GYS SMARTMIG 110 No Gas Welder User Guide

GYS SMARTMIG 110 No Gas Welder User Guide

WARNING – SAFETY RULES

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 inadequate 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 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:

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 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.

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.

CEM CLASSIFIED MATERIAL

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. This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private lowvoltage 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 enrol 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.

RECOMMENDATIONS TO ASSESS THE WELDING 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:
a) the presence of other power cables (power supply cables, telephone cables, command cable, etc…)above, below and on the sides of the arc welding machine.
b) television transmitters and receivers ;
c) computers and other hardware;
d) critical safety equipment such as industrial machine protections;
e) the health and safety of the people in the area such as people with pacemakers or hearing aids;
f) calibration and measuring equipment
g)The isolation of the equipment from other machinery. The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This may require extra precautions;
h) make sure of the exact hour when the welding and/or other operations will take place. The surface of the area to be considered around the device depends on the the building’s structure and other activities that take place there. The area taken in consideration can be larger than the limits determined by the companies.

Welding area assessment
Besides the welding area, the assessment of the arc welding systems installation itself can be used to identify and resolve cases of disturbances. The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION

• a. National power grid: The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the filtering of the power suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to ensure good electrical contact between the conduct and the casing of the welding current source.

• b. Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine
  maintenance check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on.. The arc welding equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.

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

• d. Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It is necessary to insulate the operator from such metal objects.

• e. Earthing of the welded part : When the part is not earthed – due to electrical safety reasons or because of its size and its location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national regulations.

• f. Protection and plating : The selective protection and plating of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

⚠ The machine is fitted with handle(s) 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. 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.

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

• All welding connections must be firmly secured, check regularly !
• Check that the metal piece fixation is strong and without any electrical problems !
• Attach or hang all the electrically conductive elements, such as the trolley and slinging equipment, in order to insulate them
• Do not place any electrical equipment, such as drills or grinders, on top of the welding machine without insulating them !
• Always place welding torches or electrodes holders on an insulated surface when they’re not in use !

EQUIPMENT INSTALLATION

• The torch must be fully uncoiled to prevent overheating.
• Switch off the generator before each maintenance and before replacing or control wearing parts.
• Regularly check the condition of the torch. If damaged, the torch must be replaced.
• Put the machine on the floor (maximum incline of 10°).
• Ensure the work area has sufficient ventilation 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 power cables, extensions and welding cables must be fully uncoiled to prevent overheating.
⚠ The manufacturer does not incur any responsibility 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

DESCRIPTION

Thank you for choosing this machine. To get the best from your machine, please read the following carefully : The SMARTMIG 110 is a traditional machine for semi-automatic welding of flux cored wire only (AC current). Adjustment and Setting of this machine is easy with its SMART feature.

ELECTRICITY SUPPLY

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

DEVICE PRESENTATION (FIG-I)

1. Wire speed regulator
2. Control panel and table for SMART feature
3. Power Switch Off/On
4. Voltage selection
5. Power cable
6. Fixed torch
7. Fixed earth cable
8. Drive Reel
9. Wire Reel Support
10. Handle

SEMI-AUTOMATIC WELDING FOR STEEL (FIG-II)

This machine can only weld with no gas wire of Ø0.9 (no gas flux cored wire) Using no gas wire does not require a gas supply This machine is supplied to work with a Ø0.9 no gas wire. The contact tip, the rollers, the torch liner are made for this use. The product is equipped with a two Ø0.9 grooves roller. One is U shaped (recommended for no gas wire) and the the other is V shaped.
The SMARTMIG 110 is recommended for welding steel 1 to 2mm thick. For thicker sheets, up to 4mm, the assembly will require several passes. This welding process requires a slow speed in order to obtain a good quality welding bead. Warning : The current circulates in the torch and can create a welding arc without pressing on the trigger. Watch a demonstration video of the SMARTMIG 110 on YouTube. https://www.youtube.com/watch?v=lvqBXjqbAUk

PROCESS OF REEL AND TORCH ASSEMBLY (FIG-III)

Remove the Nozzle (fig III-E) from the torch by turning clockwise and then remove the contact tip, leaving the support and the spring on the torch (fig III-D).

• Open the door of the machine FIG III-A : Position the reel on to the support.
• Adjust the reel break (1) to avoid reel movement tangling the wire when welding stops. Be careful not to tighten too much – the reel must rotate without straining the motor.
• Tighten the plastic screw (2). FIG III-B : Installing the drive roller. FIG III-C : To select the adjustment of the drive rollers, proceed as follows :
• Loosen the drive roller knob as far as possible.
• Insert the wire until it exits the other side by about 2cm, tighten the knob again slightly.
• Start the motor by pressing the trigger of the torch.
• Tighten the knob (fig III-C) whilst pressing the trigger until the wire starts to move. Nb : When welding with Aluminium, use the minimum possible pressure to avoid crushing the wire
• Leave approximately 5cm of wire out of the end of the torch, then attach the contact tip suitable for the wire used, and then the nozzle (fig III-E). The SMARTMIG 110 can accommodate 100mm diameter wire reels.

DIRECTIONS FOR USE (FIG IV)

The SMARTMIG feature allows you to adjust the voltage and the wire speed.

• The voltage (button A/ B)
• Wire speed – adjust the regulator (1) to the colour zone indicated. Examples : To weld 1.0mm thick steel :
• Move button (2) to the « A » position
• Move the regulator (1) to the zone of lightest colour and adjust « by sound » if required

ADVICE AND THERMAL PROTECTION

– Respect the normal rules of welding
– Leave the machine plugged in after welding to allow it to cool
– Thermal Protection : The LED will illuminate. Cooling will take between 10 and 15 minutes depending on the ambient temperature.
– The excessive bending of the cable will disrupt the wire feed.
– The torch cable must be maintained in a straight position throughout inner liner loading to avoid permanent damage. – Thermal protection: the indicator lights up and the cooling time is 5 to 10 minutes depending on the ambient temperature.

Splashes :
– During welding, the spatters can easily damage the torch and welding equipment. To avoid constraints to the cable, the welding arc’s stability. Any spatter on the nozzle or difuser should be cleaned as soon as possible.
– The spatters accumulated in the nozzle that are not cleaned in due course will cause a short-circuit which could damage the torch elements.
– The use of anti-spatter agenst to reduce the spatters is recommended. In order to avoid to deteriorate the torch, do not use a cutting tool to clean th splashes.
– The torch mustn’t be used for heating and cutting.
– The torch cable mustn’t be used for pulling heavy objects (such as the welding station).
– The torch must be clean and tidy when the welding operation has ended.
– If the torch is not used for more than one week, the welding wire must be removed to avoid the increase of friction inside the intern sheath wire (by wire oxidation).
– Additonal external protections are necessary when the torch is used in the following cases:
a. High risk of electric shock ;
b. Combustible environment ;
c. Work position at height ;
d. Noisy environment ;
e. Environment with airstream ;
f. Closed tanks.

TECHNICAL CHARACTERISTICS OF THE TORCH

DUTY CYCLE & WELDING ENVIRONMENT DURING USE

• The welding unit describes an output characteristic of “constant current” type. The duty cycles following the standard EN60974-1 (at 40°C on a 10mn cycle) are indicated in the table below :

During intensive use (> duty cycle) the thermal protection can activate, if this event the arc switches off and the thermal protection indicator switches on. The welding machine has a constant voltage output. Note: The machines’ duty cycle has been tested at room temperature (40°C) and has been determined by simulation;

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 lay a hand to swivel or moving components or parts to the drive!
• Ensure that the housing covers or protective covers remain closed during operation!

TROUBLESHOOTING

SPARE PARTS

CIRCUIT DIAGRAM

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

ACCESSORIES

GYS SAS
1, rue de la Croix des Landes
CS54159
53941 SAINT-BERTHEVIN Cedex
France

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