GYS 75687 Arc Welding Battery Chargers And Body Repair Owner’s Manual

GYS 75687 Arc Welding Battery Chargers And Body Repair

Product Information

Specifications

• Model : ARCPULL 200
• Product Code : 75687
• Version : V6
• Release Date : 04/04/2024

Product Usage Instructions

Power Supply and Startup
Refer to section 2 of the user manual for detailed instructions on power supply and startup procedures.

Extension Cord Usage
Follow the guidelines in section 2.2 of the manual when using an extension cord with the ARCPULL 200.

Fusion Bath Protection
Ensure proper protection of the fusion bath as described in section 4.5 of the user manual to maintain safety during operation.

Electrode Holder Positioning and Arc Blowing
Follow the recommendations in section 4.5 for correct positioning of the electrode holder and arc blowing techniques.

Trigger Operation
Learn about trigger operation in section 5.1 of the manual for effective usage of the welding equipment.

Using Welding Accessories
Section 5.3 provides guidance on using accessories for placing pull rings correctly during welding tasks.

Synergic Welding Mode
Explore the synergic welding mode described in section 7.1 for optimized welding results based on material specifications.

Frequently Asked Questions (FAQ)

• Q: How do I change electrode lengths for the ARCPULL 200?
  

  • A: To adjust electrode lengths, loosen the locking knob, remove the existing electrodes, and replace them with new ones before tightening the knob securely. Refer to section 5.1 for detailed instructions.

• Q: What gases are compatible with the ARCPULL 200?
  

  • A: The ARCPULL 200 is compatible with Argon and ArHe 30% gases. Refer to section 6 of the user manual for more information on gas compatibility.

• Q: How do I weld steel studs using the ARCPULL 200?
  

  • A: Follow the welding instructions provided in section 6 of the manual for welding steel studs effectively with the ARCPULL 200.

WARNINGS – SAFETY INSTRUCTIONS

GENERAL INSTRUCTIONS

These instructions must be read and fully understood before use.
Do not carry out any alterations or maintenance work that is not directly specified in this manual.

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 a problem or uncertainties, please consult a qualified person to handle the installation properly…

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. In the event of improper or dangerous use, the manufacturer cannot be held responsible.
The machine must be used in an environment free of dust, acid, flammable gases or any other corrosive substances. Operate the machine in an open, or well- ventilated area.

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

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

Altitude
Up to 1,000m above sea level (3280 feet).

INDIVIDUAL PROTECTIONS AND OTHERS
Arc welding can be dangerous and cause serious injury or death.
Welding exposes people to dangerous heat, light radiation from the arc, electromagnetic fields (beware if you have a pacemaker), risk of electrocution, noise, and gas emissions.
To protect yourself and others, please comply with the following safety instructions:

To protect yourself from burns and radiation, wear clothes without cuffs/lapels, that are insulating, dry, fireproof and in good condition, and that cover the whole body.

Wear protective gloves which provide electrical and thermal insulation.

Use a mask or goggles with a tint between 5 and 9. Protect your eyes during cleaning procedures. Contact lenses are specifically forbidden.

Wear noise protection headphones if the welding process becomes louder than the permissible limit (this is also applicable to anyone else in the welding area).

Keep moving parts (gun) away from hair & clothing.

Newly welded parts are hot and can cause burns when handled. When servicing the gun or elec-trode holder, Make sure that it is sufficiently cool by waiting at least 10 minutes before any manipulation. It is important to secure the working area before leaving it, in order to protect people and property.

WELDING FUMES AND GAS

Fumes, gases and dusts emitted by welding are harmful to health. It is mandatory to ensure adequate ventilation, and an additional air supply may be required. An air-fed mask could be a solution in situations where there is inadequate ventilation.
Check the extraction system’s performance against the relevant safety standards.

Caution : Welding in confined spaces requires safety monitoring from a safe distance. In addition, the welding of certain materials containing lead, cadmium, zinc, mercury or beryllium can be very harmful. also remove any grease on the workpieces before welding.

Cylinders should be stored in open or well-ventilated areas. The cylinders must be in a vertical position secured to a support or trolley. Welding should not be carried out near grease or paint.

FIRE AND EXPLOSION HAZARDS
Fully protect the welding area, and ensure that flammable materials are kept at least 11 metres away. Fire fighting equipment should be kept close to wherever the welding activities are being undertaken.

• Be careful of spatter and sparks, even through cracks, as it can be the source of a fire or an explosion.
• Keep people, flammable objects and pressurised containers at a safe distance.
• Welding in closed containers or tubes is to be avoided. If the containers or tubes are open, they must be emptied of all flammable or explosive materials (oil, fuel, residual gas…).
• Grinding work must not be directed towards the source of the welding current or towards any flammable materials.

GAS CYLINDERS

• Gas escaping from cylinders can cause suffocation if there is too high a concentration of it in the welding area (ensure good ventilation).
• The machine must be transported in complete safety: gas cylinders must be closed and the welding power source turned off. They should be stored upright and supported to limit the risk of falling.
• Close the cylinder between uses. Beware of temperature variations and exposure to the sun.
• The cylinder must not come into contact with a flame, an electric arc, the gun, a ground clamp, or any other source of heat or potential ignition.
• Be sure to keep it away from electrical and welding circuits. Never weld a pressurised cylinder.
• Be careful when opening the cylinder valve, keep your head away from the tap and ensure that the gas used is suitable for the welding application.

ELECTRICAL SAFETY

The electrical network used must be earthed. Use the recommended fuse size from the rating plate. A direct or indirect electric shock can cause a serious injury, or even death.

Do not touch any live part of the machine (inside or outside) when it is plugged in (Gun, clamps), because it is connected to the welding circuit.
Before opening the welding power source, disconnect it from the mains supply and wait 2 minutes. So that all the capacitors are discharged.
Do not touch the gun shaft and the ground clamp at the same time.
Be sure to change the cables if they are damaged, by qualified and authorised persons. Measure the cable cross-section according to the intended application. Always use dry and in-fact clothing to insulate yourself from the welding circuit. Wear insulated shoes in all working environments.

EMC CLASSIFICATION

This Class A device is not intended for use in a residential environment where power is provided by the public low-voltage local supply network. There may be potential difficulties in maintaining electromagnetic compatibility at these sites, due to both conducted, and radiated radio frequency interference.
Provided that the impedance of the low-voltage public electrical network at the common interconnection point is less than Zmax = 0.45 Ohms, this equipment complies with IEC 61000-3-11 and can be connected to public low-voltage electrical mains. It is the responsibility of the installer or operator of the product to ensure this, in consultation with the distribution network operator if necessary, that the network impedance complies with the impedance restrictions.

EN 61000-3-12 This equipment complies with the IEC 61000-3-12 standard.

ELECTROMAGNETIC EMISSIONS

An electric current passing through any conductor produces localized 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, pacemakers for example. Protective measures must be taken for people with medical implants. For example, restricted access for spectators, 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 – secure them with a clip, if possible;
• 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. Place both welding cables on the same side of the body;
• connect the return cable to the workpiece as close as possible to the area that will be welded;
• do not work directly next to the welding power source, Do not sit on it or lean against it;
• do not transport the welding power source or wire feeder while welding.

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 TO ASSESS THE WELDING AREA AND WELDING INSTALLATION

General Information
It is the user’s responsibility to install and use the arc welding equipment according to the manufacturer’s instructions. If electro-magnetic interference is 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 electro-magnetically shield the welding power source and the workpiece as a whole by installing input filters. In all cases, electromagnetic interference should be reduced until it is no longer a concern.

Assessing the welding area
Before installing arc welding equipment, the user should assess the potential electromagnetic problems in the surrounding area. The following should be taken into account:

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

• radio and television receivers and transmitters;

• computers and other control equipment,

• critical safety equipment, for example, industrial equipment protection;

• the well-being of nearby persons, for example, those using of pacemakers or hearing aids,

• the equipment used for calibrating or measuring

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

• the time of day when welding or other operations are to be carried out.

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 assessing the area, the arc welding equipment’s assessment can be used to identify and resolve cases of interference. 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

• The mains power grid : Arc welding equipment should be connected to the mains power grid according to the manufacturer’s recommendations. If 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 shield should be connected to the welding power source to ensure that there is good electrical contact between the conduit and the welding power source enclosure.
• The maintenance of arc welding equipment : Arc welding equipment should be subject to routine maintenance as recommended by the manufacturer. All access points, covers and service openings 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 changes and adjustments mentioned in the manufacturer’s instructions. It is advisable, in general, the arc ignition and stabilization parts should be adjusted and maintained according to the manufacturer’s recommendations.
• Welding cables : Cables should be as short as possible, placed close together either near or on the ground.
• Equipotential bonding: Consideration should be given to linking all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of an electric shock to the operator if they touch both the metal objects and the gun shaft It is necessary to insulate the operator from such metal objects.
• Earthing the workpiece: In cases where the part to be welded is unearthed for electrical safety reasons or due to its size and location, which is the case, for example, the hull of a ship or steel frameworks of buildings, an earthed connection can in some cases, and not systematically, reduce emissions. 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 connection of the workpiece to earth should be made directly, but in some countries; rules may not allow such a direct connection, he connection should be made with a suitable capacitor chosen according to national regulations.
• Protection and shielding : The selective protection and encasing of other cables and equipment in the surrounding area may limit interference problems. The safeguarding of the entire welding area may be considered for special applications.

THE TRANSPORTING AND MOVING OF THE MACHINE’S POWER SOURCE
The machine is equipped with a handle to easy transportation. Be careful not to underestimate its weight. The handle cannot be used to hang or attach the machine on something else.
Do not use the cables or gun to move the welding power source. It should be moved in an upright position.
Do not carry or transport the power source overhead of people or objects.
Never lift the machine while there is a gas cylinder on the support shelf. Their transportation requirements are different.

SETTING UP THE EQUIPMENT

• Place the welding power source on a floor with a maximum inclination of 10°.
• The welding power source should be protected from heavy rain and not exposed to direct sunlight.
• The equipment has an IP33 protection rating, meaning
  • its dangerous parts are protected from being entered by objects greater than 2.5 mm and,
  • it is protected against rain falling up to 60° from vertical.
• 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/ADVICE

• Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
• Switch off the power supply by pulling out the plug, and wait two minutes before working on the equipment. Inside, the voltages and currents are high and dangerous.
• Regularly check the condition of the power cable. If the power cable is damaged, it must be replaced by the manufacturer, its customer service department, or a similarly qualified person, to avoid any danger.

DESCRIPTION OF THE PRODUCT

The ARCPULL 200 is a single-phase inverter arc-welding machine that can be used to weld inserts (pull rings studs, insulation pins) on aluminium or steel based materials. It has a Synergic operating mode, and a Manual operating mode.

Fig 1: External view of the power source

Fig 2 : External view of the gun and its HMI (without welding forks and accessories)

POWER SUPPLY AND POWER UP

• This product is fitted with a 16 A CEE7/7 socket which must be connected to a single-phase power supply with a earthed neutral between 110 VAC and 240 VAC (50 – 60 Hz). The absorbed current (I1eff) is indicated on the device, for its maximum setting. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current required during use. This equipment is designed to operate on an electrical installation equipped with a 16A curve C, D or K circuit breaker.
  In some countries, changing the plug may be necessary to ensure the machine’s optimum performance. The user has to make sure that the socket is accessible.

• Switching on is done by positioning the ON/OFF switch to «|».

• The device will activate protection mode if the power supply voltage is over 265 V AC. If this is the case, the machine displays POWER DEFAULT. Normal functioning will resume once the power supply is under 265V.

WORKING OFF A GENERATOR
This equipment can operate with single-phase generators provided they meet the following requirements

• The voltage must be AC, regulated as specified (110-240 Vac) and with a peak voltage of less than 400 V,
• The frequency must be between 50 and 60 Hz.
• The power must be at least 7kVA.

It is imperative to check these conditions, as many generators produce high voltage spikes that can damage equipment.

USE OF EXTENSION LEAD
This equipment can be connected to the electrical installation with an extension lead as long as it matches the following requirements

• Single-phase extension lead with earth conductor.
• The length must not exceed 10m
• The cable cross-section must not be less than 2.5 mm².

CONNECTING THE GUN TO THE POWER SOURCE
The connection and disconnection of the gun control connector to the power source socket must only be done with the power source switched off.
The ring of the gun control connector must always be properly screwed to the power source socket before starting the product.

It is possible to connect an Arc Pull 700 gun to this power source. In this case, use Texas adapters 25 mm² -> 50 mm² (2 x 038127) to connect the gun connector to the power source sockets.

PRODUCT UPDATE
The product has a USB connector on the front panel protected by a cap, to update the software (adding synergies, new features). Contact your reseller for more details.

PROCESS FOR WELDING AN INSERT WITH DRAWN ARC

The drawn arc is used to weld inserts (draw ring, studs, studs, etc.) on a workpiece by bringing the two parts together in an electric arc and making contact between them.
Reminder of the principles of drawn arc welding (for more details, refer to ISO 14555):
There are 4 main stages: ignition, penetration and cleaning, the arc, and the binding

Arc current is limited to 100A when the product is connected to a 110Vac 50Hz/60Hz power supply.

Ignition : the insert (pull ring studs, etc.) is placed in contact with the supporting material. Pressing the trigger starts the welding process: the power source sends current to the stud, the gun shaft rises slightly, A low- intensity electric arc is then created.

Penetration and cleaning : This phase could also be called preheating. The power source regulates a current to ensure a low-intensity arc, the heat generated by this arc allows

• burning off impurities from the backing sheet (grease, oil, electrolytic zinc coating).
• to preheat the two pieces, and thus limiting the thermal impact of the welding arc, to improve the quality of the weld.

During this phase neither the insert, or the support plate, is melted. Also, this phase does not allow the zinc layer of a galvanised plate to be removed.

The arc: the power source significantly increases the current to create a high-energy arc that creates a molten pool on the support plate and causes the end of the insert to melt.
Binding: The gun plunges the insert into the molten weld pool.

STUD DESIGN AND WELD POOL PROTECTION

The different types of inserts (shape, dimensions, material) designed for the drawn arc process are listed in the ISO 13918 standard. In addition to low carbon steel inserts, in stainless steel and copper-plated steel, the product can also weld certain aluminium inserts.

SURFACE CONDITION OF THE WORKPIECE AND CLEANING
Welding of inserts must be carried out on a grease-free workpiece. It is also necessary to strip this workpiece if it has a chemical treatment (zinc coating for galvanised steel, anticorrosive for heat-treated steels, alumina for aluminium).
The welding of the insert especially aluminium parts, must be carried out on a flat support surface.

THICKNESS OF THE SUPPORT SHEET IN RELATION TO THE DIAMETER OF THE STUD
With the exception of pulling ring applications for bodywork removal, the thickness of the supporting sheet must not be less than ¼ of the diameter of the base of the insert in the case of steel, and ½ of the diameter in the case of aluminium.

Examples (non-exhaustive list)

Workpieces (according to ISO 13918)| Base diameter| Minimum sheet thickness
M5 copper plated steel stud| 6 mm| 1.5 mm
Insulation nail Ø2.5 in copper-plated steel| 4 mm| 1 mm
AlMg stud M4| 5 mm| 2.5 mm

PROTECTION OF THE WELD POOL
Depending on the material to be welded, gas protection may be necessary.
The table below lists the recommended gas to use depending on the workpiece and its material. These gases maximise the weld strength and are the appropriate gases to use when the machine is operating in Synergic Mode (see §7.1).
This table is given as an indication, pre-weld tests are recommended.

Low-carbon steel

(Fe)

| Steel pulling ring|

ArCO² 8 %

|

Possible

Cop-

per-plated steel (FeCu)

| Stud, insulation nail| ArCO² 8%| Not recommended
| Accessory to be used| Steel Studs Box 200 & 350 (Ref 059443)

Alu Studs Box 200 & 350

(Ref 059436)

Pull ring (Ref 059610)

If gas shielding is used, the flow rate should be set between 12 l and 15 l/min.
Note : In the case of welding aluminium, pure Argon (Ar) can be used instead of the 30% Argon-Helium mixture (ArHe30%). Also, in the case of steel (Fe or FeCu) welding, pure Argon (Ar) can be used instead of the 8% Argon-CO² mixture (ArCO² 8%). In both cases, the welding characteristics of the synergies are no longer guaranteed, and it may be necessary to switch to Manual Mode (see §7.2).

In all three cases, the welding characteristics of the synergies are no longer guaranteed, and it may be necessary to switch to Manual Mode (see §7.2).

Do not set the torque over 5Nm when tightening the gas input coupling.

POLARITY OF THE GUN

The polarity of the gun has an impact on the quality of the weld.
Depending on the type of part to be welded, and its material, it is recommended to connect the positive texas connector from the gun to the + or – terminal of the power source. Below is a table showing the preferred polarity used by GYS.

Insert to be welded| Connecting the positive texas connector of the gun (red mark)|
---|---|---
Alu pulling ring| Negative texas of the power source (-)
Steel pulling ring| Positive texas of the power source (+)
Stud, internally threaded stud, cop- per-plated steel insulation nail| Positive texas of the power source (+)

POSITIONING OF GROUND CLAMPS AND CONTROLLING THE ARC
For diameters of 6 mm and above, the welding of inserts requires the use of a ground cable with two clamps in order to avoid any arc blowback effects.
Reminder of the ISO 14555 standard on the positioning of ground clamps depending on the configuration of welding.

INSTALLATION OF ACCESSORIES AND GUN ADJUSTMENT

| The fitting of accessories and the adjustment on the gun must be done while:

• the gun is connected to the power source
• the product is turned on
• the gun initializing phase is completed (trigger pull command)

|

Present rigger

---|---|---

REPLACEMENT AND LENGTH ADJUSTMENT OF THE GROUND RODS (059627)
Note : Replacement of the ground rods is necessary if they have excessive markings on the tips, or if they have been bent as a result of the gun being dropped.

ADJUSTING A STUD HOLDER/INSULATION NAIL HOLDER

1. Unscrew the locking nut on the stud holder adjusting spindle.
2. Insert the attachment into the stud holder and adjust the screw so that the end of the attachment protrudes 5 mm from it..
3. Screw on the locking nut.

Note: If the weld of the insert shows marks of the stud holder at the weld, adjust the stud holder screw so that the insert extends a little further from the stud holder.

Note : In the case of insulation nail application, no adjustment is necessary. Insert the insulation nail into the holder as far as it will go.

USING THE PULL RING ATTACHMENT (059610)

USING THE STEEL AND ALU STUD BOX 200 & 350 (REF 059443 & 059436)
Note : Prepare the ground rods as explained in §5.1.
Note 2 : Prepare the stud holder as explained in §5.2.

HANDLING THE GUN

WELDING PULL RINGS

1. Mount the ring holder (see §5.3).
2. Strip off all paint from the area where the weld is to be executed.
3. Select the correct synergy to suit the welding of the ring.
4. Connect the negative texas plug from the gun to the unit (no earth clamp is used).
5. In the case of manual operation; set the digital spring «Flex» to OFF (see §7.4.2).
6. Insert a ring into the ring holder.
7. Unlock the ground rods with the knob.
8. Position the gun on the workpiece and bring the ring into contact with it. As soon as the gun makes a «beep» or that the LED contact (blue) is switched on, lock the ground rods with the knob.
9. Press the trigger
10. Once the weld is complete, unlock the knob to release the rods and lift the gun to remove the ring

|
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Every 30 pull ring welds, the message «Check stems» appears on the dis-play. Check the end of the ground rods (no. 4 figure 2). If they show signs of welding, lightly sand them with abrasive paper to
restore their electrical contact.

Press to confirm and reset the counter. To deactivate this function, see ( §7.4.3.1 )

Note : This function is not possible when an ArcPull 700 gun is used (see §2.3)

WELDING OF ACCESSORIES EXCLUDING PULL RINGS

1. Mount and adjust the accessory (gas shield, ceramic adapter, rivet extraction attachment)
2. Position the ground clamps on the support sheet so that it is equidistant between each clamp and the area where the insert is to be welded (see section 4.5). The grounding areas should be stripped, cleaned and free of grease.
3. Select the appropriate synergy, or, in the case of manual operation: turn ON the digital «Flex» spring (see §7.4.2).
4. Place the gun on the sheet. As soon as the gun makes a «beep» or that the LED contact (blue) is switched on, press the gun so that the attachment is properly pushed onto the sheet (there must be no tilting movement).
5. Squeeze the trigger while holding the gun firmly against the support plate.
6. Once the weld is complete, lift the gun to release the insert.

|
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PRODUCT OPERATION

Fig 3: Overview of the power source’s keypad

WELDING IN MANUAL MODE
In Synergic Mode the height of the arc, the time and current for the different phases are selected automatically by the machine. A synergy is therefore determined by the type of part to be welded, its material, its gas protection, its size, and the supporting plate.
The gas type to be used is shown on the display. In case of incorrect polarity on the gun, a message appears on the display and the fault LED (red), on the gun, flashes.

The different welding parameters are defined for the attachments that GYS sell.
These synergies remain applicable for inserts up to 35mm, as long as they are of the same type and material as those sold by GYS (according to ISO 13918).

The synergies of aluminium inserts (excluding pull rings), were established on support plates that had been preheated to a temperature of 50-60°C.
It is advisable to carry out a few test welds on a suitable support plate beforehand, to ensure that the weld will hold.
On the main Mode screen, Synergies are displayed:

1. The material of the insert: AlMg, Fe, FeCu, etc.
2. The type of weld pool protection: No Gas, the type of gas recommended
3. The pictogram of the part to be welded
4. The thickness of the sheet metal to which the part will be welded
5. A message field specifying the status of the product (see § 7.3)

TYPE OF WORKPIECE TO BE WELDED
From the synergy displayed on the screen, defined by a part type (3), its material (1) and its protection (2), it is only possible to change the size of the part (M4, M5, etc.) by pressing G+ and G- without having to go through the setup menu (see § 7.4.1).

THICKNESS OF THE SUPPORT PLATE

• Thickness displayed in millimetres.
• To increase or decrease the thickness of the sheet on which the insert will be welded, press the D+ and D- keys.
• The thickness ranges that can be selected are dependent on the type, size, and material of the part to be welded.
• If the thickness of the sheet metal is less than that shown on the display, the sheet may be distorted at the welding point.
• When the display shows , the sheet thickness is sufficient and the welding parameters of the synergy are no longer affected. If this symbol does not appear, then the maximum sheet metal thickness has been reached. Over this thickness, the welding of the insert is no longer guaranteed.

Note : When switching from Synergic to Manual mode, all welding parameters (current, time, height, etc.) associated with that synergy are transferred to manual mode. This makes it possible to fine-tune the machine settings if the selected synergy does not achieve the expected result (welding with too much, or not enough, energy).

WELDING IN MANUAL MODE
In Manual Mode the time, current, the lift height for the insert and the activation of the digital spring are user-defined. The main Manual Mode screen displays:

1. The arc time in milliseconds (see § 3)
2. The arc current (see § 3)
3. A message field specifying the status of the product (see § 7.3)

LIST OF PROMPTS SHOWN AT THE BOTTOM OF THE DISPLAY

power source (no. 6 in figure 2).
Texas inverted| (Synergic mode only) The polarity of the texas connectors is reversed in relation to the polarity required by the selected synergy.
Ready| The rest period is complete the unit is now available to weld.
Movement only| A trigger pull was detected without an insert being brought into contact with the support plate. The gun then performs a mechanical movement only, the power source is not switched on.
Contact| The product detects that an insert is in contact with the support plate. If welding is done with gas shielding, the solenoid valve opens for pre-gas.
Welding| Welding cycle in progress
Welding completed| The welding cycle is complete
Pre-Gas| Displayed when a trigger pull is detected before the pre-gas time has elapsed (see section 7.4.3). For the welding to take place, it is necessary to remain in the right position (insert is always in contact with the support sheet), and wait for the end of the pre-gas.
Lost contact| Displayed when contact between the insert and the support sheet is lost before the pre-gas time has elapsed.
Arc breakage| An arc break occurred during the welding cycle. Checking the weld will be necessary.
Lift gun| Displayed at the end of the welding cycle, if the gun is still in position on the insert.

MAIN MENU
To access the Main Menu from Synergic and Manual modes, press the Menu/Enter button

Press the G+ and G- keys to move the section cursor. Make the selection by pressing the Menu/Validate button.

• «Settings» accesses the welding parameters (synergic or manual).
• «Manual Mode»/» Synergic Mode» changes the welding method of the machine
• «Configuration» accesses the advanced configuration of the machine (languages, gas management, information, etc.).

Press the back button to return to the welding screen.

SYNERGIC MODE SETTINGS MENU
When operating in synergic mode, the setting menu is used for selecting the type of insert to be welded, its size, its material and type of gas shielding.

In Synergic Mode, the settings are selected in order from top to bottom:

1. Type of insert : studs, pins, rings.
2. Size of the insert «EP. elec»: Mx, Øx, etc.
3. Material of the insert: Fe, FeCu, Al, etc.
4. Type of welding protection: Ferrule, No gas, or with Gas

Note : When welding is to be done with gas shielding, the gas that is displayed is the one recommended to guarantee the weld strength (see § 4.3). In the event that this gas is not available, it may be necessary to switch to Manual Mode (see §7.2).

Press the G+ and G- keys to move the left cursor, and press the D+ and D- keys to change the values of each item. Push the Menu/Validate button to confirm the synergy settings and return to the synergic welding screen. Press the return button to ignore the settings and return to the Main Menu.

MANUAL MODE SETTINGS MENU
When operating in manual mode, the setting menu allows individual adjustment of any welding-related parameter.

Pressing the G+ and G- keys will highlight the selected parameter. Pressing the D+ and D- buttons changes the value of this parameter.

1. Digital « flex » spring

   • Releases (ON) or locks (OFF) the drive shaft of the electrode holder when the insert comes into contact with the support sheet.
   • It is recommended to activate this function for all attachments except for pull rings.

2. Ignition

   • Adjustable from -2 to +8. Directly affects the set value of the power converter in the unit.
   • At 0 (default value), the product provides optimal ignition without the risk of arc separation when the insert is lifted, while limiting the short-circuit current.
     Slightly increase the ignition in the case of repeated arcing failures.

3. Penetration and cleaning : Time adjustment (in milliseconds), and cleaning current. See page §4 for explanations.

4. Arc : Time adjustment (in milliseconds), and arc current. See page §3 for explanations.

5. Attachment

   • Adjustable from -2 to +8. Directly affects the set value of the power converter in the unit.
   • At 0 (default value), the product ensures optimal bonding of the electrode to the support material

6. Height

   • Height of lift (in millimetres) of the insert during the welding process.
   • Too much height will increase arc blowback (see §4.5). Too little height exposes the Too little height exposes the weld to short circuiting because of deformation of the stud tip during welding.

7. Force

   • Adjustable from 0 to 4. Applies to the force with which the insert is pushed into the weld pool (forging).
   • At 0 the immersion force is zero, at 4 it is maximum. If the weld does not comply with the ratio between the diameter and the maxi-mum thickness of the sheet (see §4.2). It may be necessary to reduce this force to avoid piercing through.

Pressing the Menu/Validate button will confirm the weld settings and return the unit to the manual weld screen. Press the return button to ignore the settings and return to the Main Menu.

CONFIGURATION MENU

Press the G+ and G- keys to move the cursor on the left (Pre-gas, Post-gas, Language Reset machine, Information). When the pre-gas, post-gas or language items are highlighted, press the D+ and D- keys to change their respective values.

recommended to have a pre-gas of at least 0.4 seconds.
Post-gas| NoGas or 0.2 to 3 seconds| When welding is done with gas shielding, it is recom- mended to have a post-gas of at least 0.4 seconds.
Language| FR, GB, DE, NL, ES, IT, RU|

Push the return button to return to the Main Menu.

COUNTERS
When «Counters» is selected, the display shows

• the log counter: number of welds made correctly since the product was put into operation. This counter is reset to zero when the product is restarted.
• the total counter: number of welds made correctly by the unit since it left the factory.
• The activation/deactivation of the warning message regarding checking the ground rods (see §6.1). Valid in the case of pull ring welding only, and for the ArcPull 200-350 gun only. Press G+ and G- to switch ON or OFF.

RESET MACHINE
When the «Reset Machine» option is selected from the Configuration menu, pressing menu/validate opens the reset machine  sub-menu.

Press menu/validate for 3 seconds to confirm product reset.
Push the return button to return to the Configuration menu and cancel resetting the unit.

Resetting the ArcPull 200 switches the product back to French, and the pre-gas and post-gas are reset to 0.4s.

INFORMATION PANEL

The information panel shows the software and hardware versions of the power source and gun.

ERROR MESSAGE, DEFECTS, CAUSES SOLUTIONS

This device has a fault monitoring system. In the event of a fault, error messages may be displayed.

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 during transport.

• The general wear and tear of parts (i.e: electrode holder, earth return rods, etc.).

• Incidents caused by misuse (incorrect power supply, dropping, disassembly).

• Faults due to the environment (pollution, rust, dust).
  In the event of a fault, please return the appliance to your distributor, along with

  • a dated proof of purchase (receipt, invoice…)
  • a note explaining the malfunction.

DIAGRAMA ELECTRICO

SPARE PARTS

1. Ventilator 24 V 51018
2. Fan support ARCPULL 98050
3. 2-way solenoid valve 24V 70991
4. Gas coupler BSP20 C31322
5. Graphic card 51992
6. Screen protection 56175
7. Screen support 56172
8. Keypad 51961
9. Female dines connector 25 51524
10. Prepared gun connector SN <23.09.xxxxxx.xxxxxx contacted SAV contact After-sales service SN >23.09.xxxxxx.xxxxxx
11. OFF switch 52460
12. Protection cap 43124
13. Electronic board 97433C
14. Output capacitor 63644
15. Power supply cable 3P + Earth 1.5 mm² 21570

DIAGRAMA ELECTRICO

TECHNICAL SPECIFICATIONS

| ARCPULL 200
---|---
Primary
Power supply voltage| U1| 230 V +/-

15%

| 110 V +/-

15%

Mains frequency| 50 / 60 Hz
Fuse| 16 A
Apparent Power| 7.4 (kVA)
Secondary|
No load voltage| U0| 100 V
Rate current output (I2)| I2| 10  200 A| 10  100 A
Conventional voltage output (U2)

(U2)

|

U2

|

20,4  28 V

|

20,4  24 V

 EN60974-1

Duty cycle*

EN60974-1.  EN60974-1-Norm

Norma EN60974-1

|  Norm EN60974-1.

Norma EN60974-1.

|

Imax

|

100 %

|
Functioning temperature| -10°C  +40°C
 Storage temperature| -20°C  +55°C
 Protection level| IP33
Dimensions (LxWxH)| 205 x 250 x 330 mm
 Weight| 8.7 kg
Gun
 Interconnection cable length| 3 m
Gun weight| 3.3 kg

60974-1 à 40°C et sur un cycle de 10 min.
The duty cycles are performed according to standard EN60974-1 at 40°C and over a 10 minute cycle.
When used intensively (above the duty cycle) the thermal protections may be activated, in which case the arc will be extinguished and the indicator light Leave the device connected to the power supply to allow it to cool down until the protective measures are no longer active.
The welding power source displays a declining output profile.

SPARE PARTS

S81142

If manufactured after 05/2022| E0024C
18| Ground stud| 059627
19| Rod spring| 55234 (x2)
20| Trigger| 56029
21| Locking nut| 90598
22| Front cover| SN < 23.05.xxxxxx.xxxxxx : contactor le SAV| 56188
23| Earth rods locking wheel| 56270
24| Rear cover| 56189
25| Ring holder| 059610
26|  Texas plug H14 Male| 51523 (x2)
27*|  Complete bundle without gun| SN <23.09.xxxxxx.xxxxxx| contacted SAV contact After-sales service
SN >23.09.xxxxxx.xxxxxx| SO SAV S81106

includes all the grey part on the diagram

SYMBOLS

Warning ! Read the user manual before use.

User manual symbol

Undulating current technology based source delivering direct current.

Pulled arc welding

Suitable for welding in an environment with an increased risk of electric shock. However this a machine should not placed in such an environment.

Direct welding current

Open circuit voltage

Duty cycle according to standard EN 60974-1 (10 minutes – 40°C).

Corresponding conventional welding current

Amperes

Conventional voltage in corresponding loads.

Volt

Hertz

Three-phase power supply 50 or 60Hz

Assigned voltage

Maximum rated power supply current (effective value).

Maximum effective power supply current.
Device complies with europeans directives, The EU declaration of conformity is available on our website (see cover page).
Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).

Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website
(see cover page).

The device is compliant with standard EN60974-1 and EN60971-10 class A device.

This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin !

This product should be recycled appropriately

EAEC Conformity marking (Eurasian Economic Community).

Temperature information (thermal protection)

Gas input

Gas output

Remote control

Equipment complying with Chinese requirements on the restricted use of hazardous substances in electrical and electronic products.

GYS UK

• Filiale / Subsidiary
• Unit 3
• Great Central Way
• CV21 3XH – Rugby – Warwickshire United Kingdom
• www.gys-welding.com
• +44 1926 338 609
• uk@gys.fr

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