GYSMI E160 - Welding machine GYS - Free user manual and instructions

USER MANUAL GYSMI E160 GYS

INSTALLATION – FONCTIONNEMENT PRODUIT

GENERAL INSTRUCTIONS Read and understand the following safety recommendations before using or servicing the unit. Any change or servicing that is not specied in the instruction manual must not be undertaken. The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual . In the event of problems or uncertainty, please consult a qualied person to handle the inspection 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 cases of inedaquate or unsafe use, the manufacturer cannot be held liable. 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 -25 and +55°C (-13 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). Up to 2000 meters above sea level (6500 feet).

INDIVIDUAL PROTECTIONS AND OTHERS

Welding exposes the user to dangerous heat, arc rays, electromagnetic elds, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device. In order to protect you from burns and radiation, wear clothing with long sleeves. These clothes must be insulated, dry, reproof and in good condition, and cover the whole body. Wear protective gloves which guarantee electrical and thermal insulation. It may be necessary to install reproof welding curtains to protect others against arc rays, weld spatter and sparks. Inform the people around the working area to never look at the arc ray or the molten metal, and to wear protective clothes. It is necessary to protect yourself with a welding hood (rated NR.10 or higher) and to protect your eyes during cleaning operations. Do not operate whilst wearing contact lenses. Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit. Ensure ear protection is worn by anyone in the welding area . Keep hands, hair, clothes etc... away from moving parts (e.g. fan) Never remove the safety cover of the wire feeder 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 precau- tions. The pieces that have just been welded are hot and may cause burns when touched. During maintenance work on the torch or electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. 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 insufcient 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. In addition, the welding of certain materials containing lead, cadmium, zinc, mercury or beryllium may be particularly noxious. Do not weld in areas where grease or paint are stored.10 GYSMI E160

Protect the entire welding area. Compressed gas containers and other inammable material must be moved to a minimum safe distance of 11 meters. A re extinguisher must be readily available at all times. Be careful of spatter and sparks, even through cracks. They can be the source of a re or an explosion. Keep people, ammable 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 inammable or explosive materials (oil, petrol, gas...). Grinding operations should not be directed towards the device itself or any ammable 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 xed support or trolley. 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. 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 ame. 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 accidents, or death . Never touch live parts inside or outside of the device when it is powered on (Torches, clamps, cables, electrodes) as they are connected to the welding circuit. Before opening the device, it is imperative to disconnect it from the electrical supply 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. Be sure to change the cables and torches if they are damaged, to be performed by qualied and authorized personnel. Ces accessoires doivent correspondre à la machine (taille, puissance...) 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 difculties 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 as specied in the following table : Reference E160 Zmax admissible 0.34 Ohms11 GYSMI E160

ELECTROMAGNETIC INTERFERENCES The electric currents owing through a conductor cause electrical and magnetic elds (EMF). All wel- ders should use the following guidelines to minimize exposure to the welding circuit’s electromagnetic elds: The EMF elds 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 elds (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 wrap 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 elds 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 be 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 (see note). In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire piece by tting input lters. 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. Other cables, control cables, telephone cables: above, below and besides the device; b. Radio/TV transmitters and receptors, c. Computers and other control equipments, d. Critical safety equipments such as industrial machines’ emergency controls. e. The health and safety of the people who are close to the machine, e.g. people who wear a pacemaker, a hearing aid, etc ... f. Equipment used to calibrate and measure, g. The immunity of the other equipments installed in the welding area or near the welding machine. The user will have to make sure that the devices in the same room are compatible with each other. This may require additional precautions. h. The time of day during which the unit must operate; 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 specied in Article 10 of CISPR 11: 2009. In situ measurements can also be used to conrm 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 ltering of the power supply 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 machine to ensure good electrical contact between the metal conduct and the casing of the welding machine.12 GYSMI E160

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 modied 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 groud. 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 because for 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 equipments. 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 specic situations.

TRANSPORT AND TRANSIT OF THE MACHINE

The machine is equipped with a handle to facilitate transport. Be careful not to underestimate the machine’s weight. Do not use the cables or torch to lift or move the machine. The welding equipment must be moved in an upright position. . Transportation standards are different. INSTALLATION Rules to follow:

• Put the machine on the oor (maximum incline of 10°.)

• Ensure the work area has sufcient ventillation for welding, and that there is easy access to the control panel.

• The machine must be placed in a sheltered area away from rain or direct sunlight.

• The machine must not be used in an area with metallic dust.

• The machine benets from an IP21 protection index, which means: - Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and, - Protection against vertically falling water droplets The manufacturer does not incur any responsibility regarding damage 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 qualied person.

• Ensure the machine is unplugged, and that the inside fan has stopped before carrying out mainte- nance work. Caution - High Voltage and dangerous Current levels can be present 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 qualied 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 qualied person to prevent danger.

• Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.

Only qualied 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. Connecting generators in a series or a parallel circuit is forbidden .HARDWARE DESCRIPTIONThese welding machines are Inverter technology based welding machines, portable, single phase, fan cooled, designed for electrode welding (MMA) in direct current (DC). In MMA mode, these machines can weld all types of electrodes : rutile, basic/low hydrogen, stainless and cast iron. In TIG mode, these machines can weld most metals except alumi- nium and its alloys. They’re protected to work with generators (Alim 230 V +- 15% ou 400V +- 15% depending on the reference).POWER SUPPLY – STARTING UP• The welders are tted with a 230V 16A socket type CEE7/7 which must be connected to a 230 V (50 - 60 Hz) power supply WITH earth. 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. Under intensive use, we recommend a 20A power supply for single phase models from 160A onward. The user has to make sure that the plug can be reached.• The device is switched on by pressing the « » button.• The device turns into protection mode if the power supply tension is over 265V. To indicate this default, the screen displays Normal operations resume once the power supply is back to its nominal range.CONNECTION TO A GENERATORThe machine can work with generators as long as the auxiliary power matches these requirements :- The voltage must be AC, always set as specied, and the peak voltage below 400V,- The frequency must be between 50 and 60 Hz.It is imperative to check these requirements as several generators generate high voltage peaks that can damage these machines.ELECTRODE WELDING (MMA)CONNECTIONS AND RECOMMENDATIONS• Connect the cables, electrode holder and earth clamp in the connectors,• Respect the welding polarities and intensities indicated on the electrodes boxes,• Remove the electrode from the electrode holder when the machine is not in use.• Your machine has 3 features exclusive to Inverters : - The Hot Start delivers overcurrent at the beginning of the welding. - The Arc Force delivers overcurrent to prevent sticking when the electrode enters the welding pool. - The Anti-Sticking technology allows you to easily unstick your electrode.• These machines have a «dropping» current output specication.• The duty cycle following the norm EN60974-1 is indicated in the table here below X @ 40°C (T cycle = 10 min) MMA TIG I max 19% @ 160 A 24% @ 160 A60% 90 A 105 A100% 75 A 95 A While under intensive use (> to duty cycle) the thermal protection can activate, in that case, the arc swictes off and the thermal protection indicator switches on. The tests have been performed according to the standard at a temperature of 40 °C.14 GYSMI E160

Activating the MMA mode and setting the intensity : - Select the MMA mode (2) using the switch (5) - Set the desired dintensity (display(1)) using the (4) keys. E160 HOT START 0 > 60% ARC FORCE - Recommendations : Low Hot start, for thin sheets– High Hot start for difcult metals (dirty or oxydised) To set the Hot Start, follow these steps : Press the switch (5) for 3 seconds. «HS» (Hot Start) blinks and a number is displayed. Set the desired percentage (display (1)) using the (4) keys. Validate by pressing the switch (5). TIG WELDING WITH INERT GAS (TIG MODE) TIG welding requires gas shield protection of pure gas (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 (–).

3. Connect the torch’s gas hose to the gas bottle’s regulator

It may be necessary to cut it before the bolt if the latter does not match the regulator.

4. Select the TIG mode (3) with the switch (5).

5. Set the desired intensity (display(1)) using the (4) keys, according to the thickness

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

8. Once done wit the workpiece : quickly lift the torch, stop the gas ow after the

electrode has cooled down. Recommended combinations / electrode grinding Current (A) Ø Electrode (mm) = Ø wire (ller metal) Ø Shroud (mm) Flow (Argon l/mn) 0,5-5 10-130 1,6 9,8 6-7 4-7 130-190 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 = 2,5 x d.

TROUBLESHOOTING Symptoms Causes Remedies MMA-TIG The machine does not deliver any current and the yellow thermal protection indicator is switched on (6). The thermal protection has swit- ched on. Wait the end of the cooling cycle, about 2 min. The indicator (6) switches off. The indicator is on but the product does not deliver any current. The earth clamp or the electrode holder is not conencted 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 polarity (+/-) recom- mended on the electrode box. When the machine starts, the display shows

The power supply voltage is not suitable (100V-240 V AC) Check the power supply network or the generator TIG Unstable arc Fault due to the tungsten electrode Use an electrode size more sui- table to the thickness of your metal. Use an tungsten electrode properly prepared. Gas ow too high Reduce the gas ow The tungsten becomes oxidized and dull at the end of the welding Welding area. Check and tighten every gas connection. Wait for the electrode to cool down before switching off the glas ow. Gas problem, or gas ow stops too early Check that the earth is connected to the + The electrode melts Polarity error Check that the earth is connected to the +16 GYSMI E160

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