding current is delivered only when the electrode makes contact with the workpiece (low resistance). The VRD function lowers the voltage as soon as the electrode is removed.
The voltage reduction device is deactivated by default. In order to activate it, the user must first open the product and complete the following proce- dure:

DISCONNECT THE PRODUCT FROM THE POWER SUPPLY and wait for five minutes to ensure that it is safe.
Remove the power source’s side panel (see page 89).
Locate the control board and VRD switch (see page 89).
Turn the switch to the ON position.
The VRD function is now activated.
Replace the power source’s side panel.
The VRD icon on the device’s user interface (HMI) will now be lit up.
To deactivate the VRD function, simply switch the switch back to the OFF position.

RECOMMENDED COMBINATIONS $GYS-400 AC-DC-Titanium-TIG-Welder- $11$$ $GYS-400 AC-DC-Titanium-TIG-Welder- $12$$

TIG WELDING MODE (GTAW)

CONNECTIONS AND ADVICE

TIG welding requires gas shielding (argon).
Connect the earth clamp to the positive (+) connector. Connect the torch’s power cable to the negative (–) connection as well as to the torch and gas button(s) connections.
Make sure that the torch is well fitted and that the consumables (vice grip, collar support, diffuser and nozzle) are not worn out.
The choice of electrode depends on the TIG welding current.

SHARPENING THE ELECTRODE
For optimum performance, it is recommended to use an electrode sharpened in the following way:

L = 3 x d for a low current
L = d for a strong current

PROCESS SETTINGS $GYS-400 AC-DC-Titanium-TIG-Welder- $14$$

Accessing certain welding parameters is dependent on the selected display mode: Settings/Display mode: Easy, Expert or Advanced. Refer to the HMI manual.

WELDING PROCESSES

Synergy TIG
No longer based on the chosen DC current or the welding cycle’s parameter settings but, instead, incorporates welding rules/synergies based on experience. As a result, this mode restricts the number of settings to three basic ones: Material type, welding thickness and welding position.
TIG DC
Suitable for welding ferrous metals such as steel and stainless steel as well as copper, its alloys and titanium.
AC TIG
Suitable for welding aluminium, its alloys and copper.
TIG Wizard
Wizard Lab:
see «Wizard Lab» chapter on the subsequent pages.

Aluminum Wizard, Stainless Steel Wizard, Steel Wizard, Copper Wizard:
This mode is used for pre-assembling or welding parts made of light alloys (AlSi, AlMg and Al99), stainless steel (CrNi), steel (Fe) and copper (CuZn and Cu). The relevant settings, in the form of pre-installed synergies, are the thickness of the parts to be welded and the joint type (butt welding (BW), fillet weld (FW), interior angle (BP), exterior angle or fusing wires together when butt welding. To switch from one mode to the other, press button n°4 on the keyboard (see HMI user manual).

SETTINGS – DC TIG

Standard
This welding method enables high-quality welding on most ferrous materials such as steel, stainless steel, copper, its alloys and titanium. The various current and gas management options offer the user perfect control of the welding operation, from the very start of the welding process to the final cooling of the weld bead.
Pulsed
This pulsed current welding mode combines strong current pulses (I, welding pulse) with weak current pulses (I_Cold, cooling pulse). This pulsed mode allows parts to be assembled whilst limiting both the temperature rise and amount of distortion. Also ideal for in-position welding.

Example:
The welding current (I) is set to 100 A and % (I_Cold) is set to 50%, i.e. cold current = 50% x 100 A = 50 A.
F (Hz) is set to 10 Hz, the frequency of the pulse will be 1/10 Hz = 100 ms; this means that every 100 ms, there will be a pulse at 100 A, then another at 50 A will follow.

FastPulse
This very high-frequency, pulsed-current welding mode combines high current pulses (I, welding pulse) with low current pulses (I_Cold, workpiece cooling pulse). FastPulse mode maintains the arc when using the high-frequency pulsed welding mode, however, it operates at frequencies that are less unpleasant, or even inaudible, to the welder.
Spot welding
This spot welding mode allows parts to be pre-assembled before welding. Spot welding can be controlled manually using the trigger or by a predefined time delay. This spot welding time makes it easier to reproduce and produce non- oxidised spot welds.
Multi-Spot
This is a spot welding mode similar to SPOT TIG but with defined spot welding and stopping times as long as the trigger is held down.
Tack welding
The machine’s tack welding mode can also be used to pre-assemble parts before welding but this time in two phases: the first phase of pulsed DC welding concentrates the arc for better penetration; this is followed by a second phase of standard DC welding, which widens the arc and therefore the weld pool to ensure the tack weld.
The times of the two tack welding phases are adjustable which makes it easier to reproduce and carry out non-oxidised tack welds.
Multi-Tack
It is a pointing mode similar to TIG Tack, but with a sequence of pointing times and stop times defined as long as the trigger is pressed.

SETTINGS – AC TIG

Standard
This welding mode is dedicated to welding aluminium and its alloys (Al, AlSi, AlMg and AlMn). The alternating current allows the aluminium to be stripped clean, which is essential for welding properly.

Balance (%T_AC
During the positive wave, any oxidation is removed. During the negative wave, the electrode cools down and the parts are welded together, this is called penetration.
By changing the ratio between the two alternations via the balance setting, either cleaning is favoured or penetration (the default setting is 30%).

$GYS-400 AC-DC-Titanium-TIG-Welder- $16$$

Pulsed
This pulsed current welding mode combines strong current pulses (I, welding pulse) with weak current pulses (I_Cold, cooling pulse). This pulsed mode allows parts to be assembled whilst limiting both the temperature rise and amount of distortion. Also ideal for in-position welding.

Example:
The welding current (I) is set to 100 A and % (I_Cold) is set to 50%, i.e. cold current = 50% x 100 A = 50 A.
F (Hz) is set to 10 Hz, the frequency of the pulse will be 1/10 Hz = 100 ms; this means that every 100 ms, there will be a pulse at 100 A, then another at 50 A will follow.

SPOT WELDING
This spot welding mode allows parts to be pre-assembled before welding. Spot welding can be controlled manually using the trigger or by a predefined time delay. This spot welding time makes it easier to reproduce and produce non- oxidised spot welds.
Multi-Spot
This is a spot welding mode similar to SPOT TIG but with defined spot welding and stopping times as long as the trigger is held down.
AC Mixed
This AC welding method is used to weld aluminium and its thick alloys. It mixes DC sequences during AC welding processes which increases the energy delivered to the workpiece. The ultimate goal is to accelerate the work flow rate and, therefore, subsequent productivity when assembling aluminium. This mode cleans the workpiece less, so it is important to work on clean sheet metal.

E-TIG

This mode allows welding with a constant power supply by measuring the arc length variations in real time to ensure a weld bead with consistent width and penetration. In cases where the assembly process requires the welding energy to be controlled, E-TIG mode guarantees that the welder will respect the welding power regardless of the torch’s position in relation to the workpiece.

$GYS-400 AC-DC-Titanium-TIG-Welder- $17$$

Wizard Lab
This welding mode allows complex (non-standard) welding cycles to be carried out with a series of steps. Each step is characterised by a current ramp, a step and a particular current type (DC, AC or pulsed).
Wizard Lab is configured in three stages:

welding cycle sequence (number of steps, repetition loops, etc.)
each step’s parameter settings (ramp and current type, etc.)
specific, advanced parameter settings $GYS-400 AC-DC-Titanium-TIG-Welder- $18$$
STEP: each step can be customised by changing the current type (DC or AC), the current form (standard or pulsed) as well as the ramp up to the set welding current (see «Setting a STEP» section). Each step can be fully customised.
Welding cycle: a welding cycle consists of a Pre-Gas stage, one or more welding steps (see «Welding Cycle Definition» section) and a Post-Gas stage.

Loops: there are two different loops (see «Definition of the welding cycle» section):

The welding cycle’s inner loop (B1). Within the cycle, the user can choose to make one or more loops (repeating two or more of the welding steps); the user can even carry out infinite loops depending on the application, for example, AC MIX welding, which repeats two DC and AC steps.
Cycle loops (B2). The user can choose to repeat the cycle (excluding the Pre-Gas and Post-Gas phases) once or several times (or even infinitely). They can also adjust the delay period between two repeated welding steps if necessary (e.g. MULTITACK welding, which repeats the TACK welding cycle with a delay period between two points as long as the trigger is held down).

Defining the welding cycle $GYS-400 AC-DC-Titanium-TIG-Welder- $19$$

Setting up a STEP $GYS-400 AC-DC-Titanium-TIG-Welder- $20$$

In 2T mode, the step duration settings control allows the user to control for how long the configured step will go on when the trigger is released; the cycle will end between the chosen exiting step and the last one.

The step time setting allows the user to switch from step-to-step by pressing and releasing button 2 in 4T mode or with a two-button torch.

Advanced settings, only available in «Advanced» display mode: $GYS-400 AC-DC- Titanium-TIG-Welder- $22$$

CHOOSING THE ELECTRODE’S DIAMETER $GYS-400 AC-DC-Titanium-TIG-Welder- $23$$ $GYS-400 AC-DC-Titanium-TIG-Welder- $24$$

CHOOSING THE IGNITION TYPE

Lift: Arc-Lift ignition (for HF-sensitive environments).
HF: non-contact, high-frequency ignition system for tungsten electrodes.
Touch HF: Delayed, high-frequency ignition after the tungsten electrode has made contact with the workpiece.

Position the torch’s nozzle and the electrode tip on the workpiece and acti-vate the torch’s button.
Tilt the torch until a gap of about 2 – 3 mm separates the electrode’s tip from the workpiece. The arc will start.
Return the torch to its normal position to start the welding cycle.
Place the torch in the welding position above the workpiece (with a distance of about 2 – 3 mm between the electrode’s tip and the workpiece).
Press the torch’s button (the arc will ignite without contact using high voltage [HF] ignition pulses).
The initial welding current circulates, the welding continues according to the welding cycle.
Position the electrode’s tip on the workpiece and press the torch button.
Lift the electrode from the workpiece.
After a delay of 0.2 s, the arc will ignite without contact using high voltage (HF) ignition pulses; the initial welding current will flow and the welding will continue according to the welding cycle.

Advanced settings, only available in «Advanced» display mode: $GYS-400 AC-DC-Titanium-TIG-Welder- $28$$

COMPATIBLE TORCHES AND TRIGGER ACTIONS $GYS-400 AC-DC-Titanium-TIG- Welder- $29$$

For the one-button torch, the button is called the «main button».
On the two-button torch, the first button is called the «main button» and the second is called the «secondary button».

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).

When the double-button torch is in 2T mode, the secondary button is operated in the same way as the main button.

T1 – The main button is pressed, the cycle starts from the Pre Gas and stops in the I_Start phase.
T2 – The main button is released, the cycle continues to UpSlope and welding processes.
T3 – The main button is pressed, the cycle goes into DownSlope and stops in the I_Stop phase.
T4 – The main button is released, the cycle ends with Post Gas. NB: for torches, double-button torches and double-button torches with a potentiometer => «high/welding current» button and active potentiometer, «low» button inactive.
T1 – The main button is pressed, the cycle starts from the Pre Gas and stops in the I_Start phase.
T2 – The main button is released, the cycle continues in UpSlope and welding.
LOG: This operating mode is used in the welding phase:
- A brief push of the main button (< 0.5 s) switches the current from I_Welding to I_Cold and vice versa.
- When the secondary button is held down, the current switches from I_Welding to I_Cold.
- When the secondary button is held down, the current switches from I_Cold to I_Welding.
T3 – Holding down the main button (> 0.5 s) makes the cycle go into DownSlope and then stop in the I_Stop phase.
T4 – The main button is released, the cycle ends with Post Gas.

For double-button or double trigger torches with a potentiometer, the «upper» trigger carried out the same function as the single-trigger torch. The «lower» trigger switches the machine to a cold current when it is held down. The torch’s potentiometer, when present, allows the usedr to adjust the welding current from 50 – 100% of the displayed value. The «Up & Down» feature allows the current to be adjusted at the torch.

TRIGGER-CONTROL CONNECTION

$GYS-400 AC-DC-Titanium-TIG-Welder- $33$$

SRL18 torch wiring diagram $GYS-400 AC-DC-Titanium-TIG-Welder- $34$$

Up & Down torch wiring diagram

$GYS-400 AC-DC-Titanium-TIG-Welder- $35$$

$GYS-400 AC-DC-Titanium-TIG-Welder- $36$$

MANUAL GAS PURGE

Oxygen in the torch can lead to decreased mechanical performance and may result in a decreased corrosion-resistance level. To purge the gas from the torch, press and hold push-button n°1 (see HMI user manual) and follow the on- screen procedure.

CHOOSING THE SETTINGS

$GYS-400 AC-DC-Titanium-TIG-Welder- $37$$ $GYS-400 AC-DC-Titanium-TIG-Welder- $38$$

Access to some welding parameter settings depends on the welding process used (synergy, AC or DC, etc.) and the selected display mode (Easy, Expert or Advanced). Refer to the HMI manual. Some settings in % or A depend on the display mode selected (Easy, Expert or Advanced).

MMA (SMAW) WELDING MODE

CONNECTIONS AND ADVICE

Connect the cables, electrode holder and earth clamp to the socket connections.
Respect the polarities and observe the welding currents indicated on the electrode’s box.
Remove coated electrodes from the electrode holder when the welding power source is not in use.
This device is equipped with three Inverter-specific features:
- Hot Start provides an overcurrent at the beginning of the welding process.
- Arc Force delivers an overcurrent that prevents the electrode from sticking to the workpiece when the electrode enters the weld pool.
- The Anti-Stick feature means the electrode can be easily detached without allowing it to turn red if it becomes stuck.

PROCESS SETTINGS

$GYS-400 AC-DC-Titanium-TIG-Welder- $39$$

*only for TITANIUM 400 AC/DC
Accessing certain welding parameters is dependent on the selected display mode: Settings/Display mode: Easy, Expert or Advanced. Refer to the HMI manual.

WELDING PROCESSES

Standard
This welding mode is suitable for most applications. It can be used with all types of coated, rutile, basic and cellulosic electrodes and on all materials: steel, stainless steel and cast iron.
Pulsed
This welding mode is suitable for applications in the vertical up position (PF). Pulsing keeps the weld pool cold while promoting material transfer. Without pulsing, vertical up welding requires a «Christmas tree» movement, i.e. a difficult, triangular movement. Thanks to MMA pulsed welding , this movement is no longer necessary; depending on the thickness of your workpiece, a straight up movement may suffice. However, if you wish to enlarge the weld pool, a simple sideways movement, similar to flat welding, is adequate. In this instance, you can set the pulse current frequency on the display screen. This method offers greater control of the vertical welding process.
AC
This welding mode is used in very specific cases where the arc is not stable or straight, when it is subjected to magnetic blow-outs (magnetised parts or nearby magnetic fields, etc.). The alternating current leaves the welding arc unaffected by its electrical environment. It is necessary to check that your coated electrode can be used with an AC current.

CHOOSING COATED ELECTRODES

Rutile electrode: very easy to use in all welding positions.
Basic electrode: used in all positions, suitable for safety work due to its increased mechanical properties.
Cellulosic electrode: very dynamic arc with a high melting speed, its capacity for use in all positions makes it especially suitable for working on pipelines.

CHOOSING THE SETTINGS

$GYS-400 AC-DC-Titanium-TIG-Welder- $40$$

Accessing certain welding parameters is dependent on the selected display mode: Settings/Display mode: Easy, Expert or Advanced. Refer to the HMI manual.

ADJUSTING THE WELDING CURRENT
The following settings correspond to the available current range depending on the type and diameter of the electrode. These ranges are quite wide as they depend on the application as well as the welding position. $GYS-400 AC-DC- Titanium-TIG-Welder- $41$$

ADJUSTING ARC FORCE

It is advisable to set the Arc Force to the middle position (0) when starting to weld and to adjust it according to the welding results and the user’s pre- ferences. Note: the Arc Force setting range is determined by the type of electrode selected.

HOT START SETTINGS
It is advisable to set the Hot Start feature low for thin sheet metal and to set it high for thicker and more difficult sheet metal (dirty or oxidised parts).

ENERGY

In addition to the weld bead’s energy reading after welding, this mode, developed for welding with DMOS-supported energy control, allows the user to change the following settings:

The thermal coefficient according to the standard used: 1 for ASME standards and 0.6 (TIG) or 0.8 (MMA) for European standards. The displayed energy is calculated taking into account this coefficient.
The weld bead’s length (OFF – mm): If a length is recorded, then the energy display is no longer in joules, but in joules/mm (the unit in the display «J» will flash).

SAVING AND RECALLING JOBS

Accessible through the «JOB» icon on the main screen.
The active settings are automatically saved and recalled the next time you turn on the machine.
In addition to the active settings, it is possible to save and recall»JOB» configurations.
There are 500 JOBS for TIG welding processes and 200 for MMA welding processes. Memory storage is based on the current process settings, the active settings and the user profile.

JOB mode

JOB mode allows you to create, save, recall and delete JOBs.
Quick Load – Recall JOBs from the trigger when not welding.
Quick Load is a non-welding JOB recall mode (20 JOBs max.) and is only available for TIG processes.
From a list of previously created JOBs, JOB recalls are done by short trigger presses. All trigger modes and welding modes are supported.
MultiJob – Recall JOBs using the trigger when welding.
From a MultiJOB list made up of previously created JOBs, this linking mode makes it possible to weld up to 20 JOBs in sequence with no interruption.
When the mode is activated, JOB N°1 in the list will be loaded and displayed. The trigger mode is forced to 4T.
During welding, this mode allows the JOBs in the uploaded list to be linked together by carrying out short presses on the torch’s buttons.
The welding process is stopped by holding down the torch’s buttons or, when the welding cycle is finished, JOB N°1 is reloaded for a future welding sequence.

$GYS-400 AC-DC-Titanium-TIG-Welder- $42$$

When the mode is activated, JOB N°1 in the list will be loaded and displayed.
The JOBs recall sequence is looped: when the last JOB on the list is reached, the next one will be JOB N°1.
Activate the welding process by holding down the torch’s buttons.

C5
From a previously created C5 list of 5 JOBs, this simple automation mode from the Remote Control connector allows the user to recall JOBs via a PLC (see note on the website – https://planet.gys.fr/pdf/spdoc/fr/CONNECT_5.pdf).)

OPTIONAL REMOTE CONTROL

Analogue remote control RC-HA1 (P.N. RC-HA1):
An analogue remote control can be connected to the power source via the connection (I-11).
This remote control allows the current to be adjusted between 50 – 100% of the set current. In this configuration, all of the power source’s modes and features can be accessed and configured.
Analogue remote control RC-MMA/DEGAUSS (P.N. 066496)
An analogue remote control can be connected to the power source via the connector (I-4).
In MMA only, the control allows the current to be varied from 50% to 100% of the current set via a potentiometer, the welding polarity to be reversed via the polarity switch and the welding current source to be activated or deactivated to protect the welder during handling.
Remote control RC-MMA/TIG-FA1 pedal (P.N. 045682):
A remote-control pedal can be connected to the power source via the connection (I-11).
The pedal allows you to adjust the current from the minimum to 100% of the set welding current. In TIG mode, the power source will only work in 2T mode. Furthermore, the current’s rise and fall are no longer managed by the power source (inactive functions) but by the user using the foot pedal.
Remote HMI – RC-HD2 digital remote control (P.N. 062122):
400 AC/DC: A digital remote control can be connected to the power source via the connection (I-12).
230 AC/DC FV: A digital remote control can be connected to the power source via the optional NUM-1 kit (I-7).
This remote control is designed for MMA and TIG welding processes. It allows the user to remotely adjust the welding unit. An ON/OFF button is used to switch on or off the digital remote control. When the digital remote control is switched on, the power source’s HMI will display the current and voltage values. As soon as the HMI is turned off or disconnected, the welding machin’es HMI is reactivated.

Terminals
This product is equipped with a female remote control terminal.
The purposely designed, seven-prong, male connector (optional extra, PN: 045699) allows different types of remote control to be connected. For wiring, follow the diagram below. $GYS-400 AC-DC-Titanium-TIG-Welder- $43$$

OPTIONAL COOLING UNIT $GYS-400 AC-DC-Titanium-TIG-Welder- $44$$

The machine will automatically detect the cooling unit. To deactivate the cooling unit (OFF), please refer to the HMI’s user manual. The following safeguarding measures are supported by the cooling unit to ensure that the torch and user are protected:

Minimum coolant level
Minimum coolant flow rate through the torch
Thermally protected coolant

Ensure that the cooling unit is switched off before disconnecting the torch’s fluid inlet and outlet hoses. Coolant is harmful and can irritate the eyes, mucous membranes and skin. Hot liquids can cause burns.

OPTIONAL FILTER KIT

Dust filter (P.N 046580) with fine filtration: 630 µm (0.63 mm).
Please note that using this filter reduces the welding machine’s duty cycle.
The dust filter should be cleaned regularly to avoid the risk of overheating due to blocked air vents. Unclip and clean with compressed air.