GYS VAS 821 005 Welding Unit Instruction Manual

GYS VAS 821 005 Welding Unit Instruction Manual

GAS FITTINGS

Cut the gas hose in 4 (any length)

ERSTE VERWENDUNG

Insert the supplied USB flash drive into its dedicated port and start the device.

The above screen appears if a new version is detected.

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:

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 (400 V VERSION)

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 responsibility 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:

• a) the presence of power, control, signal and telephone cables above, below and next to the arc welding equipment,
• b) radio and television receivers and transmitters,
• c) computers and other control equipment,
• d) critical safety equipment, e.g. the protection of industrial equipment,
• e) the health of nearby persons, e.g. those using of pacemakers or hearing aids,
• f) the equipment used for calibrating or measuring,
• g) 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;
• h) 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

• a. 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.
• b. 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.
• c. Welding cables: Cables should be as short as possible, placed close together either near or on the ground.
• d. 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.
• e. 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.
• f. 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

⚠ 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 machine protection level is IP21, which means :
  – Protection against acess to dangerous parts from solid bodies of a 12.5mm diameter and,
  – Protection against vertically falling drops.
  ⚠ 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 secured 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

The VAS 821 005 is a «synergic» semi-automatic welding machine, ventilated for welding (MIG or MAG). This machine is recommended for welding steel, stainless steel, aluminium and the brazing. Its adjustment is quick and easy with its «synergic» mode.

DESCRIPTION OF THE EQUIPMENT (I)

1. Cable gland (mains cable)
2. On/Off switch
3. Gas connector T1
4. Gas connector T2
5. Gas connector T3
6. Cylinders support
7. Reel supports 1, 2 et 3
8. Wire feeder motor
9. Switch for purge-gas and wire feeding
10. USB connector
11. MMI
12. Push Pull (PP) connector
13. Spool Gun (SP) connector
14. Texas connector (-)
15. Euro connector T1
16. Euro connector T2
17. Euro connector T3

HUMAN-MACHINE INTERFACE (HMI)

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

POWER SWITCH

– The 400 V model is supplied with a 16 A plug, type EN 60309-1, and should only be used in a three-phase 400 V (50-60 Hz) four-wire electrical installation with a grounded neutral conductor.
– The 208/240 V model is supplied without a plug and should only be used on a three-phase 200-240 V (50-60 Hz) four-wire electrical installation with a grounded neutral. The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings.
– The 400V model is designed to operate on 400V +/- 15% electrical voltage. It will go into protection if the supply voltage is less than 330Vrms or greater than 490Vrms. (a fault code will appear on the keypad display).
– The 208/240V model is designed to operate on 220V – 15% +20%. It will go into protection if the supply voltage is less than 185Vrms or greater than 270Vrms. (a fault code will appear on the keypad display). · Power up the machine by switching the on / off switch (2 – FIG 1) to the I position, and stop it by switching it to the 0 position. Warning! Never disconnect the power supply while the machine is charging.

CONNECTING TO A POWER SOURCE

The machine can work with generators as long as the auxiliary power matches these requirements:
– For the 400 V model: The voltage must be alternating, its RMS value must be 400V +/- 15%, and its peak voltage must be less than 700V,
– For the 208/240 V model: The voltage shall be alternating, its rms value shall be 220V – 15% +20%, and its peak voltage shall be less than 375V
– The frequency must be between 50 and 60 Hz. It is imperative to check these requirements as several generators generate high voltage peaks that can damage these machines.

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.
Open the power source’s hatch.
– 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

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)

VAS 821 005 can weld steel wire from Ø 0.6 to 1.2 mm and stainless steel from Ø 0.8 to 1.2 mm (II-A). The device is supplied as standard with rollers Ø 0.6/0.8 and Ø 0.8/1.0 for steel or stainless steel. The contact tube, the roller groove, the torch sheath are designed for this application. Welding steel requires a specific gas (Ar+CO2). The proportion of CO2 may vary depending on the gas used. For stainless steel, use a mixture with 2% CO2. When welding with pure CO2, it is necessary to connect a gas preheating device to the gas cylinder. For specific gas requirements, please enquire with your gas distributor. The gas flow rate for steel is between 8 and 15 litres / minute depending on the environment. Synergies in Pulse mode are optimized for a gas flow between 12 and 15 liters / minute. To measure the gas flow at the flare outlet, you can use the optional flowmeter (ref. 053939).

SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE)

VAS 821 005 can weld aluminium wire from Ø 0.8 to 1.2 mm (II-B). Aluminium use requires a specific pure argon gas (Ar). For specific gas requirements, please enquire with your gas distributor. The aluminium gas flow rate is between 15 and 20 l/min depending on the environment and the welder’s experience. Synergies in Pulse mode are optimized for a gas flow between 12 and 15 liters / minute. The differences between using the unit on steel or aluminum are:
– Use specific drive rolls for aluminium welding. – Apply minimum pressure on the pressure rollers of the motor-driven reel to avoid crushing the wire.
– Use the capillary tube (designed to guide the wire between the drive rolls in the motor and the EURO connector) only for steel/stainless steel welding (II-B).
– Use a torch designed for aluminium. This aluminium torch is fitted with a Teflon torch liner in order to reduce frictions. DO NOT cut the liner at the edge of the fitting! This liner guides the wire from the drive rolls.
– Contact tube: use a SPECIAL aluminium contact tube corresponding to the diameter of the wire.
When using red or blue sheathing (aluminium welding), it is recommended to use the 90950 (II-C) accessory. This stainless steel sheath guide improves the cantering 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.

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.

MIG / MAG (GMAW/FCAW) WELDING MODE

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

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

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

MIG/MAG WELDING CYCLES

Standard 2T process:

OPTIONAL PUSH-PULL TORCH

A push-pull torch can be connected to the power source via the socket (I-12). 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 SPOOL GUN TORCH

A Spool Gun torch can be connected to the power source via the socket (I-13). It can only be used in synergic, standard and manual mode.
– In manual mode, only the wire speed adjustment button is remote on the torch (no adjustment possible on the machine interface).
– In synergic mode, the adjustment button allows to act between 50% and 100% of the value set on the HMI.
The detection of the Push-Pull torch is done by simply pressing the trigger. For more details, please read the instructions provided with the torch.

DEFECTS: CAUSES & SOLUTIONS

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..

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