GYS WS-4R Welding Wire Feeder Instruction Manual

GYS WS-4R Welding Wire Feeder

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. Read the welding machine’s instruction manual before using the wire feeder.

ENVIRONMENT

This equipment must only be used for welding and gouging 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).

INDIVIDUAL PROTECTIONS AND 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. Protect yourself and others. Ensure the following safety precautions are taken:

• In order to protect you from burns and radiations, wear clothing without 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.
• Wear welding protective gear for the whole body: hood, gloves, jacket, trousers… (variable, depending on the application). Protect your eyes during cleaning procedures. 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 people who are around the working area to never look at the arc ray or the molten metal, and to wear protective clothes.
• Wear ear protection if the work exceeds the authorised noise limit. The same applies to anyone 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 due to non-compliance with the safety precautions.
• Parts that have just been welded will be hot and may cause burns when touched. During the maintenance of the torch, make sure that the torch has sufficiently cooled down and wait at least 10 minutes before any operation. 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.Caution, welding in small work areas 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. 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 EXPLOSIONS 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 create a hazard 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 careful with gas bottles placed in areas of high temperature, or in 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 flame. 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. These devices are not compliant with the CEI 61000-3-12 standard. 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.

People wearing pacemakers are advised to consult their doctor before using this device. Exposure to electromagnetic fields while welding may have other health effects which are not yet known.

TRANSPORT AND TRANSIT OF THE WIRE FEEDER

The wire feeder is equipped with handles for easy transportation. Be careful not to underestimate the machine’s weight. The handle cannot be used to hang the machine from other equipment. 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. The removal of the wire reel from the machine is recommended before undertaking any lifting operation. The machine is fitted with non-insulated lifting eye bolts, they are designed for wire feeder maintenance and not for wire feeder lifting during welding operations. If they are used during welding, the eye bolts must be insulated from the building’s earth.

• Stray welding currents/voltages may destroy earth conductors, damage electrical equipment or cause components to warm up which may cause a fire.

INSTALLATION

• The wire feeder must be switched on with all access panels closed.
• Put the wire feeder on a floor with a maximum incline of 10°.
• The machine must be placed in a sheltered area away from rain or direct sunlight.
• The equipment’s 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 .

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualified person. Annual maintenance is recommended.
• Ensure the wire feeder is disconnected from the welding machine, and wait for two minutes before carrying out maintenance work.
• 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 connection cable between the wire feeder and the machine. If damaged, the connection cable cable must be replaced.
• Warning ! If the welding machine is transported/handled by another solution than the one recommended by the manufacturer; the wire feeder casing must be insulated from the transporting/handling solution. Rules to follow :
• The wire feeder must be switched on with all access panels closed.

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. Risk of injury due to moving parts! The wire feeders contain moving parts that may catch hand, hair, clothes or tools which can lead to injuries! Take extra care.

• Do not place your hand on mobile/pivoting/wire feeding parts of the machine!
• Make sure that all panels remain closed when in use !

DESCRIPTION

The WS4L is a wire feeder suitable for a water cooled torch and designed for use with MIG WS 500. THE WS4R wire feeder is suitable for MIG 400 GR / 500 GR. They work with 200mm reels and 300mm reels. The unit comes with a swivel support to be mounted on the generator.

DEVICE PRESENTATION

1. Reel support (200 or 300mm)
2. Wire feeder
3. Handle
4. Wire speed potentiometer
5. Euro torch connector
6. Upper section of the swivel support
7. Gas connector of the connecting harness
8. Control cable connector
9. Power cable connector
10. Eye rings (Don’t lift by the handles (3))
11. Setting connection base
12. Hose clamp

ASSEMBLY & CONNECTION

Installing the swivel support on the generator
Use the 3 screws (included with the generator) supplied to fix the bottom part of the swivel support onto the generator The upper part of the support is already fixed under the wire feeder.

Connection of interconnection cable:

WIRE REEL INSTALLATION

• Open the door of the machine.
• Position the reel on to the support (1) taking care of the pin.
• Adjust the break (2), to avoid reel movement tangling the wire when the welding stops.
• Tighten the plastic screw firmly (3).
• For the first use :
  • Release the fixing screw of the wire guide (4)
  • Put the rollers in place (5). The visible diameter on the roller should be equal to the wire diameter used.
  • Place the wire guide (6) as close as possible to the roller but without touching it, then tighten the fixing screw.
• To select the adjustment of the drive rollers: loosen the drive roller knob as far as possible (7), insert the wire until it exits the other side by about 2cm. Start the motor by pressing the torch trigger, tighten the knob whilst pressing the trigger. Bend the wire where it comes out of the nozzle and hold it in place to stop its progress – the setting is correct when the guide roller slides over the wire, even when it is blocked at the end of the torch.

USE

WS-4R / WS-4L allows the user welding using the parameters set on the MIG generator. To adjust the settings to the type and diameter of wire used, please refer to the 400 GR, 500 GR and 500 WS user manual. It is possible to change the wire speed, in synergic or manual mode using the potentiometer on the front panel

TROUBLESHOOTING

There are sparks between the electrode and the filler wire.

| ****

Metal fillings have accumulated on the drive roller.

| ****

Clean the drive roller and the reels with an air- gun.

Failure to start welding| No gas| Gas valve closed or bottle empty
The gas is continuous| Solenoid valve blocked or dirty| Remove, check and clean the solenoid valve.
The torch overheats| The torch is not suitable for the wire feeder duty

cycle

| Change the torch for a one which is suitable for

the machine

The welding wire speed is not constant.

| The wire skids in the rollers| Check the roller pressure or replace it.
Frein de bobine trop serré| Desserrer en agissant sur la vis de frein de la bobine de fil
Covering wire guide in the torch| Vérifier la torche
incompatible.| Vérifier la pression des galets
Reel brake too tight| Adjust the reel brake
The torch is bent which might inhibit the wire output| Check the torch
The rollers slide over the wire| Check and tighten the roller screws
Sheath crushed| Change it
Roller grooves do not match the diameter of wire used| Change for size suitable for wire used.
The wire speed potentiometer is not working| The button on the separate wire feeder is inactive but active on the generator| Refer to the user manual of generator to make

the change

MACHINE MAINTENANCE DETAILS

Machine maintenance or alteration should only be carried out by a qualified person. Failure to comply may void the warranty. Any maintenance or action performed on the machine should be done with power supply off (machine disconnected from the power supply network), wait at least 5 minutes before any operation, block access to the installation if necessary.

Daily :

• Check the torch, the rollers and the tightening, the connections.

Twice a year :

• Clean the inside of the machine with a compressed air cleaner.
• Make sure not to put any conductor inside the machine, such as the torch.
• Check the wear and coupling of the connections, retighten if necessary.
• Check the following parts: electrical, gas, wire reel support, wire-feeding motor and bottle support.

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

GYS 1, rue de la Croix des Landes CS 54159 53941 SAINT-BERTHEVIN Cedex France

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