GYS MIG 25 Aluminium Toolstop Instructions
- September 17, 2024
- GYS
Table of Contents
GYS MIG 25 Aluminium Toolstop
Product Specifications:
- Models: MIG 15 / MIG 25 / MIG 36 / TT120 / PT120
- Input Voltage: 113 V
- Output Current:
- MIG 15: 150 A at 35%, 180 A at 60%
- MIG 25: 180 A at 60%, 230 A at 60%
- MIG 36: 340 A at 60%
- TT120: 120 A at 35%
- PT120: 120 A at 35%
- Cooling Method: Air
- Connection Type: EURO
- Gas Type: CO2 and Mixtures
- Gas Flow Rate: 10-25 L/min
- Wire Feed Speed: Variable
- Wire Diameter Compatibility: Various
- Torch Length: 3m to 4m
Product Usage Instructions
Installation:
Ensure torch connection requirements are met. Follow the projection guides
for each torch model (MIG 15, MIG 25, MIG 36, TT120, PT120) for proper
installation.
Individual Protection & Safety:
Arc welding poses risks of serious injury or death. Always wear appropriate
protective clothing to prevent burns and radiation exposure.
General Safety Rules:
Read and understand all safety instructions before use. Do not attempt any
modifications not specified in the manual to avoid injury. Seek professional
help if unsure.
FAQ:
-
Q: What should I do if I encounter any issues during installation?
A: If you face any problems during installation or are uncertain about any step, it is recommended to consult a qualified person to ensure correct setup. -
Q: How should I protect myself while using the welding machine?
A: To protect yourself, wear insulating, dry, fireproof clothing that covers your entire body and does not have turn-ups or cuffs to prevent burns and radiation exposure.
MIG 15 / MIG 25 / MIG 36 / TT120 / PT120
WARNING – SAFETY RULES
GENERAL INSTRUCTIONS
Read and understand the following safety instructions before use.
Any modification or updates that are not specified in the instructions manual
should not be underta-ken.
The manufacturer is not liable for any injury or damage due to a non- compliance with the instructions featured in this manual. If there is any issue or uncertainty, please consult a qualified person to handle the installation correctly.
INDIVIDUAL PROTECTION & OTHERS
- 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.
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.
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 GASES
The fumes, gas and dust generated by cutting are a potential health hazard. You must ensure adequate ventilation through the installation of air supplies in order to extract fumes and gases. Using an air fed welding helmet is recommended in case of insufficient ventilation in the workplace. Check that the air supply is effective by referring to the recommended safety regulations.
- Caution, welding in small spaces requires surveillance 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. They must be stored vertically and held by a support or trolley to limit the risk of fall. Do not weld in areas where grease or paint are stored.
FIRE AND EXPLOSION RISKS
Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters. A fire extinguisher must be readily available near the welding operations.
- Be careful of weld spatter and sparks, even through cracks. If not careful then this could potentially lead to a fire or an explosion. Keep people, flammable materials/objects and containers that are under pressure at a safe distance. Welding in closed containers or pipes should be avoided and , if they are opened, they must be emptied of any flammable or explosive material (oil, fuel, gas …).
- Grinding operations should not be carried out close to the power supply or any flammable materials.
ELECTRICAL SAFETY
An electric shock could cause serious injuries or potentially even deadly accidents.
- Do not touch any live part of the machine (inside or outside) when it is plugged in because they are connected to the welding circuit.
- Do not touch the torch or and the earth clamp at the same time.
- Always wear dry clothes which are in good condition in order to be isolated from the welding circuit. Always wear insulated shoes, regardless of the environment in which you work in.
PRECAUTION FOR USE
- Never wrap the welding leads around your body.
- Do not use the torch to move the welding power source or wire feeder.
- The torch must be fully uncoiled to prevent overheating.
- Switch off the generator after the torch is cooled and before each maintenance and before replacing or control wearing parts. Regularly check the condition of the torch. If damaged, the torch must be replaced.
GENERAL DESCRIPTION
SPECIFICATIONS
The MIG 15 / MIG 25 / MIG 36 / TT120 / PT120 torches are intended to the manual MIG / MAG welding processes.
TECHNICAL SPECIFICATIONS
Part number
| Component| ****
072121
| ****
063754
082151
| ****
063761
| Component| ****
063778
| ****
063785
| ****
063792
| ****
063808
| Component
---|---|---|---|---|---|---|---|---|---|---
71846
| 71847
063754
| 71848
072138
| 71866
072145
| 71879
072152
| ****
C71453
| ****
C71454
| ****
53277
| ****
C71391
| ****
71392
Name| MIG 15| MIG 25| MIG 36| TT120| PT120
Process| MIG / MAG| MIG / MAG| MIG / MAG| NO GAS MIG| MIG/MAG
Guidance method| Manual| Manual| ****
Manual
| ****
Manual
| ****
Manual
Rated current Corresponding duty cycle| 150 A
35%
| 180 A
60%
| 230 A
60%
| ****
340 A
60%
| ****
120 A
35%
| ****
120 A
35%
Rated voltage| ≤113 V| ≤113 V| ≤113 V| ≤113 V| ≤113 V
Cooling mode|
Air
| ****
Air
| ****
Air
| ****
Air
| ****
Air
Connections| EURO| EURO| EURO| Fixed| Fixed
Gas protection| 150 A CO2 /
120 A Mix| 180 A CO2 /
150 A Mix
| 230 A CO2 /
200 A Mix
| 340 A CO2 /
300 A Mix
| ****
–
| 120 A CO2 /
100 A Mix
Gas flow| 10-18 L/min
(2.64/4.75 US
gpm)
| ****
10-25 L/min
(2.64/6.60 US gpm)
| ****
10-25 L/min
(2.64/6.60 US gpm)
| 10-25 L/min
(2.64/6.60 US
gpm)
| ****
–
| 6-15 L/min
(1.58/3.96 US
gpm)
**** Contact tube| Ø 0.8
Steel
| Ø 1.0
Steel
| Ø 1.0
Steel
| Ø 0.8
Steel
| Ø 0.8
Alu
| Ø 1.2
Alu
| Ø 0.8
Steel
| Ø 1.0
Steel
| Ø 1.0
Steel
| Ø 1.0
Steel
| Ø 1.0
Alu
| Ø 1.2
Steel
| Ø 1.2
Alu
| Ø 0.9
Steel
| Ø 0.8
Steel
Cable length|
3m
| ****
3m
| ****
3m
| ****
3m
| ****
4m
| ****
4m
| ****
3m
| ****
4m
| ****
3m
| ****
2.5m
| ****
2.35m
| ****
2.2 m
| ****
2.4m
Cross section| 14 mm²| 16 mm²| 25 mm²| 42 mm²| 10 mm²| 10 mm²
Switch trigger
voltage| ****
10 V
| ****
10 V
| ****
10 V
| ****
10 V
| ****
10 V
Functionning temperature| – 10 +40°C
Storage
temperature| – 10 +55°C
Applied standard| IEC 60974-7
SET UP
TORCH CONNECTION REQUIREMENT
MIG 15-25-36
The generator must be switched off. Insert the torch connector (A) in the
female connector (E) and screw the part B. Make sure the torch is tight
enough.
To remove the torch, unscrew as shown below.
TT120 – TP120
The generator must be switched off.
- Open the cover.
- Unscrew the 4 screws (framed in black).
- Disconnect the cables and remove the torch.
- Replace the new lamp.
- Reconnect in the same way and then screw it back on.
TORCHES EQUIPMENT
The torch must be fitted with the appropriate consumables, selected based on
the application and selected current.
Using the wrong consumables will result in poor cutting, excessive use of
consumables and possibly prevent the machine from working.
Welding Spatter :
- When welding, the spatter can easily damage the torch and welding equipment. To avoid constraints on the wire feeder, decrease arc stability or reduce the gas isolation effect, spatter and other depots build-up in the nozzles must be cleaned as soon as necessary.
- Accumulated spatter in the nozzle will cause a short-circuit which could damage the torch over time if not cleaned in due course.
- The use of anti-splatter spray or paste is recommended. In order to avoid to damage to the torch, do not use a cutting tool to clean it.
Torch MIG 15 :
Torch MIG 25 :
Torch MIG 36 :
Torch TT120
Torch PT120
Consumables :
Regularly check the wear condition of the contact tube 3 and the nozzle 4 .
| 1 Sheath | MIG 15 | MIG 25 | MIG 36 |
|---|---|---|---|
| Steel | Alu | Steel | Alu |
Ø 0.6/0.8 mm
| 3 m| 041592| 041578| –| –| –| –
4 m| 041837| 044050| –| –| –| –
Ø 1.0/1.2 mm
| 3 m| –| –| 041608| 041585| 041608| 041585
4 m| –| –| 041844| 044067| 041844| 044067
5 m| –| –| 062276| –| 062276| –
8 m| –| –| –| 038677| –| 038677
2
| Contact tube support|
MIG 15
|
MIG 25
|
MIG 36
---|---|---|---|---
150 A
| A1 x 5| 042902| –| –
A2 x 10| 042988| –| –
250 A
| B1 x 5| –| 042995| –
B2 x 5| –| 042919| –
350 A
| D1 x 3| –| –| 043008
D2 x 5| –| –| 042926
3 Contact tube| MIG 15| MIG 25| MIG 36| TT120 / PT120
---|---|---|---|---
Ø 0.6| x 10| 041905| –| –| 041905
Ø 0.8| x 10| 041912| —| –| 041912
Ø 1.0| x 10| 041929| 041066| 419803| 041929
Ø 1.2| x 10| 041974| 041073| 419810| 041974
4 Nozzle| MIG 15| MIG 25| MIG 36| TT120 / PT120
---|---|---|---|---
150 A| 041875| –| –| 041875
250 A| –| 041882| –| –
350 A| –| –| 041783| –
TROUBLESHOOTING, CAUSES, SOLUTIONS
| SYMPTOMS | POSSIBLE CAUSES | SOLUTIONS |
|---|
Torch overheating
| The contact tube and its support are not tight enough.| Check and tighten
the contact tube and its support.
Excessive welding current.| Adjust the current on the machine.
Inoperative trigger
| The wire control is cutted or damaged.| Repair the wire
The euro connector of the torch is not connected correctly to the machine.|
Check the connection of the torch.
Wire welded in contact tube| Incorrect settings Contact tube used.| Check or
correct the setting. Change the contact tube.
Irregular wire feed
| Roller pressure is too low or too high| Change roller pressure (on the feed
motor)
The feed sheathing is clogged.| Clean both ends
Contact tip incompatible with the wire diameter.| Change the contact tip.
The wire feeder roller is worn-out or incorrectly fitted.| Change the wire
feeder roller.
Wire feed not working correctly.| Check/repair the reel
Arc between the nozzle and the part to weld| Short circuit between the contact
tip and the nozzle due to spatter.| Clean the nozzle and spray anti-spatter
agent inside.
Damaged isolator contact tip.| Change the nozzle.
Unstable arc| Worn-out contact tip or inadequate contact tip with the diameter
of the wire.| Check and change the contact tip.
Incorrect setting of the welding machine.| Correct the setting of the welding
machine.
Internal sheath wire deteriorated.| Change the wire liner in the 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.
SYMBOLS ICONOS
****| 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).
**
| Equip- ment in conformity with Moroccan standards. The declaration Cم
(CMIM) of conformity is available on our website (see cover page). **
| This product should be recycled appropriately **
|
SAS GYS
1, rue de la Croix des Landes CS 54159
53941 SAINT-BERTHEVIN Cedex France