GYS E2 MIG MAG Welding Machine Instruction Manual

: August 27, 2024
: GYS

GYS E2 MIG MAG Welding Machine

PRODUCT INFORMATION

BOTTLE SUPPORT

BALANCING ARM ONLY

E2 / E3

UPDATE PROCEDURE

USB key not included.

GAS FITTINGS

I

SAFETY INSTRUCTIONS

GENERAL INSTRUCTIONS

These instructions must be read and fully understood before use.
Do not undertake any alterations or maintenance work that is not directly specified in this manual.
The manufacturer shall not be liable for any damage to persons or property resulting from use not in accordance with the instructions in this manual.
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 the event 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. Ensure good air circulation when in use.

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 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 source of heat, light radiation from the arc, electromagnetic fields (caution to those using pacemakers) and risk of electrocution, as well as noise and fumes.

To protect yourself and others, please observe the following safety instructions:

To protect yourself from burns and radiation, wear insulating, dry and fireproof clothing without lapels. Ensure the clothing is in good condition and that covers the whole body.
Wear gloves that ensure electrical and thermal insulation.
Use welding protection and/or a welding helmet with a sufficient level of protection (depending on the specific use). Protect your eyes during cleaning operations. Contact lenses are specifically forbidden. It may be necessary to section off the welding area with fireproof curtains to protect the area from arc radiation and hot spatter. Inform people in the welding area not to stare at the arc rays or molten parts and to wear appropriate clothing for protection.
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 hands, hair and clothing away from moving parts (the ventilation fan, for example). Never remove the cooling unit housing protections when the welding power source is live, the manufacturer cannot be held responsible inthe event of an accident.
The newly welded parts are hot and can cause burns when handled. When maintenance work is carried out on the torch or electrode holder, ensure that it is sufficiently cold by waiting at least 10 minutes before carrying out any work. The cooling unit must be switched on when using a water-cooled torch to ensure that the liquid cannot cause burns. It is important to secure the work area before leaving it in order to protect people and property.

WELDING FUMES AND GAS

The fumes, gases and dusts emitted by welding are harmful to health. Sufficient ventilation must be provided 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 even beryllium can be particularly harmful. Remove any grease from the parts before welding.

Cylinders should be stored in open or well-ventilated areas. They should be stored in an upright position and kept on a stand or trolley. Welding should not be carried out near grease or paint.

RISK OF FIRES AND EXPLOSIONS

Fully shield the welding area, flammable materials should be kept at least 11 metres away.
Fire fighting equipment should be kept close to wherever the welding activities are being undertaken.
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.
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, gas residues, etc.).
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 changes and sun exposure.
The cylinder must not come into contact with flames, arcs, torches, earth clamps or any other sources of heat or ignition.
Be sure to keep it away from electrical and welding circuits. 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.
An electric shock can be the source of a serious accident, whether directly or indirectly, 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 use high-quality, dry clothing to insulate yourself from the welding circuit. Alongside this, wear well-insulated footwear in all working environments.

EMC CLASSIFICATION

This Class A equipment is not intended for domestic use where electrical power is supplied from the low-voltage mains system.
Ensuring electromagnetic compatibilty may be difficult at these sites due to conducted, as well as radiated, radio frequency interference.
This equipment complies with IEC 61000-3-11.
This equipment complies with the IEC 61000-3-12 standard.

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 – securing them with a clamp 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 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 responsibilit 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:

the presence of power, control, signal and telephone cables above, below and next to the arc welding equipment,
radio and television receivers and transmitters,
computers and other control equipment,
critical safety equipment, e.g. the protection of industrial equipment,
the health of nearby persons, e.g. 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 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

GUIDELINES ON HOW TO REDUCE ELECTROMAGNETIC EMISSIONS

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.
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.
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 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.
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.
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 moved 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 transportation 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 benefits from an IP21 protection index, which means:
- its dangerous parts are protected from being entered by objects greater than 12.5 mm and,
- Protection against vertically falling drops
  Warning: 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

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 personnel, authorised by the manufacturer, may carry out the machine’s set-up. During set-up, ensure that the power source is unplugged 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 optimum product settings.

DESCRIPTION

The unit is a semi-automatic «synergic» welding unit, 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 (II)

E1

Reel support ® 200/300 mm
Accessory box hatch
Cable support
Torch support
HMI
START/STOP switch
Ground clamp cable (3.5 m)
Euro connector (torche)
Storage space
Gas connector
Mains cable (6.25 m)
Bottle holder 4 m3
USB connector
Wire-feed motor

E2

Gas connector (torch 1)
Gas connector (torch 2)
Reel support ® 200 mm (torch 1)
Reel support ® 200/300 mm (torch 2)
Cable support
Torch support
HMI
START/STOP switch
Ground clamp cable (3.5 m)
Euro connector (torch 1)
Euro connector (torch 2)
Bulkhead connector for gas
Mains cable (6.25 m)
Bottle holder 4 m3 or 2 x 4 m3
USB connector
Wire-feed motor (torch 1)
Wire-feed motor (torch 2)

E3

Gas connector (torch 1)
Gas connector (torch 2)
Gas connector (torch 3)
Reel support ® 200 mm (torch 1)
Reel support ® 200 mm (torch 2)
Reel support ® 200 mm (torch 3)
Cable support
Torch support
HMI
START/STOP switch
Ground clamp cable (3.5 m)
Euro connector (torch 1)
Euro connector (torch 2)
Euro connector (torch 13
Bulkhead connector for gas
Mains cable (6.25 m)
Bottle holder 4 m3 or 2 x 4 m3
USB connector
Wire-feed motor (torch 1)
Wire-feed motor (torch 2)
Wire-feed motor (torch 3)

HUMAN-MACHINE INTERFACE (HMI)

Please read the Interface (HMI) manual which is part of the equipment’s user literature.

POWER SWITCH

The material is supplied with a 16A plug type CEE7/7 and must only be used on a single-phase electrical installation 230V (50-60 Hz) with 3 wires including one connected to earth. The absorbed effective current (I1eff) is shown on the device for optimum operating conditions. Check that the power supply and its safeguards (fuse and/or circuit breaker) are compatible with the electric current being used. In some countries, it may be necessary to change the plug to allow the use at maximum settings.

The power source is designed to operate on 230 V -20% +15%. The machine goes into protection mode if the supply voltage is below 185 Veff or above 265 Veff. (an error code will appear on the display screen).
The power is switched on by pressing the START/STOP switch (On), conversely switching off is done by pressing the same switch (Off). Warning! Never disconnect the machine from the power supply while the machine is charging.

CONNECTING TO A POWER SOURCE

This equipment can be operated with electric generators provided that the auxiliary power supply meets the following requirements:

The voltage must be alternating, and the RMS value must be 230 V -20% +15%, with peak voltage below 400V,
The frequency must be between 50 and 60 Hz.

It is imperative to check these requirements, as many 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.

Input voltage	Extension lead cross section ( <45m)
230 V	2.5 mm²

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. Do not over tighten as this will cause the power source to overheat.

LOADING THE FILLER WIRE

To change the rollers, do the following:

Loosen the knob (a) to the maximum and lower it.
Unlock the rollers by removing the retaining screws (b)
Fit the appropriate drive rollers for your application and retighten the retaining screws.

The rollers supplied are double groove rollers:

steel Ø 0.6/0.8 (E1 + E2 + E3)
steel Ø 0.8/1.0 (E3)
aluminium Ø 0.8/1.0 (E2 + E3).
Check the inscription on the roller to ensure that the rollers are suitable for the wire diameter and the wire material (for Ø 1.0 wire, use the Ø 1.0 groove).
Use V-grooved rollers for steel and other hard wires.
Use U-grooved rollers for aluminium and other soft, alloyed wires.
- : visible inscription on the roller (example: 1.0)
- : groove to be used

To install the wire, follow the steps below:

Loosen the knob to the maximum and lower it.
Insert the wire, then close the motor reel and tighten the knob as shown.
Operate the motor via the trigger of the torch.

Notes:

Too narrow a sheath can lead to unreeling issues and can lead to the overheating of the motor.
The torch connection must also be properly tightened to prevent it from overheating.
Ensure that neither the wire, nor the reel, touches the device’s mechanism, otherwise there is a danger of short-circuiting the machine.

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’s spool.

SEMI-AUTOMATIC

SEMI-AUTOMATIC STEEL/STAINLESS STEEL WELDING (MAG MODE)

This machine can weld steel and stainless steel wire from Ø 0.6 to 1.0 mm (I-A).

E1 / E2: The unit is supplied with Ø 0.6/0.8 rollers for steel or stainless steel as standard.
E3: The unit is supplied with Ø 0.6/0.8 and Ø 0.8/1.0 rollers for steel or stainless steel as standard.

The contact tip, the sheave groove and the welding torch sheath are designed for this use.

To do this using steel requires a specific welding gas (Ar+CO2). The amount of CO2 may vary depending on the type of gas used. For stainless steel, use a 2% CO2 mixture. When welding with pure CO2, it is necessary to connect a gas pre- heater to the gas cylinder. For specific gas issues, please contact your gas distributor. The gas flow rate for steel is between 8 and 15 litres per minute depending on the surroundings. To measure the gas flow rate at the torch outlet, it is recommended to use the optional flow meter (ref. 053939).

SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE)

This machine can weld aluminium wire from Ø 0.8 to 1.2 mm (I-B) (Ø 1.2 mm, non-intensive welding).

E2 / E3: The unit is supplied as standard with Ø 0.8/1.0 rollers for aluminium.

For use with aluminium, pure argon gas (Ar) is required. Seek advice from a gas distributor for a wide selection of gases. The gas flow rate for aluminium is between 15 and 20 l/min depending on the surrounding environment and the welder’s experience.

The differences between steel and aluminium processing are as follows:

Use specific rollers for aluminium welding.
Put minimum pressure on the motorised reel’s pressure rollers so as not to crush the thread.
Only use the capillary tube (for guiding the wire between the feed rollers and the EURO connector) for steel/stainless steel welding (I-B)
Use a special aluminium torch. This aluminium torch has a Teflon coating to reduce friction. DO NOT cut away the coating at the tip of the connector!
This coating is used to guide the wire from the rollers.
Contact tips: use a SPECIAL aluminium contact tip that matches the wire’s diameter.

When using red or blue sheathing (for aluminium welding), it is recommended to use the accessory 90950 (I-C). This stainless steel sheath guide improves the centering 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 1.0 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. For brazing, pure argon (Ar) should be used..

GAS SUPPLY

Bulkhead connector: E2 / E3

Fit a suitable pressure regulator to the gas cylinder. Connect to the machine with the hose(s) supplied, see diagram on page 6. Fit the 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.

RECOMMENDED COMBINATIONS

| ****

(mm)

| ****

Current (A)

| ****

Ø Wire (mm)

| ****

Ø Nozzle (mm)

| ****

Flow (L/min)

---|---|---|---|---|---
MIG| 0.8-2| 20-100| 0.8| 12| 10-12
2-4| 100-200| 1.0| 12-15| 12-15
MAG| 0.6-1.5| 15-80| 0.6| 12| 8-10
1.5-3| 80-150| 0.8| 12-15| 10-12
3-8| 150-300| 1.0/1.2| 15-16| 12-15

MIG / MAG WELDING MODE

MIG / MAG (GMAW/FCAW) WELDING MODE

| Welding processes|
---|---|---
Settings| Settings| Manual| Synergies (pre-installed user settings)|
Torque material/gas| – Fe Ar 15% CO2

– …

| –| | Choice of the material to be welded. Synergic welding parameters
Wire diameter| Ø 0.6 > Ø 1.2 mm| –| | Choice of wire diameter
Using the trigger| 2T, 4T| ****

| ****

| Choice of trigger welding management mode
---|---|---|---|---
Spot mode| Spot, Spot-Delay| Selecting the spot mode

First Setting

| Thickness Start-up Speed| ****

–

| ****| Choosing the main setting to be displayed (thickness of the workpiece, average welding current or wire speed).

Access to some of the welding parameters depends on the selected display mode: Settings/Display mode: Easy or Expert. Refer to the HMI manual.

WELDING PROCESSES

For more information on GYS pre-installed user settings and welding processes, scan the QR code:

2 WELDING MODES (EASY)

Welding (continuous)
Stitch Welding
- This function allows the assembly of very thin sheet metal while limiting the risk of piercing and deformation of the material. Chain-stitch welding is done manually with the trigger.

SPOT MODE (EXPERT)

Spot

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. Spot welding allows for better reproduction and non-oxidised weld points.

Spot-Delay

This is a welding mode similar to Spot welding but with predefined weld and dwell times, as long as the trigger is held down. This function allows welding very thin steel or aluminium metal sheet, limiting the risk of piercing and distortion (especially for aluminium welding).

CONFIGURING THE SETTINGS

| Units|
---|---|---
Burnback| –| Feature to help prevent the wire sticking to the bead. This is timed to coincide with the wire rising from the weld pool.
Crater Filler| –| This idling current is the next phase after the current is lowered.
Delay| s| Time between the end of a point (excluding Post-Gas) and the start of a new point (including Pre-Gas).
Thickness| mm| The pre-installed user settings (syngergies) allow for a fully- automatic set-up. Changing the thickness setting automatically sets the appropriate wire tension and speed.
Hot Start| –| The Hot Start is an overcurrent used at the start that prevents the wire from sticking to the workpiece.
Current| A| The welding current is adjusted according to the type of wire used and the material to be welded.
I Start| –| Adjustment of the ignition current.
Arc length| –| Used to adjust the distance between the end of the wire and the weld pool (tension adjustment).
Pre-Gas| s| When the torch is bled and the gas shield is created before ignition.
Tack welding| s| Set duration.
Post-Gas| s| Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from oxidation.
Self-Induction Coil| –| Lessens the welding current more or less. To be set according to the welding position.
Voltage| V| Control over the cord’s width.
Approach speed| –| Progressive yarn speed. Before priming, the wire moves slowly to create the first contact without jolting.
Wire speed| m/min| Amount of filler metal deposited and consequently the welding intensity and penetration.

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

GAS FLOW CONTROL

In the main screen, a long press on button N°1 allows you to adjust the gas flow on the manometer without unwinding the supply wire. Once started, the proceedure is illustrated with an animation on the screen. The gas flow setting should be checked periodically to ensure optimal welding.

DEFECTS

DEFECTS: CAUSES & SOLUTIONS

SYMPTOMS	POSSIBLE CAUSES	SOLUTIONS

The flow rate of the welding wire is not

constant.

| Clogs blocking the opening.| Clean the contact tube or replace it with non- stick material.
The wire is slipping on the rollers.| Reapply the non-stick product.
One of the rollers is spinning.| Check the tightness of the roller screw.
The torch cable is twisted.| The torch cable should be as straight as possible.
The unwinding mechanism is not working.| The spool’s brake or roller is too tight.| Loosen the brake and rollers.

Incorrect unwinding of the wire.

| Dirty or damaged wire guide.| Clean or replace.
Roller pin key is missing.| Reposition the pin in its slot.
Spool’s brake is too tight.| Release the brake.

No current or wrong welding current.

| Incorrect mains outlet connection.| Check the plug connection and verify that the plug is connected to the power supply.
Poor earth connection.| Check the earthing cable (its connection and the condition of the clamp).
No power.| Check the torch trigger.

The wire jams after passing through the rollers.

| Crushed wire guide sheath.| Check the wire-guide sheath and body of the torch..
Wire blockage in the torch.| Replace or clean.
No capillary tube.| Check that the capillary tube is present.
Wire speed too high.| Reduce the wire speed.

The weld bead is porous.

| The gas flow is insufficient.| Adjustment range from 15 to 20 L / min. Clean the base metal.
Gas cylinder empty.| Replace it.
Unsatisfactory gas quality.| Replace it.
Air circulation or wind influence.| Avoid draughts and protect the welding area.
Gas nozzle is too clogged.| Clean or replace the gas nozzle.
Bad wire quality.| Use a wire suitable for MIG/MAG welding.
Condition of the welding surface is too poor (rusted, etc.).| Clean the workpiece before welding.
The gas is not connected.| Check that the gas is connected to the power source’s inlet.

Excessive sparks.

| Arc voltage is too low or too high.| See welding settings.
Poor earth connection.| Check and position the earth clamp as close as possible to the area to be welded.
Insufficient gas protection.| Adjust the gas flow.

No gas coming from the torch.

|

Poor gas connection.

| Check the connections of gas inlets.
Check that the solenoid valve is working.
Error while downloading.| The data on the USB stick is incorrect or corrupted.| Check your data.
Backup error.| You have exceeded the maximum number of backups.| You need to delete some programs.

The number of backups is limited to 200.

Automatic deletion of JOBS.

| Some of your JOBs have been deleted because they were incompatible with the new pre-installed user settings (synergies).|

–

USB key error.

| There is no JOB detected on the USB stick.| –
The product’s memory space is full.| Free up some space on the USB key.

File error.

| The file does not match the pre-installed user settings (synergies) downloaded to the product.| The file was created with pre-installed user settings (synergies) that are not present on the machine.

Update problem

| The USB stick is not recognised. The visualization of step 4 of the update procedure does not appear on the display.| 1- Insert the USB key into its socket. 2- Turn on the power source.

3- Hold down on the HMI thumbwheel to force the update.

DRIVE ROLLERS (B) OPTIONAL

Diameter

| Part Number (x2)
---|---
Steel| Aluminium
ø 0.6/0.8| 042087| –
ø 0.8/1.0| 042360| 042377
ø 1.0/1.2| –| 040915

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. : clamps, etc.).
Incidents caused by misuse (incorrect power supply, dropping or dismantling).
Environment-related faults (such as pollution, rust and dust).

In the event of a breakdown, please return the appliance to your distributor, along with:

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

SPARE PARTS

E1 GYS AUTO

| E1| E2| E3
---|---|---|---
1| Wire reel holder| 71613
2| Screen protector| 56296
3| Handle| 56047
4| HMI| E0267C
5| Knob| 56294
6| Switch| 52472
7| Ground cable with clamp| 350 cm

25 mm2

| A0216ST
8| Motodévidoir / Wirefeeder| 51207
9| Swivel wheel| 71360
10| Wheel| 71375
11| Output self| 63739
12| Current sensor| 64452
13| Fan| 92 x 92| 51048
14| Solenoid valve| 70991
15| Power cord| 625 cm| 21588
16*| Main circuit| E0149C| E0150C| E0122C
17| Hinge| 56239

see details on next page.

CIRCUIT PRINCIPAL / MAIN CIRCUIT

| E1| E2| E3
---|---|---|---
16-1| Side B| K0662
16-2| Control board| E0124C
16-3| Transformer support| K0664
16-4| Power transformer| 63108
16-5| Fan| 92 x 92| 51048
16-6| Side A| K0661
16-7| Power board| E0149B| E0150B| E0122B
16-8| PFC self| 63662
16-9| Self holder| K0663
16-10| Power block| E5036

CIRCUIT DIAGRAM

E1

E2

E3

TECHNICAL SPECIFICATIONS

| E1| E2| E3
---|---|---|---
Primary
Power supply voltage| ****

U1

| ****

230 V +/- 15%

Mains frequency| 50 / 60 Hz
Number of phases| 1
Fuse| ****

16 A

Maximum effective supply current| ****

I1eff

| ****

14.3 A

Maximum supply current| ****

I1max

| ****

26.1 A

Mains cable section| ****

3 x 2.5 mm²

Maximum active power consumed| ****

5848 W

Idle consumption| 9.13 W
Efficiency at I2max| 83 %
Power factor at I2max| ****

λ

| ****

0.996

EMC class| A
Secondary| MIG-MAG

(GMAW-FCAW)

No load voltage| U0 (TCO)| ****

65 V

Type of welding current| ****

DC

Welding modes| MIG-MAG
Minimum welding current| ****

10 A

Rate current output| ****

I2

| 10 200 A
Conventional voltage output| ****

U2

| 14.5 24 V
| * Duty cycle at 40°C (10 min), Standard EN60974-1.| Imax| 20 %
| 60 %| 145 A
| 100 %| 130 A
Minimum and maximum diameter of filler wire| Acier / Steel| 0.6 1.0 mm
Inox / Stainless| 0.6 1.0 mm
Aluminium| 0.8 1.2 mm
CuSi / CuAl| 0.8 1.0 mm
Torch connector| **

Euro

Drive roller type| B
Motor speed| 1 15 m/min
Motor power| ****

50 W

Maximum diameter of the supply reel| ****

Ø 300 mm

| ****

Ø 300 mm

| ****

Ø 200 mm

Maximum weight of the filler wire reel| ****

15 kg

| ****

15 kg

| ****

5 kg

Maximum gas pressure| ****

Pmax

| ****

0.5 MPa (5 bar)

Functionning temperature| -10°C +40°C
Storage temperature| -20°C +55°C
Protection level| IP21
Minimum coil insulation class| ****

B

---|---
Dimensions (LxWxH)| ****

74 x 49 x 78 cm

| ****

87.5 x 63 x 90 cm

Weight| 38.5 kg| 48.8 kg| 51 kg
Weight with accessories| 40.5 kg| 58.3 kg| 62.5 kg

*The duty cycles are measured according to standard EN60974-1 à 40°C and on a 10 min cycle. While under intensive use (> to duty cycle) the thermal protection can turn on, in that case, the arc swictes off and the indicator switches on. Keep the machine’s power supply on to enable cooling until thermal protection cancellation. The current source describes a flat output characteristic. In some countries, U0 is called TCO.

SYMBOLS

FAQ

Q: How do I choose the welding parameters for different materials?
- A: The welding parameters can be set based on the material type, wire diameter, and gas flow rate. Refer to the user manual for specific parameter settings.
Q: What is the difference between the Easy and Expert display modes?
- A: The Easy mode provides simplified access to essential welding parameters, while the Expert mode offers more advanced settings for experienced users.
Q: How often should I perform maintenance on the welding machine?
- A: Regular maintenance checks should be conducted as per the guidelines in the user manual, typically after a certain number of operating hours or at specified intervals.