GYSMI E163 Multi Process Welder Machine User Manual

GYSMI E163

MMA (SMAW) and TIG (GTAW) welding machine

75514_V6_05/01/2022

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Translation of the original instructions

GYSMI E163

MADE IN FRANCE

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).

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:

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 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 lead to suffocation 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 wary of temperature changes or exposure to 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 flames.
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.

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

This equipment complies with IEC 61000-3-11 if the power supply network’s impedance at the electircal installation’s connection point is inferior to the network’s maximum admissible impendance Zmax = 0.383 Ohms.

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.

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

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.
Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item.

EQUIPMENT INSTALLATION

• Put the machine on the floor (maximum incline of 10°.)
• Ensure the work area has sufficient ventillation 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 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 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 set up, the operator must ensure that the machine is disconnected from the mains. Connecting generators in series or in parallel is forbidden. It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings.

PRODUCT DESCRIPTION

The GYSMI E163 is an Inverter technology based welding machine, portable, single phase, fan cooled, designed for coated electrode welding (MMA) and tungsten electrode arc welding (TIG Lift) in direct current (DC). In MMA mode, this machine can weld all types of electrodes: rutile, stainless steel, cast iron and basic. In TIG mode, this machine can weld most metals except aluminium and its alloys. They are protected to work on generators (230 V +- 15%).

POWER SUPPLY – STARTING UP

• This machine is fitted with a 16 A socket type CEE7/7 which must only be used on a single-phase 230 V (50 – 60 Hz) mains 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 required by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings.

• The device is switched on by pressing the « » button.

• The device turns into protection mode if the mains voltage is over 265 V (to indicate this default, the screen displays )
  Normal operation resumes once the power supply is back within the range.

CONNECTION TO A GENERATOR

The machine can work with generators as long as the auxiliary power matches these requirements:
– The voltage must be AC, set as per specifications, and with a 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 the machine.

COATED ELECTRODE WELDING (MMA)

CONNECTIONS AND RECOMMENDATIONS

• Connect the cables, electrode holder and earth clamp to the connectors,
• Follow the welding polarities and power recommendations indicated on the electrodes boxes,
• Remove the electrode from the electrode holder when the machine is not in use.
• The machine has 3 features exclusive to Inverters:
  – The Hot Start creates an overcurrent at the beginning of the welding.
  – The Arc Force creates an overcurrent which prevents the electrode from sticking to the weld pool.
  – The Anti-Sticking technology makes it easier to unstick the electrode from the metal.

MMA WELDING PROCESSES

• MMA STANDARD
  The MMA STANDARD mode is recommended for most applications. It can weld any type of electrode: rutile, basic, cellulosic… and on any materials: steel, stainless steel, cast iron.

Activating the MMA mode and setting the intensity:

• Select the MMA mode (2) using the switch (5).
• MMA blinks for 1 second every 5 seconds (display (1)).
• Set the desired intensity using the keys (4).
• The machine is ready to operate.

To set the Hot Start, follow these steps :
Recommendations:
– Low Hot start, for thin sheets
– High Hot start for difficult-to-weld metals (dirty or oxydised)

When the machine is in MMA Standard mode:

• Press shortly the switch (5).
• «HS» (Hot Start) blinks and a number is displayed. (display (1)).
• Set the desired percentage using the keys (4).
• The machine is ready to operate.
• MMA PULSE
  The MMA Pulsed mode is recommended for vertical-up welding (PF) The pulse mode keeps the weld pool cold and eases the transfer of matter. Without the pulse mode, vertical-up welding requires a difficult «Christmas tree» triangular movement. With the MMA Pulsed mode, this movement is no longer required and a simple straight up movement is enough (depending on the thickness of the workpiece). If you wish to widen your weld pool, a simple lateral movement is enough (similar to normal welding).
  In this case the pulse current frequency can be adjusted on the display. This process allows greater control during vertical-up welding.

Activating the MMA Pulsed mode and setting the intensity:

When the machine is in MMA Standard mode:

• Press the switch (5) for 3 seconds.
• «PLS» (Pulsed) blinks and a number is displayed (display (1)).
• Set the desired intensity using the keys (4).
• The machine is ready to operate.

To set the Hot Start, follow these steps :

Recommendations:
– Low Hot start, for thin sheets
– High Hot start for difficult-to-weld metals (dirty or oxydised)

When the machine is in MMA Pulsed mode:

• Press shortly the switch (5) to set the HOT START.
• «HS» (HOT START) blinks and a number is displayed (display (1)).
• Set the desired percentage using the keys (4).
• Validate by pressing the switch (5).

To set the frequency, follow these steps:

When the machine is in MMA Pulsed mode with HOT START feature:

• Press shortly the switch (5) to set the frequency.
• «FrE» (FREQUENCY) is displayed and then a number is displayed. (display (1)).
• Set the desired frequency (Hz) using the keys (4).
• The machine is ready to operate.

TUNGSTEN ELECTRODE WELDING WITH INERT GAS (TIG MODE)

CONNECTIONS AND RECOMMENDATIONS

TIG DC requires gas protection (Argon).

To do TIG welding, follow these steps :

1. Connect the earth clamp to the positive connector (+).

2. Connect a valve torch to the negative connector (-­). (ref. 044425)

3. Connect the torch gas hose to the gas bottle regulator
   It may be necessary to cut it before the nut if it is not suitable for the regulator.

4. Activating the TIG mode and setting the intensity (see paragraph: TIG LIFT).

5. Set the gas flow on the gas bottle regulator, then open the torch valve.

6. To start the arc : make contact between the electrode and the workpiece.

7. At the end of the weld: lift the torch quickly (up-down) to activate the automated downslope (see paragraph below). This movement must be done at a height between 5 and 10 mm. Then close the torch valve to stop the gas after the electrode has cooled down.

• TIG LIFT
  Activating the TIG Lift mode and setting the intensity:

When the machine is in MMA Pulsed mode:

• Press the switch (5) for 3 seconds.
• «tIG» (TIG) blinks and a number is displayed (display (1)).
• Set the desired intensity using the keys (4).
• The machine is ready to operate.

DOWNSLOPE feature: this is the time during which, after the downslope, the current is going down until the arc stops completely. This feature prevents craters and cracks at the end of the weld.
Downslope activation (progressive arc reduction) :

When the machine is in TIG LIFT mode:

• Press shortly the switch (5) to set the duration of the progressive arc reduction.
• «dSt» (DOWNSLOPE) blinks and a number is displayed (display (1)).
• Set from 1 to 10 seconds, with the possibility to desactivate it (OFF).
• Validate by pressing the switch (5).
• The machine is ready to operate.

Recommended combinations / electrode grinding

| Current
( A)| Ø Electrode (mm)
= Ø wire
(filler metal)| Ø Nozzle
( mm)| Flow
( Argon l/mn)
---|---|---|---|---
0,5-5| 10-130| 1,6| 9,8|

6-7

4-6

| 130-160| 2,4| 11|

7-8

To optimise the welding process, it is recommended to grind the electrode prior to the welding, as described below:

L = 3 x d.       

TROUBLESHOOTING

MMA-TIG

| The machine does not deliver any current and the yellow thermal protection indicator is switched on (6).| The thermal protection has switched on.| Wait the end of the cooling cycle, about 2 min. The indicator (6) switches off.
MMA-TIG| The earth clamp, the electrode holder or the welding torch are not connected to the unit.|

Check the connections

The product is connected to the mains, you are feeling tingling when touching the case.

| The earth contact is faulty.| Check the plug and the earth of your installation.
The machine welds poorly.| Polarity error|

Check the recommended polarity (+/-) on the electrode box.

When the machine starts, the display shows .

| The power supply voltage is not suitable (230 V +/- 15%)| Check the power supply network or the generator
TIG| Unstable arc| Fault due to the tungsten electrode|

Use an electrode size more suitable to the thickness of your metal.

Use an tungsten electrode properly prepared.

Gas flow too high|

Reduce the gas flow

The tungsten electrode becomes oxidized and tainted at the end of the welding

| Welding area.| Protect the welding area against draught.
Gas problem, or gas flow stops too early|

Check and tighten every gas connection. Wait for the electrode to cool down before switching off the glas flow.

The electrode melts

| Polarity error|

Check that the earth is connected to the +

SPARE PARTS

 | DÉSIGNATION|

E163

---|---|---

1

| Connectors|

51469

2

| Display|

51914

3

| Electronic card|

97442C

4

| Power cord|

21487

5

| Fan|

51048

6

| Feets|

56167

CIRCUIT DIAGRAM

INTERFACE

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

 |

GYSMI E163

---|---
Primary|
Power supply voltage|

230 V +/- 15%

Mains frequency|

50 / 60 Hz

Number of phases|

1

Fuse|

16 A

Maximum effective supply current I1eff|

16 A

Maximum supply current I1max|

34.9 A

Mains cable section|

3 x 1.5 mm²

Maximum active power consumed|

5208 W

Idle consumption|

2.81 W

Efficiency at I2max|

84 %

Power factor at I2max (λ) |

0.63

EMC class|

A

Secondary|

MMA

|

TIG

No load voltage|

72 V

Type of welding current|

DC

Welding modes|

MMA, TIG (lift)

Minimum welding current|

10 A

Normal current output (I2)|

10 → 160 A

Conventional voltage output (U2)|

20.4 → 26.4 V

|

10.4 → 16.4 V

Duty cycle at 40°C (10 min)*
Standard EN60974-1.|

Imax

|

14%

|

19%

60%

|

85 A

|

100 A

100%

|

70 A

|

85 A

| |
Functioning temperature|

-10°C → +40°C

Storage temperature|

-20°C → +55°C

Protection level|

IP21

Minimum coil insulation class|

B

Dimensions (Lxlxh)|

19 x 25 x 13.4 cm

Weight|

3.7 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 welding power source describes an external drooping characteristic

SYMBOLS

| – Caution ! Read the user manual.
---|---
| – Single phase inverter, converter-rectifier
| – Electrode welding (MMA – Manual Metal Arc)
| – 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

U o

| – Rated no-load voltage

X(40°C)

| – Duty cycle according to standard EN 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. The certificate of compliance is available on our website.

EN60974-1
EN60974-10
Class A

| – The device complies with EN60974-1, EN60974-10, Class A standard relative to welding units
| – Separate collection required – Do not throw in a domestic dustbin
| – Conformity mark EAC (Eurasian Economic Commission)
| – CMIM : Moroccan Certification
| – Material complies with British requirements. The British Declaration of Conformity is available on our website (see cover page).
| – Thermal protection information
| – standby/On
| – The mains disconnection mean is the mains plug in combination with the house installation. Accessibility of the plug must be guaranteed by user.

(GYS)

| – Number of standardized electrodes weldable over 1 hour of continuous work, divided by the number of electrodes weldable in the same conditions without thermal shutdown.
| – Number of standardized electrodes weldable during 1 hour at 20°C, with a delay of 20 s. between each electrode.
| – Ventilated
| – The product’s manufacturer contributes to the recycling of its packaging by contributing to a global recycling system.

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

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