GYS MULTICOOL 500 Arc Welding Battery Chargers and Body Instruction Manual

: July 26, 2024
: GYS

GYS MULTICOOL 500 Arc Welding Battery Chargers and Body

Product Information

Specifications

Model: MULTICOOL 500 / 1300
Manufacturer: GYS
Website: www.gys.fr

Product Usage Instructions

Environment Protection and Safety

Arc welding can be dangerous and expose users to various risks.
To ensure safety:

Wear appropriate insulating, dry, fireproof clothing covering the entire body.
Use protective gloves for electrical and thermal insulation.
Wear welding protective gear like hoods, gloves, jackets, and trousers.
Install fireproof welding curtains to protect against arc rays and sparks.
Inform others in the area not to look at the arc or molten metal.
Wear ear protection if noise levels exceed limits.
Avoid contact with moving parts and ensure safety covers are in place.
Avoid touching hot parts and allow time for cooling before servicing.

Maintenance and Safety Tips

Ensure the following steps are taken for safe operation:

Ensure the cooling unit is switched on when using a water-cooled torch.
Secure the working area before leaving to protect goods and people.

SAFETY RULES

Read and understand the following safety recommendations before using or servicing the unit. Any change or servicing that is not specified in the instruction manual must not be undertaken.

The manufacturer is not liable for any injury or damage caused due to non- compliance with the instructions featured in this manual . In the event of problems or uncertainties, please consult a qualified person to handle the installation properly.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. The operator must respect the safety precautions that apply to this type of welding. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury.
This equipment must be used and stored in a place protected from dust, acid or any other corrosive agent. Operate the machine in an open, or well-ventilated area.

Operating temperature

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

Air humidity

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

Altitude

Up to 1000 meters above sea level (3280 feet).

PROTECTION OF THE INDIVIDUALS

Arc welding can be dangerous and can cause serious injury or even death.
Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, risk of electric shock, noise and gas fumes. People wearing pacemakers are advised to consult a doctor before using the welding machine.
To protect oneself as well as others, ensure the following safety precautions are taken:

In order to protect you from burns and radiations, wear clothing without turn-up or cuffs. These clothes must be insulating, dry, fireproof, in good condition and cover the whole body.
Wear protective gloves which guarantee electrical and thermal insulation.
Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Contact lenses are prohibited during use. It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatter and sparks. Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective clothes.
Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any person in the welding area).
Keep hands, hair and clothes away from moving parts such as fans, and engines. Never remove the safety covers from the cooling unit when the machine is plugged in. The manufacturer is not liable for any injury or damage caused due to non-compliance with the safety precautions.
Parts that have just been welded will be hot and may cause burns when touched. When servicing the torch or electrode holder, make sure that it is cold enough by waiting at least 10 minutes before doing so. When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns that could potentially be caused by the liquid.
It is important to secure the working area before leaving it to ensure protection of the goods and the safety of people.

WELDING FUMES AND GAS

The fumes, gases and dust produced during welding are hazardous. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gases away from the work area. An air fed helmet is recommended in cases of insufficient air supply in the workplace.
Check that the air intake is in compliance with safety standards.

Care must be taken when welding in small areas, and the operator will need supervision from a safe distance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to degrease the workpiece before welding. Gas cylinders must be stored in an open or ventilated area. The cylinders must be in a vertical position secured to a support or trolley. Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION RISKS

Protect the entire welding area. Compressed gas containers and other inflammable material must be moved to a minimum safe distance of 11 meters.
A fire extinguisher must be readily available.
Be careful of spatter and sparks, even through cracks. It can be the source of a fire or an explosion.

Keep people, flammable objects and containers under pressure at a safe distance.
Welding of sealed containers or closed pipes should not be undertaken, and if opened, the operator must remove any inflammable or explosive materials (oil, petrol, gas…).
Grinding operations should not be directed towards the device itself, the power supply or any flammable materials.

ELECTRIC SAFETY

The machine must be connected to an earthed electrical supply. Use the recommended fuse size. An electrical discharge can directly or indirectly cause serious or deadly accidents.

Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit.
Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged.
Do not touch the torch or electrode holder and earth clamp at the same time.
Damaged cables and torches must be changed by a qualified and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions and welding cables). Always wear dry clothes in good condition, in order to be insulated from the electrical circuit. Wear insulating shoes, regardless of the environment in which you work in.

CLASSIFICATION

This equipment is Class B.
This equipment complies with the IEC 61000-3-12 standard. This equipment complies with the IEC 61000-3-11 standard.

RECOMMENDATIONS TO ASSES THE AREA AND WELDING INSTALLATION

Overview
The user is responsible for installing and using the arc welding equipment in accordance with the manufacturer’s instructions. If electromagnetic disturbances are detected, it is the responsibility of the user of the arc welding equipment to resolve the situation with the manufacturer’s technical assistance. In some cases, this remedial action may be as simple as earthing the welding circuit. In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by fitting input filters. In all cases, electromagnetic interferences must be reduced until they are no longer bothersome.

Welding area assessment
Avant d’installer un matériel de soudage à l’arc, l’utilisateur doit évaluer les problèmes électromagnétiques potentiels dans la zone environnante. Ce Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned.
In particular, it should consider the following:

a) the presence of other power cables (power supply cables, telephone cables, command cable, etc…)above, below and on the sides of the arc welding machine.
b) television transmitters and receivers ;
c) computers and other hardware;
d) critical safety equipment such as industrial machine protections;
e) the health and safety of the people in the area such as people with pacemakers or hearing aids;
f) calibration and measuring equipment
g) The isolation of the equipment from other machinery.
The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This may require extra precautions;
h) make sure of the exact hour when the welding and/or other operations will take place.

The surface of the area to be considered around the device depends on the the building’s structure and other activities that take place there. The area taken in consideration can be larger than the limits determined by the companies.
Welding area assessment
Besides the welding area, the assessment of the arc welding systems intallation itself can be used to identify and resolve cases of disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION

a. National power grid: The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the filtering of the power suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source.
b. Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine maintenance check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on.. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.
c. Welding cables: Cables must be as short as possible, close to each other and close to the ground, if not on the ground.
d. Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.
e. Earthing of the welded part : When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.
f. Protection and plating : The selective protection and plating of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORTATION OF THE MACHINE

It is preferable to drain the cooling unit before transport. Do not place/carry the unit over people or objects.

INSTALLATION

Put the machine on the floor (maximum incline of 10°.)
Ensure the work area has sufficient ventillation for welding, and that there is easy access to the control panel.
The machine must be placed in a sheltered area away from rain or direct sunlight.
The machine must not be used in an area with conductive metal dusts.
The MULTICOOL 500 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
The MULTICOOL 1300 machine protection level is IP23S, which means :
- Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and,
- Protection against the rain inclined at 60% towards the vertical.

These devices can be used outside in accordance with the IP23S protection index.

The manufacturer does not incur any responsability regarding damages to both objects and persons that result from an incorrect and/or dangerous use of the machine.

The power cables, extensions and welding cables must be fully uncoiled to prevent overheating.

MAINTENANCE / RECOMMENDATIONS

Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
Ensure the machine is unplugged from the mains, and wait for two minutes before carrying out maintenance work. DANGER High Voltage and Currents inside the machine.
Remove the casing 2 or 3 times a year to remove any excess dust. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufacturer, its after sales service or an equally qualified person.
Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.

The cooling liquid must be changed every 12 month in order to avoid sediments which could block the torch cooling circuit.
Any leak or residual fluid, after use, must be handled within the appropriate purification factory. If possible, recyclke the product. It is prohibited to empty the product in a river, a sceptic tank or a draining system. The diluted fluid must not be emptied in the sewers, unless euthorised by the local regulations.

INSTALLATION – PRODUCT OPERATION

Only qualified personnel authorized by the manufacturer should perform the installation of the welding equipment. During the installation, the operator must ensure that the machine is disconnected from the mains.

EQUIPMENT DESCRIPTION (FIG-1)

The MULTICOOL cooling unit is a system designed to cool the water-cooled torches connected to all types of welding machines (MIG/MAG and TIG). This device is autonomous and has its own power supply.
The MULTI COOL 1300 is equipped with water flow protection to protect the torch against a plug on the water circuit or a deterioration of the torch beam.

Water inlet (red)
Water outlet (blue)
ON/OFF button
Filling cap
Flow sensor connector (MULTI COOL 1300 only)
Tank level indicator
Power supply cable
Fuse

POWER SUPPLY

This machine is fitted with a 16A socket type CEE7/7 which must be connected to a single-phase 230V (50 – 60 Hz) power supply fitted with three wires and one earthed neutral. The absorbed effective current (I1eff) is indicated 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.

STARTUP

Fill the tank (see «Cooling liquid» section below).
Connect the torch to the Multicool.
Connect the MULTICOOL power supply cable to a single-phase 230V +/- 15% (50 – 60 Hz) power supply WITH earth. This machine must only be used with a single-phase electricity supply system with three wires and one earthed neutral The absorbed effective current (I1eff) is indicated 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.
Turn on the MULTICOOL with the ON/OFF button located on the front of the machine.
After 1 minute, check the coolant level and fill if necessary.

COOLANT

Make sure that the cooling unit is turned off before disconnecting the liquid inlet and/or outlet hoses of the torch. The coolant is harmful and irritates the eyes, the mucous membranes, and the skin. Hot liquid may cause burns.

Risk of burns due to hot liquid Never drain the cooling unit immediately after use. The liquid contained inside is boiling, wait until it cools down before draining.

INITIATING THE COOLANT CIRCULATION

When using the product for the first time or after completely emptying the coolant tank, the following procedure must be followed to start the circulation:

Fill the tank to its maximum level with coolant.
Connect the coolant starting kit to the cold liquid connector on the unit (blue connector). Place the other end of the kit in an empty container.
Switch on the liquid pump. To activate it, depending on the products, it will be necessary to connect a torch and then push the trigger, or simply turn on the device.
The pump should start instantly and the liquid should flow into the container. If the pump still does not start, cut off its supply, inject compressed air into the starting kit to remove the liquid from the pipes and then restart the pump.
Once the liquid starts flowing, the pump is running. Turn off the unit, disconnect the staring kit, refill the coolant in the tank and connect your system to the liquid connectors on the unit. Your cooling unit is ready to be operated.

FLOW SENSOR WIRING – MULTI COOL 1300 ONLY (EXAMPLE WITH A MIG TORCH)

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour). The warranty does not cover:

Transit damage.
Normal wear of parts (eg. : cables, clamps, etc..).
Damages due to misuse (power supply error, dropping of equipment, disassembling).
Environment-related failures (pollution, rust, dust).

In case of failure, return the unit to your distributor together with:

The proof of purchase (receipt etc …)
A description of the fault reported

FAQ (Frequently Asked Questions)

Q: What should I do if I encounter problems or uncertainties while using the welding machine?

A: Consult a qualified person to handle the installation properly if you face any issues or uncertainties during usage.

Q: How should I protect myself when welding?

A: Wear appropriate insulating, dry, fireproof clothing covering your whole body, along with protective gloves and gear. Ensure the working area is secured before starting work.

Q: Can I service the torch or electrode holder immediately after welding?

A: No, wait at least 10 minutes before servicing to allow the parts to cool down and avoid burns.