GYS 012448 ORBITIG 200A Welding Machine Instruction Manual

012448 ORBITIG 200A Welding Machine
Instruction Manual 08-13 / 44-52

**** 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 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 work piece 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.
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.
This equipment complies with the IEC 61000-3-12 standard.
ELECTROMAGNETIC INTERFERENCE
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.

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 equipment 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 shroud be given to bonding all metal objects in the surrounding area. However, metal objects connected to the work piece increase the risk of 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
** 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.
EQUIPMENT INSTALLATION**

• Put the machine on the floor (maximum incline of 10°).
• The IP protection rating depends on the integration in the enclosure of the welding system.
• The machine must be placed in a sheltered area away from rain or direct sunlight.

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

Only qualified personnel authorized by the manufacturer should perform the installation of the welding equipment.
During the installation, the operator must ensure that the machine is disconnected from the mains. Connecting generators in serial or in parallel is forbidden.
PRODUCT DESCRIPTION
This welding machine is an inverter welding unit designed for use on refractory electrodes (TIG) in direct current (DC).
Totally driven by a robot, the communication is made through a CAN BUS and a protocol CAN OPEN.
The welding machine follows and regulates the current instruction in real time. This mode is called « TRACKING ».
POWER SUPPLY – POWER UP
The Orbiting 200A is supplied without a plug and features the «Flexible voltage» technology and as such needs to be connected to an electrical earthed installation supplying power between 110V and 240V (50-60 Hz).
The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply used and its protection (fuse and/or circuit breaker) are compatible with the current required by the machine. The user has to make sure that the plug can be reached.
The device switches to protection mode if the power supply voltage is below or above the required voltage by 15% (the screen displays an error code).
USE ON EXTENSION LEADS
All extension leads must have appropriate size and thickness for the machine voltage.
Use an extension that complies with national safety regulations.

| Current input| Length and thickness of the extension lead
---|---|---
200A source| 230V| < 100m – 2.5 mm²
110V| < 45m – 2.5 mm²
< 100m – 4 mm²

TUNGSTEN ELECTRODE WELDING WITH INERT GAS (TIG MODE)

CONNECTIONS AND RECOMMENDATIONS
Connect the earth clamp to the positive connector (+).
Connect the torch earth cable to the negative plug (–).
Ensure that the torch is equipped and ready to weld, and that the consumables (Vise grip, ceramic gas nozzle, collet and collect body) are not damaged.
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 while keeping the machine cooler.

SELECT IGNITION MODE
The arc initiating and stabilizing device is designed for manual and mechanically guided operation.
HF TIG: High Frequency start without contact.
Warning: Increasing the length of the torch or earth return cables beyond the maximum length specified by the manufacturer will increase the risk of electric shock.
TIG LIFT: Contact start (for environments sensitive to HF disturbances).

RECOMMENDED COMBINATIONS

DC| | Current (A)| Ø Electrode (mm)| Ø Nozzle (mm)| Flow (Argon l/mn)
---|---|---|---|---|---
0.3 – 3 mm| May-75| 1| 6.5| 7-Jun
2.4 – 6 mm| 60 – 150| 1.6| 8| 7-Jun
4 – 8 mm| 100 – 200| 2| 9.5| 8-Jul
6.8 – 8.8 mm| 170 – 220| 2.4| 11| 9-Aug

ELECTRODE GRINDING
To optimize 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

TROUBLESHOOTING

defective (the fuses, the circuit breakers or the differential are defective).| Check the power supply network and replace, if necessary, the faulty protections.
The 200A source does not answer to the automaton.| The communication CAN OPEN between the automaton and the power supply does not happen.| Check the wired connection, the wiring direction and the pins allocation. 1- GND (0Vdc)
2 – CAN LOW
3 – CAN_HIGH
4 – GND (OVdc)
The 200A source does not answer to the automaton.| The communication CAN OPEN between the automaton and the power supply does not happen.| Bit [1;3] : Baud rate = 250 Kbit/s (100b)
Bit [4;8] : Object address = 10 (01010b)
The 200A source is power up but it no longer delivers power.| The thermal protection has switched on.| Wait for the end of the theatrical protection during 3 minutes max.
The 200A source is power up but the machine does not weld.| Fault with earth clamp/cable connection.| Check the connections of the cables and clamps.
The 200A source is power up, you are feeling tingling when touching the case.| No earth continuity.| Multi-meter on position « Ohmmeter » Unplugged source, control the earth continuity between the machine and the mains cable.
The measured resistance must be low (short-circuit)
If OK
Check our electrical installation by a professional.
The 200A source is power up but the machine does not weld well.| Polarity error (+/-).| Check the polarity (+/-).

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

TECHNICAL SPECIFICATIONS

Primary

Power supply voltage| 230 V +/- 15%| 110V +/- 15%
 Mains frequency| 50 / 60 Hz
Number of phases| 1
Fuse| 16 A| 32 A
 Maximum effective supply current I1ef| (13 A max)| (20 A max)
Maximum supply current I1max| 20 A| 38.5 A
Mains cable section| 3 x 2.5 mm²
Maximum active power consumed| 4332 W
Idle consumption| 9.00 W
Efficiency at I2ma| 83%
Power factor at I2max (λ)| 0.991
EMC class| A
Secondary| TIG
No load voltage| 76 V
Manual striking system’s maximum voltage (EN60974-3)| 9 kV
Type of welding current| DC
Welding modes| TIG
Minimum welding current| 5:00 AM
Normal current output (I2)| 5 A – 220 A| 5 A – 180 A
 Conventional voltage output (U2)| 10.2 V – 18.8 V| 10.2 V – 17.2 V
Duty cycle at 40°C (10 min)* Standard EN60974-1.
Imax
60%
100%| 35%| 40%
165 A| 125 A
140 A| 110 A
Functioning temperature| -10°C → +40°C
Storage temperature| -20°C → +55°C
Minimum coil insulation class| B
Dimensions (L x l x h)| 39 x 16 x 28 cm
Weight| 9 kg

• The duty cycles are measured according to standard IEC 60974-1 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 switches off and the indicator switches on.
  Keep the machine’s power supply on to enable cooling until thermal protection cancellation.
  The welding power source describes an external drooping characteristic.

SPARE PARTS

CIRCUIT DIAGRAM

SYMBOLS

**| Caution ! Read the user manual.
| Undulating current technology based source delivering directcurent.
| TIG – welding (Tungsten Inert Gas)
| Adapted for welding in environments with increased risk of electrical shock.
However, the welding machine should not be placed in such places.
| Welding direct current
Uo| Rated no-load voltage
X(40°C)| Duty cycle according to standard IEC 60974-1 (10
minutes – 40°C).
I2| I2 : corresponding conventional welding current
A| Amps
U2| U2 : conventional voltages in corresponding load
V| Volt
Hz| Hertz
| Single phase power supply 50 or 60Hz
U1| rated supply voltage
I1max| Rated maximum supply current (effective value)
I1eff| Maximum effective supply current
**| The device complies with European Directive.
| – Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website (see cover page).
IEC 60974-1
IEC 60974-10
Class A| The device complies with IEC 60974-1, IEC 60974-10, Class A standard relative to welding units
IEC60974-3| The device complies with IEC 60974-3 standard relative to welding units
| This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin !
| – Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
| This product should be recycled appropriately
| Conformity mark EAC (Eurasian Economic Commission)
| Thermal protection information

CS 54159
53941 SAINT-BERTHEVIN Cedex
France
www.gys.fr

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