GYS TIG 300 DC Langfield Welding Machine User Manual
- June 3, 2024
- GYS
Table of Contents
GYS TIG 300 DC Langfield Welding Machine User Manual
GENERAL INSTRUCTIONS
These instructions must be read and fully understood before using the equipment.\ Do not make any alterations or undertake any maintenance procedures that are not explicitly mentioned in this user manual. The manufacturer cannot be held responsible for any bodily injury or material damage resulting from use that does not comply with the instructions in this manual.\ In the event of a problem or query, please consult a qualified person to properly set up the machine.
PROTECTING YOURSELF AND OTHERS
Arc welding can be dangerous and cause serious injury or death. Welding exposes people to a dangerous heat source, light radiation from the arc, electromagnetic fields (please note that those with pacemakers must\ be aware of this) and the risk of electrocution, as well as loud noises and gas fumes. To properly protect yourself and others, please observe the following safety instructions:
Wear insulating, dry and flame-retardant clothing without cuffs. Make sure that this clothing is in good condition and that it covers the entire body to protect yourself from burns and radiation.
Wear electrically and thermally insulated gloves.
Take protective measures and / or a welding mask with a sufficient level of protection (this will change depending on the application). Protect your eyes during cleaning operations. Contact lenses are strictly prohibited. It is sometimes necessary to mark out welding zones using flame-retardant curtains to protect the welding area from arc rays, spatter and red-hot waste. Instruct persons in the welding area not to stare at arc rays or molten parts and to wear appropriate protective clothing.
Use a noise-reducing welding mask if the welding process reaches a noise level above the permissible limit (this applies to anyone in the welding area).
Parts that have just been welded are hot and can cause burns when handled. When carrying out maintenance on the torch or the electrode holder, ensure that it is sufficiently cold by waiting at least 10 minutes before undertaking any intervention. The cooling unit must be turned on when using a water-cooled torch to ensure that the liquid cannot cause burns. It is important to secure the work area before leaving it in order to protect people and property
WELDING FUMES AND GASES
The fumes, gases and dust emitted by welding are harmful to your health. Sufficient ventilation must be provided, an additional air supply may sometimes be necessary. An air-fed mask could be a solution in cases where there is insufficient ventilation. Check that the suction is effective by checking it against safety standards. Attention: Welding in confined spaces requires remote supervision for safety reasons. Furthermore, welding certain materials that contain lead, cadmium, zinc, mercury or even beryllium can be particularly harmful. Also, remember to degrease parts before welding them.
FIRE AND EXPLOSION RISKS
Fully protect the welding area; flammable materials must be kept at least 11 metres away. Firefighting equipment must be present near welding operations.
GAS CYLINDERS
The gas coming out of the
cylinders can cause suffocation if it becomes too concentrated in the welding
area (ventilate well). Transporting the welding machine must be done safely,
ensuring all the cylinders and the welding unit are switched off. The gas
cylinders and the machine must be stored upright and held in place by a
support to limit the risk of falling.
ELECTRICAL SAFETY
It is crucial that the electrical system used is properly earthed. Use the fuse size recommended on the rating table. Electric shocks can cause serious direct or indirect accidents and even death. Never touch live parts inside or outside the live current source (torches, clamps, cables or electrodes) because these are connected to the welding circuit. Before opening the welding machine, disconnect it from the power-supply network and wait a further two minutes so that all the capacitors are fully discharged. Do not touch the torch or the electrode holder and the earth clamp at the same time. If the cables or torches become damaged, make sure that they are changed by a qualified and authorised person. Measure the length of cable required according to its intended application. Always use dry, undamaged clothing to insulate yourself from the welding circuit. Wear insulating shoes, whatever the working environment.
THE EQUIPMENT’S EMC CLASSIFICATION
This Class A equipment is not intended for use on residential sites where the
electrical current is supplied by the public, lowvoltage mains network. There
may be difficulties in ensuring electromagnetic compatibility at these sites
due to conducted, as well as radiated, radio-frequency disturbances.
PROTIG 221:
This equipment complies with IEC 61000-3-11 and can be connected to a public,
low-voltage mains network, providing that the impedance at the common coupling
point on the aforementioned network is less than Zmax = 0.29 Ohms. It is the
installer or user’s responsibility to ensure that the network impedance
complies with relevant impedance restrictions by consulting the power
network’s distribution operator if necessary. This equipment complies with IEC
61000-3-12.
TIG 300:
This equipment does not comply with IEC 61000-3-12 and is intended to be
connected to a private, low-voltage power network or connected to the public
mains network, although only at medium and high voltage levels. If it is
connected to a public, lowvoltage power-supply network, it is the installer or
user’s responsibility to ensure that the equipment can be safely connected to
the power-supply network by consulting with the power-distribution network
operator if necessary
ELECTROMAGNETIC RADIATION
Electric currents passing through any conductor produce localised electric and
magnetic fields (EMF). Welding currents produce an
electromagnetic field around the welding circuit and welding equipment.
Electromagnetic fields (EMF) can interfere with some implanted medical
devices, such as pacemakers. Protective measures should be taken for those
people with implanted medical devices. For example, restricted access for
passers-by or an individual risk assessment for welders.
All welders should use the following procedures to minimise exposure to electromagnetic fields from the welding circuit:
- Position the welding cables together, securing them with a tie if possible.
- Position yourself (torso and head) as far as possible from the welding circuit.
- Never wrap welding cables around your body.
- Do not position your body between the welding cables.
- Keep the two welding cables on the same side of your body.
- Connect the return cable to the workpiece as close as possible to the area being welded.
- Do not work near the welding machine and certainly do not sit on it or lean against it.
- Do not weld when transporting the welding machine or wire feeder.
ASSESSING THE WELDING AREA AND EQUIPMENT
a. The public mains network: Arc-welding equipment should be connected to the
public mains network according to the manufacturer’s recommendations. If
interference occurs, it may be necessary to take additional preventive
measures such as filtering the public power-supply network. Consideration
should be given to shielding the power cable inside a metal conduit or similar
device for permanently instal weldingequipment. The shielding used must be
electrically continuous along its entire length. The shield should be
connected to the welding machine’s power source to ensure good electrical
contact between the conduit and the power source’s casing.
b. Maintaining arc-welding equipment: Arc-welding equipment should be
routinely maintained according to the manufacturer’s recommendations. All
access points, service doors and protective covers must be closed and properly
locked when the arc-welding equipment is in use. Arc-welding equipment should
not be modified in any way, except for modifications and adjustments stated
within the manufacturer’s instructions. In particular, the ignition system’s
spark gap and arc-stabilisation features must be calibrated and serviced in
accordance with the manufacturer’s recommendations.
c. Welding cables: Cables should be as short as possible and placed close to
each other. They should be close to, or directly on, the ground.
d. Equipotential bonding: Consideration should be given to bonding all metal
objects in the surrounding area. However, metal objects attached to the
workpiece increase the risk of electric shocks if the operator touches both
these metallic parts and the electrode at the same time. The operator must be
electrically insulated from any such metallic objects.
e. Earthing the workpiece: When the workpiece is not electrically earthed for
electrical safety reasons or due to its size and location (a ship’s hull or a
building’s structural metal framework), an earthed connection can, in some
cases but not always, reduce radiation. Care should be taken to avoid earthing
component parts which could increase the risk of injury to users or damage to
other electrical equipment. If necessary, the workpiece’s earth connection
should be made directly, however, in certain countries a direct connection is
not allowed. Therefore, the connection should be made with a suitable
capacitor chosen according to national regulations.
f. Protection and shielding: Selective protection, as well as the shielding of
other cables and equipment in the surrounding area, can limit interference
problems. For special applications, the entire welding area can be protected.
SETTING UP THE EQUIPMENT
- Place the welding machine on a floor with a maximum slope of 10°.
- Provide a large enough area to ventilate the welding machine and provide access to the controls.
- Do not use in environments with conductive metal dust.
- This welding unit must be protected from heavy rain and not exposed to direct sunlight.
- This equipment is rated as IP21, meaning that it is:
- protected against solid objects with a diameter more than 12.5 mm entering the machine
- protected against vertically falling water droplets Power-supply cables, extension leads and welding cables must be fully unwound to avoid overheating.
MAINTENANCE / ADVICE
- Maintenance should only be performed by a qualified person.
- Annual maintenance is recommended.
- Disconnect the power supply by unplugging the plug from the socket and wait two minutes before beginning any work on the equipment. Inside the machine, the voltages and currents are high and dangerous.
- Regularly remove the machine’s protective cover and dust with a compressed-air blower. Take this opportunity to have the electrical connections checked with an insulated tool by qualified personnel.
- Regularly check the condition of the power cable. If the power cable becomes damaged, it must be replaced by the manufacturer, their after sales service team or a similarly qualified person in order to avoid any danger.
- Leave the welding machine’s openings free for proper air circulation.
- Do not use this welding unit to thaw pipes, recharge batteries/accumulators or to start engines.
SET-UP – OPERATING THE EQUIPMENT
Only skilled staff, authorised by the manufacturer, may carry out the
machine’s set-up. During set-up, make sure that the machine’s power source is
disconnected from the power-supply network. Series and parallel power source
connections are prohibited. Please use the welding cables supplied with the
device in order to obtain the optimal product settings
EQUIPMENT DIAGRAM (FIG-1)
- Keypad and increment buttons
- Positive polarity terminal
- Negative polarity terminal
- Torch’s gas connection
- Trigger connector
- Remote control input
- On / Off switch
- Power cable
- Gas connection
START-UP POWER SUPPLY
- The TIG 300 DC is supplied with a three-phase, five-prong (3P+N+PE) 400 V/16 A EN 60309-1 plug and is powered by a 400 V (50-60 Hz), threephase electrical system with an earth connection. This equipment should only be used on a three-phase, four-wire power system with the neutral wire properly earthed. *
- The PROTIG 221 DC FV is delivered with a single-phase, three prong (P+N+PE) 230 V/16 A CEE17 plug and is equipped with ‘Flexible Voltage’ technology. It is powered by a 1110 – 240 V (50 – 60 Hz) earthed power supply system. The effective absorbed current (I1eff) is indicated on the welding machine, as well as the most suitable operating conditions. Check that the power supply and its protections (fuse and/or circuit breaker) are compatible with the electrical current required. In some countries, changing the plug might be necessary in order to reach the machine’s ideal operating conditions. The user must ensure that the machine’s outlets are accessible.
- The welding unit will go into protection mode if the supply voltage is more than 15% lower or higher than the specified voltage (a fault code will appear on the display screen).
- The TIG 300 DC is started up by turning the on/off switch (7) to position I. Conversely, to turn the machine off, turn the switch back to position O.
- The PROTIG 221 DC FV is switched on by pressing the ON/OFF button . Please note, never turn off the power when the welding machine is on charge.
CONNECTING TO THE POWER SOURCE
These welding machines can be used with a battery-based power source provided that the auxiliary power meets the following requirements:
- The voltage must be alternating, set as stipulated and with a peak voltage of less than 700 V for the TIG 300 DC and 400 V for the PROTIG 221 DC FV.
- The frequency must be between 50 – 60 Hz. It is imperative to check these conditions as many battery-based power sources produce high voltage spikes that can damage the welding unit.
COATED-ELECTRODE WELDING (MMA-WELDING MODE)
CONNECTIONS AND ADVICE
-
Connect the cables, electrode holder and earth clamp to their plug connections.
-
Respect the welding polarities and currents indicated on the electrodes’ packaging.
-
Remove the electrode from the electrode holder when the welding machine is not in use.
CHOOSING COATED ELECTRODES -
Rutile electrodes: very easy to use in any position with a direct current.
-
Basic electrodes: suitable for all welding positions with a direct current, ideal for safety work due to its increased mechanical properties
PULSED MMA WELDING
Pulsed MMA welding is suitable for vertical-up (PF) welding. The pulsed
feature allows the weld pool to be kept cool whilst also allowing the transfer
of material. Without pulsing, vertical-up welding requires a ‘Christmas tree’
movement, in other words a complicated triangular movement. Thanks to pulsed
MMA welding, this difficult technique is no longer necessary because,
depending on the thickness of the part, a straight upward movement may be
sufficient. If, however, the weld pool needs to be enlarged, this can be done
with a simple, lateral movement similar to that of flat-position welding.
Therefore, this process offers greater control of vertical welding operations.
- Place the torch in the correct welding position above the workpiece (maintaining a distance of about 2-3 mm between the electrode’s tip and the workpiece).
- Press the torch button (the arc is ignited without contact using high voltage and high-frequency starting pulses).
- The initial welding current will now begin to circulate. The welding process will continue according to the welding cycle.
STANDARD DC TIG WELDING
Standard DC TIG welding allows high-quality welding on most ferrous materials
such as steel and stainless steel, but also titanium, copper and its alloys,
etc. The various ways of managing both the current and gas allow users to
perfectly control the welding operation, from the first ignition to the final
cooling of your weld bead.
TRIGGER-CONTROL CONNECTOR
Documents / Resources
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TIG 300 DC Langfield Welding
Machine
[pdf] User Manual
TIG 300 DC, Langfield Welding Machine, Welding Machine, Langfield Welding, TIG
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