GYS PROTIG 200 DC HF Welding Machine Instruction Manual

GYS PROTIG 200 DC HF Welding Machine

Product Specifications

• Model: PROTIG 200 DC HF
• Input Voltage : 230V
• Functions: TIG DC, MMA

Product Usage Instructions

Environment and Safety Precautions:
Before welding, ensure proper personal protective equipment is worn.

Fire and Explosion Risk:
Be cautious when handling gas cylinders to prevent fire and explosion risks.

Welding Zone Evaluation:
Follow recommendations for assessing the welding area and setup to ensure safety.

Maintenance and Advice:
Regularly maintain the equipment to ensure optimal performance.

Interface Human Machine (IHM):
Refer to FIG-2 for the interface layout.

Power On:
Connect to power source and switch on the inverter welder.

Torch Modes:
For TIG welding, follow the torch modes as per the instructions provided.

Troubleshooting:
If you encounter any issues, refer to the troubleshooting section in the user manual or contact customer support.

Frequently Asked Questions (FAQ)

• What should I do if the welding machine does not power on?
  Check the power source connection and ensure it is properly plugged in. If the issue persists, contact customer support.

• How do I select different torch modes for welding?
  Use the main buttons and follow the instructions provided in the user manual for selecting torch modes based on your welding requirements.

• Can this welding machine be used for MMA welding?
  Yes, this product supports MMA welding in addition to TIG welding.

GENERAL INSTRUCTIONS

• 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 and even fatal injuries.
• Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device.
• To protect oneself as well as the other, ensure the following safety precautions are taken:
  • In order to protect you from burns and radiations, wear clothing without cuffs. These clothes must be insulated, dry, fireproof and 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. Do not operate whilst wearing contact lenses.
  • It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatters 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).
  • Stay away from moving parts (e.g. engine, fan…) with hands, hair, clothes etc…
  • Never remove the safety covers from the cooling unit when the machine is plugged in – The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions.
  • The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling unit must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns.
  • ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

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.

GAS BOTTLE

• Gas leaking from the cylinder can lead to suffocation if present in high concentrations around the work area.
• Transport must be done safely: Cylinders closed and product off. Always keep cylinders in an upright position securely chained to a fixed support or trolley.
• Close the bottle after any welding operation. Be wary of temperature changes or exposure to sunlight.
• Cylinders should be located away from areas where they may be struck or subjected to physical damage.
• Always keep gas bottles at a safe distance from arc welding or cutting operations, and any source of heat, sparks or flames.
• Be careful when opening the valve on the gas bottle, it is necessary to remove the tip of the valve and make sure the gas meets your welding requirements.

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.

EMC CLASSIFICATION

• These Class A devices are not intended to be used on a residential site where the electric current is supplied by the public network, with a low voltage power supply. There may be potential difficulties in ensuring electromagnetic compatibility on these sites, because of the interferences, as well as radio frequencies.
• Provided that the impedance of the low-voltage public electrical network at the common coupling point is less than Zmax = 0.104 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 user of the equipment to ensure, in consultation with the distribution netwtork operator if necessary, that the network impedance complies with the impedance restrictions.
• This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage systems interfacing with the public supply only at the medium- or high-voltage level. On a public low-voltage power grid, it is the responsibility of the installer or user of the device to ensure, by checking with the operator of the distribution network, which device can be connected.

ELECTROMAGNETIC INTERFERENCES

The electric currents flowing through a conductor cause electrical and magnetic fields (EMF). The welding current generates an EMF field around the welding circuit and the welding equipment.

• The EMF fields may disrupt some medical implants, such as pacemakers. Protection measures should be taken for people wearing medical implants. For example, access restrictions for passers-by or an individual risk evaluation for the welders.
• All welders should take the following precautions in order to minimise exposure to the electromagnetic fields (EMF) generated by the welding circuit::
  • position the welding cables together – if possible, attach them;
  • keep your head and torso as far as possible from the welding circuit;
  • never enroll the cables around your body;
  • never position your body between the welding cables. Hold both welding cables on the same side of your body;
  • connect the earth clamp as close as possible to the area being welded;
  • do not work too close to, do not lean and do not sit on the welding machine
  • do not weld when you’re carrying the welding machine or its wire feeder.

RECOMMANDATIONS 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

• 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:

  • 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.

  • television transmitters and receivers ;

  • computers and other hardware;

  • critical safety equipment such as industrial machine protections;

  • the health and safety of the people in the area such as people with pacemakers or hearing aids;

  • calibration and measuring equipment

  • 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;

  • 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

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..

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.

Welding cables:
Cables must be as short as possible, close to each other and close to the ground, if not on the ground.

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.

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.

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.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

• The machine is fitted with handle to facilitate transportation. Be careful not to underestimate the machine’s weight. The handle(s) cannot be used for slinging.
• Do not use the cables or torch to move the machine. The welding equipment must be moved in an upright position.
• Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item. Do not place/carry the unit over people or objects.

EQUIPMENT 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 not be used in an area with conductive metal dusts.
• The machine must be placed in a sheltered area away from rain or 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.
    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 .

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.
• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

INSTALLATION – PRODUCT OPERATION
Only qualified personnel authorized by the manufacturer should perform the installation of the welding equipment. During set up, the operator must ensure that the machine is unplugged. Connecting generators in a series or a parallel circuit is forbidden.

HARDWARE DESCRIPTION (FIG-1)

The PROTIG 200 DC HF inverter welding unit to be used with refractory electrodes (TIG) in direct current (DC) and electrode welding (MMA). TIG welding requires gas shield protection of pure gas (Argon).
The MMA process can wel all types of electrodes : rutile, basic, stainless and cast iron.

1. Keyboard + buttons
2. + polarity plug
3. – polarity plug
4. Gas connection for torch
5. Trigger connection
6. Power supply cable
7. Gas inlet

CONTROL BOARD (IHM) (FIG-2)

1. Process selection
2. Trigger mode selection
3. Process options selection
4. Welding parameters settings.
5. Thermal protection indicator
6. Display and options
7. Standby button

POWER SUPPLY – STARTING UP

• 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 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 user has to make sure that the plug can be reached.

• The device turns into protection mode if the power supply tension over 265V RMS.

• To start the machine up, press the Standby Button (7). Attention ! Never disconnect the power supply when the machine is on.

• Fan: in MMA mode, the fan works nonstop. In TIG mode, the fan works only when welding, then stops after cooling.

• NB: If the screen displays . this indicates that the device has entered protection mode. This will occur if the power supply voltage is excessively high (over 265V). If the machine switches on in protection mode, unplug the device and plug it into a socket delivering the correct voltage.

• The arc priming and stabilization device is designed for manual and mechanically guided operation.

CONNECTION ON A GENERATOR

• The machine can work with generators as logn as the auxiliary power matches these requirements :
  • The voltage must be AC, always set as specified, and the peak voltage below 400V,
  • 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.

USE WITH EXTENSION CABLES

All extension cables must have an adequate size and section, relative to the machine’s voltage . Use an extension that complies with national safety regulations.

 |

Input voltage

| Length – Extension selection
---|---|---
< 100m
PROTIG 200 DC HF| 230V| 2.5 mm²

SYMBOLS & MENUS

ELECTRODE WELDING (MMA)

CONNECTIONS AND RECOMMENDATIONS

• Connect the cables, electrode holder and earth clamp in the connectors,
• Respect the welding polarities and intensities indicated on the electrodes boxes,
• Remove the electrode from the electrode holder when the machin is not in use.

TIG WELDING WITH INERT GAS (TIG MODE)

CONNECTIONS AND RECOMMENDATIONS

• Connect the earth clamp to the positive connector (+).
• Connect the torch to the negative plug (–), the trigger cable and the gas hose.
• Ensure that the torch is equipped and ready to weld, and that the consummables (Vise grip, ceramic gas nozzle, collet and collet body) are not da-maged.

TIG WELDING PROCESSES

• TIG DC
  This welding mode in direct current (DC) is designed for ferrous metal such as steel, stainless steel or even copper and its alloys.

• TIG DC Pulsed
  This pulse welding mode chains high current pulses (I, welding pulse) then low current pulses (I_cold, pulses to cool the piece). This pulse mode allows to assemble pieces while limiting high temperatures.
  Example :

  • The I welding current is set to a 100A and % (I_cold) = 50%, thus a Cold current of = 50% x 100A = 50A. F(Hz) is set to 10Hz, the signal period will be 1/10Hz = 100ms.
  • Every 100ms, a 100A pulse then a 50A pulse will succeeed each other.
  • The choice of frequency
  • If welding with TIG electrodes, then F(Hz) synchronised to the gesture,
  • If thin plate without TIG electrodes (< 8/10 mm), F(Hz) >> 10Hz
  • If special metal requiring a welding pool sweep for degasing, then F(Hz) >> 100Hz

• **Tack weld feature SPOT

**

SELECT STRIKING MODE

• HF TIG: High Frequency start without contact
• TIG LIFT : Contact start (for environments sensitive to HF disturbances).

1. Touch the work-piece with the electrode
2. Press the trigger on the torch
3. Pull back the torch to lift the electrode.

COMPATIBLE TORCHES

TORCHES AND TRIGGER MODES

• For the 1 button torch, the button is called «main button».
• For the 2 buttons torch, the first button is called «main button» and the second button is called «secondary button».

2T MODE

• T1 – The main button is pressed, the welding cycle starts (PreGas, I_Start, UpSlope and welding).
• T2 – The main button is released, the welding cycle is stopped (DownSlope, I_Stop, PostGas).
  For the double button torch and in 2T mode only, the secondary but-ton works like the main button.

4T MODE

• T1 – The main button is pressed, the cycle starts at PreGas and stops in the I_Start phase.
• T2 – The main button is released, the cycle continues in UpSlope and in welding.
• T3 – The main button is pressed, the cycle switches to DownSlope and stops in I_Stop.
• T4 – The main button is released, the cycle ends with PostGas.
  Nb : for torches, double button and double button with potentiometer => command « up/welding current » and active potentiometer, command «low » inactive.

4T MODE log

• T1 – The main button is pressed, the cycle starts at PreGas and stops in the I_Start phase.
• T2 – The main button is released, the cycle continues in UpSlope and in welding.
• LOG : this mode is used during welding :
  • A brief press of the main button (<0.5s), the current switches from I welding current to I cold and vice versa.
  • the secondary button is kept pressed, the weldin current switches from I welding current to I cold
  • the secondary button is kept released, the current switched from I cold to I welding current.
• T3 – A long press on the main button (>0.5s), the cycle swicthes to DownSlope and stops in the I_Stop phase.
• T4 – The main button is released, the cycle finishes with PostGas.

For this mode it may be convenient to use the dual button torch option or dual button with potentiometer. The «up» command keeps the same func-tion as the single button or trigger torch. The «down» button can, when pressed, switch to the cold current. The potentiometer of the torch, where available, allows control of the welding current from 50% to 100% of the value displayed.

RECOMMENDED COMBINATIONS

ELECTRODE GRINDING
To optimise the welding process, it is recommended to grind the electrode prior to welding as described below:

• L = 3 x d for a low current.
• L = 3 x d for a high current

SAVE AND LOAD WELDING SETTINGS

There are 10 memories in MMA and 10 in DC TIG.
Menu is accessed with the MEM button.

• Save settings
  • Once in program mode, select IN and press the access button.
  • Slect a program from P1 to P10. Press the access button and the current setting is saved.
• Load an existing setting
  • Once in program mode, select OUT and press the access button.
  • Slect a program from P1 to P10. Press the access button and the setting is loaded.

COMMAND TRIGGER CONNECTOR

Torch 2 triggers

|

Torch 1 trigger

| Common/Earth| 2 (brown and black)
Switch trigger 1| 4 (gray)
 | Switch trigger 2| 3 (red)

TROUBLESHOOTING

This device integrates a default management system.
A series of messages displayed on the control board allows for a fault and anomalies diagnosis.

WELDING MACHINE
« dEF » « 1 »| Communication error| Check the internal cabling between the MMI and the

PCB.

« dEF » « 2 »| Faulty MMI buttons| Replace the MMI.
« dEF » « 3 »| Faulty torch(es) trigger(s) / button(s)| Replace the torch.
« dEF » « 4 »| Foot pedal switch always active or faulty| Replace the pedal and check that the switch is not stuck.
« – – – »| An overvoltage was detected on the electrical distribution

network.

| A power surge is the origin of the message and origi- nates from a motor overload, lightning…

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

SPARE PARTS

TECHNICAL SPECIFICATIONS

ПВ% при 40°C (10 мин)* Норма EN60974-1.

Inschakelduur bij 40°C (10 min)*

Norm EN60974-1.

Ciclo di lavoro a 40°C (10 min)*

Norma EN60974-1.

| Imax| 20%| 20%
60%| 115 A| 90 A

100%

|

90 A

|

70 A

 |
Functionning temperature| -10°C  +40°C
Storage temperature| -20°C  +55°C
Protection level| IP21
Dimensions (Lxlxh)| 43.5 x 21.5 x 32.5 cm
Weight| 10 kg

CIRCUIT DIAGRAM

SYMBOLS

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