Neopulse 400 CW - Welding machine GYS - Free user manual and instructions

USER MANUAL Neopulse 400 CW GYS

Before using your device for the rst time, please check for new updates.

Before using the machine for the rst time, calibrate the welding cables.

INSTALLATION – FONCTIONNEMENT PRODUIT

ANOMALIES, CAUSES, REMÈDES

GENERAL INSTRUCTIONS These instructions must be read and understood before using the machine. Any modication or maintenance that is not specied in the manual must not be carried out. The manufacturer will not be held responsible for any damage to persons or property caused by the failure to follow this product’s user manual instructions. In case of problems or queries, please consult a qualied tradesperson to correctly install the product. ENVIRONMENT This equipment should only be used for welding operations performed within the limits indicated on the information panel and/or in this manual. These safety guidelines must be observed. The manufacturer cannot be held responsible in cases of improper or dangerous use. The machine must be set up somewhere free from dust, acid, ammable gases or any other corrosive substances. This also applies to the machine’s storage. Operate the machine in an open or well-ventilated area. Temperature range: Operate between -10 and +40°C (+14 and +104°F). Store between -20 and +55°C (-4 and 131°F). Air humidity: Less than or equal to 50% at 40°C (104°F). Lower than or equal to 90% at 20°C (68°F). Altitude: Up to 1,000m above sea level (3,280 feet).

PROTECTING YOURSELF AND OTHERS

Arc welding can be dangerous and cause serious injury or death. Welding exposes people to a dangerous heat source, arc light, electromagnetic elds (be aware of those wearing pacemakers), risk of electrocution, loud noises and fumes. To protect yourself and others, please observe the following safety instructions: To protect yourself from burns and radiation, wear insulating, dry and reproof clothing without lapels. Ensure the clothing is in good condition and that covers the whole body. Wear gloves that ensure electrical and thermal insulation. Use welding protection and/or a welding helmet with a su󰀩cient level of protection (depending on the specic use). Protect your eyes during cleaning operations. Contact lenses are specically forbidden. It may be necessary to section o󰀨 the welding area with reproof curtains to protect the area from arc radiation and hot spatter. Advise people in the welding area not to stare at the arc rays or molten material and to wear appropriate protective clothing. Wear noise protection headphones if the welding process becomes louder than the permissible limit (this is also applicable to anyone else in the welding area). Keep your hands, hair and clothing away from moving parts (for example, the fans). Never remove the cooling unit housing protections when the welding power source is live, the manufacturer cannot be held responsible inthe event of an accident. The newly welded parts are hot and can cause burns when handled. When maintenance work is carried out on the torch or electrode holder, ensure that it is su󰀩ciently cold by waiting at least 10 minutes before carrying out any work. The cooling unit must be switched on when using a water-cooled torch to ensure that the liquid cannot cause burns. To protect people and property, it is important to properly secure the work area before leaving.

WELDING FUMES AND GAS

The fumes, gases and dusts emitted during welding are harmful to health. Su󰀩cient ventilation must be provided and an additional air supply may be required. A n air-fed mask could be a solution in cases where there is insu󰀩cient ventilation. Check that the suction is functioning e󰀨ectively by checking it against safety standards. Caution: when welding in small areas requires supervision from a safe distance. In addition, the welding of certain materials containing lead, cadmium, zinc, mercury or even beryllium can be particularly harmful. Remove any grease from the parts before welding.EN

Operating manual NEOPULSE 400 CW Translation of the original instructions Gas cylinders should be stored in open or well-ventilated areas. They should be kept in an upright position and kept on a cart or trolley. Welding should not be undertaken near grease or paint.

FIRE AND EXPLOSION RISKS

Fully protect the welding area, ammable materials should be kept at least 11 metres away. Fire ghting equipment should be present in the vicinity of welding operations. Beware the expulsion of hot spatter or sparks, even through cracks, which can cause res or explosions. Keep people, ammable objects and pressurised containers at a safe distance. Do not weld in closed containers or tubes. If they are open, remove any ammable or explosive materials (oil, fuel, etc.) before welding. Grinding work must not be directed towards the source of the welding current or towards any ammable materials. GAS CYLINDERS Gas escaping from the cylinders can cause su󰀨ocation if it becomes concentrated in the welding area (ventilate well). Transporting the machine must be done safely: gas cylinders must be closed and the welding power source turned o󰀨. They should be stored upright and supported to reduce the risk of falling. Tightly close the bottle between uses. Beware of temperature changes and sun exposure. The bottle should not come into contact with ames, electric arcs, torches, earth clamps or any other sources of heat. Keep away from electrical and welding circuits and never weld a pressurised cylinder. When opening the cylinder valve, keep your head away from the valve and ensure that the gas being used is suitable for the welding process. ELECTRICAL SAFETY The electrical network used must be earthed. Use the recommended fuse size chosen from the information table. Electric shocks can cause serious direct and indirect accidents or even death. Never touch live parts connected to the live current, either inside or outside the power source casing unit (torches, clamps, cables, electrodes), as these items are connected to the welding circuit. Before opening the welding machine’s power source, disconnect it from the mains and wait two minutes to ensure that all the capacitors have 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, they must be replaced by a qualied and authorised person. Measure the length of cable according to its use. Always wear dry, good quality clothing to insulate yourself from the welding circuit. Alongside this, wear well-insulated footwear in all working environments. EMC CLASSIFICATION This Class A equipment is not intended for domestic use where electrical power is supplied from the low-voltage mains system. Ensuring electromagnetic compatibilty may be di󰀩cult at these sites due to conducted, as well as radiated, radio frequency interference. This equipment complies with IEC 61000-3-11. This equipment does not comply with IEC 61000-3-12 and is designed to be plugged into private, low voltage, power supply networks. It is intended to be connected to the public mains supply only at medium or high voltage level. If connected to a public, low voltage, power supply network, it is the installer or user’s responsibilty to ensure that the equipment can be properly connected by checking with the mains grid operator. ELECTROMAGNETIC INTERFERENCES An electric current passing through any conductor produces localised electric and magnetic elds (EMF). The welding current produces an electromagnetic eld around the welding circuit and the welding equipment. Electromagnetic elds (EMFs) can interfere with some medical devices, for example pacemakers. Protective measures should be taken for those with medical, implanted devices. For example, restricted access for onlookers or an individual risk assessment for welders. All welders should use the following guidelines to minimise exposure to the welding circuit’s electromagnetic elds:

• position the welding cables together - if possible, securing them with a clamp,

• position yourself (head and body) as far away from the welding circuit as possible,

• never wrap the welding cables around your body,26 Operating manual NEOPULSE 400 CW Translation of the original instructions

• do not position yourself between the welding cables and keep both welding cables on your same side,

• connect the return cable to the workpiece, as close as possible to the area to be welded,

• do not work next to, sit or lean on the source of the welding current,

• do not weld while transporting the source of the welding current or wire feeder. Pacemaker users should consult a doctor before using this equipment. Exposure to electromagnetic elds during welding may have other health e󰀨ects that are not yet known. RECOMMENDATIONS FOR ASSESSING THE WELDING AREA AND EQUIPMENT General Information It is the user’s responsibilit to install and use the arc welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, it is the user’s responsiblity to resolve the situation using the manufacturer’s technical support. In some cases, this corrective 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 current source and around the entire workpiece by setting up input lters. In any case, electromagnetic interference should be reduced until it is no longer an inconvenience. Assessing the welding area Before installing arc welding equipment, the user should assess the potential electromagnetic problems in the surrounding area. The following should be taken into account: a) the presence of power, control, signal and telephone cables above, below and next to the arc welding equipment, b) radio and television receivers and transmitters, c) computers and other control equipment, d) critical safety equipment, e.g. the protection of industrial equipment, e) the health of nearby persons, e.g. those using of pacemakers or hearing aids, f) the equipment used for calibrating or measuring, g) the protection of other surrounding equipment. The operator has to ensure that the devices and equipment used in the same area are compatible with each other. This may require further protective measures; h) the time of day when welding or other activities are to take place. The size of the surrounding area to be taken into account will depend on the building’s structure and the other activities taking place there. The surrounding area may extend beyond the boundaries of the premises. Assessment of the welding equipment In addition to the assessment of the surrounding area, the arc welding equipment’s assessment can be used to identify and resolve cases of interference. It is appropriate that the assessment of any emissions should include in situ procedures as specied in Article 10 of CISPR 11. In situ procedures can also be used to conrm the e󰀨ectiveness of mitigation measures. GUIDELINES ON HOW TO REDUCE ELECTROMAGNETIC EMISSIONS a. The mains power grid: Arc welding equipment should be connected to the mains power grid according to the manufacturer’s recommendations. If any interference occurs, it may be necessary to take additional precautionary measures such as ltering the mains power supply. Consider protecting the power cables of permanently installed, arc welding equipment within a metal pipe or a similar casing. The power cable should be protected along its entire length. The protective casing should be connected to the welding machine’s power source to ensure good electrical contact between the protective pipeline and the welding machine’s power source housing. b. The maintenance of arc welding equipment: Arc welding equipment should be subject to routine maintenance as recommended by the manufacturer. All access points, service openings and bonnets should be closed and properly locked when the arc welding equipment is in use. The arc welding equipment should not be modied in any way, except for those modications and adjustments mentioned in the manufacturer’s instructions. The spark gap of arc starters and stabilisers should be adjusted and maintained according to the manufacturer’s recommendations. c. Welding cables: Cables should be as short as possible, placed close together either near or on the ground. d. Equipotential bonding: Consideration should be given to the joining of all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of electric shocks to the user if they touch both these metal parts and the electrode. The user should be isolated from such metal objects. e. Earthing the workpiece: In cases where the part to be welded is unearthed for electrical safety reasons or due to its size and location, such as ship hulls or structural steel buildings, an earthed connection can reduce emissions in some cases, although not always. Care should be taken to avoid the earthing of parts which could increase the risk of injury to users or damage to other electrical equipment. If necessary, the workpiece’s connection should be earthed directly, but in some countries where a direct connection is not allowed, the connection should be made with a suitable capacitor chosen according to national regulations. f. Protection and protective casing: The selective protection and encasing of other cables and equipment in the surrounding area may limit interference problems. The safeguarding of the entire welding area may be considered for special applications. THE TRANSPORTING AND MOVING OF THE MACHINE’S POWER SOURCE Do not use the cables or torch to move the welding power source. It should be transported in an upright position. Do not carry or transport the power source overhead of people or objects. Never lift a gas cylinder and the welding power source at the same time. Their transport requirements are di󰀨erent. It is advisable to remove the wire spool before lifting or transporting the welding power source.EN

• Place the welding power source on a oor with a maximum inclination of 10°.

• Provide su󰀩cient space to ventilate the welding power source and access the controls.

• Do not use in an area with conductive metal dust.

• The welding power source should be protected from heavy rain and not exposed to direct sunlight.

• The equipment has an IP23 protection rating which means: - its dangerous parts are protected from being entered by objects greater than 12.5 mm and, - it is protected against rain falling up to 60° from the vertical. The equipment can be used outside in accordance with the IP23 protection certication. Stray welding currents can destroy earthing conductors, damage electrical equipment and devices and cause component parts to overheat leading to res. - All welding connections must be rmly secured and regularly checked! - Make sure that the item’s attachment is rm and secure, without any electrical problems! - Join together or suspend any electrically conductive parts of the welding source such as the frame, trolley and lifting systems so that they are insulated! - Do not place other equipment such as drills or grinding devices etc. on the welding source, trolley, or lifting systems unless they are insulated! - Always place welding torches or electrode holders on an insulated surface when not in use! Power cables, extension cables and welding cables should be fully unwound to avoid overheating. The manufacturer assumes no responsibility for damage to persons or objects caused by improper and dangerous use of this equipment. MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualied person. Annual maintenance is recommended.

• Switch o󰀨 the power supply by pulling the plug and wait two minutes before working on the equipment.. Inside the macine, the voltages and currents are high and dangerous.

• Regularly remove the cover and blow out any dust. Take advantage of the opportunity to have the electrical connections checked with an insulated tool by a qualied professional.

• Regularly check the condition of the power cord. If the power cable is damaged, it must be replaced by the manufacturer, the after sales service team or an equally qualied person to avoid any danger.

• Leave the welding power source vents free for air intake and outow.

• Do not use this welding power source for thawing pipes, recharging batteries/storage batteries or starter motors. The coolant should be changed every 12 months to prevent residue from clogging the torch’s cooling system. Any leaks or pro- duct residues found after use, must be treated in an appropriate treatment plant. If possible, the product should be recycled. It is forbidden to drain the used material into waterways, pits or drainage systems. Diluted uid should not be emptied into the sewage system, except where allowed under local regulations.

INSTALLATION - USING THE PRODUCT

Only experienced persons, authorised by the manufacturer, may carry out the installation. During installation, ensure that the power source is disconnected from the mains. Series or parallel power source connections are not allowed. It is recommended to use the welding cables supplied with the unit in order to obtain the best performance. DESCRIPTION This machine is a three-phase power source for semi-automatic, software-supported welding (MIG or MAG), coated electrode welding (MMA) and refractory electrode welding (TIG). It accepts 200 and 300 mm diameter wire spools. DESCRIPTION OF THE EQUIPMENT (I)

7- Reel support 16- Fuse

Operating manual NEOPULSE 400 CW Translation of the original instructions HUMAN-MACHINE INTERFACE (HMI) HMI Please read the Human Machine Interface (HMI) which forms part of the equipment’s user literature. POWER SWITCH

• This equipment is supplied with a 32 A EN 60309-1 socket and should only be used on a three phase, 400 V (50-60 Hz), four wire, earthed electrical system. The actual absorbed current (I1e󰀨) for optimal operating conditions is indicated on the equipment. Check that the power supply and its safe- guards (fuses and/or circuit breakers) are compatible with the current required to use the machine. For optimum functionality in certain countries, it may be necessary to change the plug.

• The power source is designed to operate at 400 V +/- 15%. • The machine will go into protection mode if the supply voltage falls below 330 Ve󰀨 (rated insulation voltage) or goes above 490 Ve󰀨, (an error code will appear on the display screen).

• To switch the machine on, turn the on/o󰀨 switch (I-3) to position I, whereas switching it o󰀨 is done by turning the switch to position 0. Caution! Never disconnect the machine from the power supply while the machine is charging.

• Ventilation fan performance: This equipment is tted with smart ventilation management system in order to minimise the noise made by the machine. The fans will adjust their speed according to useage and the surrounding temperature. They can be switched o󰀨 in MIG or TIG mode.

CONNECTING TO A POWER SOURCE

This equipment can be operated with electric generators provided that the auxiliary power supply meets the following requirements: - The voltage must be alternating with an RMS value of 400 V +/- 15% and a peak voltage of less than 700 V. - The frequency must be between 50 and 60 Hz. It is vital to check these conditions as many generators produce high voltage peaks that can damage equipment.

USING EXTENSION LEADS

All extension leads must be of a suitable length and width that is appropriate to the equipment’s voltage. Use an extension lead that complies with national safety regulations. Input voltage Length - Size of the extension cord (Length < 45m) 400 V 4 mm²

a b - Remove the nozzle (a) and contact tube (b) from your MIG/MAG torch.

Open the power source’s hatch. - Position the reel on its holder. - Take into consideration the reel stands’s drive lug (c). To t a 200 mm reel, tighten the plastic reel holder (a) to the maximum. - Adjust the brake wheel (b) to prevent the non-moving spool from tangling the wire when the welding stops. In general, do not overtighten, as this will cause the motor to overheat.

To change the rollers, do the following: - Loosen the knobs (a) to the maximum and lower them. - Unlock the rollers by turning the retaining rings (b) by a quarter turn. - Fit the correct drive rollers for your use and lock the retaining rings in place. The rollers supplied are double groove steel rollers (1.0 and 1.2).EN

Operating manual NEOPULSE 400 CW Translation of the original instructions- Check the inscription on the roller to ensure that the rollers are suitable for the wire diameter and the wire material (for a Ø 1.2 wire, use the Ø 1.2 groove).- Use V-grooved rollers for steel and other hard wires.- Use U-grooved rollers for aluminium and other soft, alloyed wires. : visible inscription on the roller (example: 1.2 VT) : groove to use

Do the following to install the ller wire:- Loosen the dials to the maximum and lower them. - Insert the wire, then close the motor reel and tighten the dials as shown.- Operate the motor using the torch trigger or the manual wire feed button (I-6).Notes:- Too narrow a sheath can lead to unreeling issues and can lead to the overheating of the motor.- The torch connection must also be properly tightened to prevent it from overheating. - Ensure that neither the wire, nor the reel, touches the device’s mechanism, otherwise there is a danger of short-circuiting the ma- chine.RISK OF INJURY FROM MOVING COMPONENTSThe reels have moving parts that can trap hands, hair, clothing or tools causing injuries!- Do not touch rotating, moving or driving parts of the machine!- Ensure that the housing covers or protective covers remain fully closed when in operation!- Do not wear gloves when threading the ller wire or changing the ller wire reel.PRIMING THE COOLING UNIT Priming the pump may prove di󰀩cult when used for the rst time and result in poor water ow. To prime it correctly, it is recommended to use the priming hose supplied with the product (I-19) and follow the instructions below:- Fill the coolant reservoir to its maximum level. The tank has a 5.5 litre capacity. - Connect the priming hose to the coolant outlet connector (I-17) and place the other end in an empty container (ideally a bottle). - Turn on the power source.- On the System/Cooling menu, select the icon to start the priming procedure. - Once the pump is primed (the tank having been lled with coolant), stop the cooling system by pressing one of the buttons on the HMI. - Disconnect the priming hose and return the liquid to the cooling system: the pump is now primed.PRIMING THE PUMP SHAFTProlonged periods of inactivity and impurities in the coolant can cause the coolant pump to become blocked. Pump shaft priming procedure:1/ Turn o the machine’s power source.2/ Insert a at screwdriver (Ø 9 mm max.) into the centre of the pump shaft passing through the service port. Then turn the screwdriver clo-ckwise until the pump shaft turns again easily.3/ Remove the screwdriver.4/ Switch on the machine’s power source.30 Operating manual NEOPULSE 400 CW Translation of the original instructions LIQUID COOLING FILLING MAX MIN The cooling unit’s tank must be lled to the MAX level recommended by the gauge on the front of the cooling unit. However, the coolant level must never fall below the MIN level, this will bring up a warning message. It is essential to use a specic coolant for welding machines that has low electrical conductivity as well as being anti-corrosion and anti-freeze (ref. 052246). The use of other coolants, in particular the standard automotive coolants, can lead to the accumulation of solid deposits in the cooling system through electrolysis, thus degrading the cooling system and even clogging it entirely. This recommended MAX level is essential for optimum performance of the liquid-cooled torch. Any damage to the machine caused by the use of a coolant other than the recommended variety will not be covered under the warranty.. USAGE

NEVER USE the machine’s power source WITHOUT COOLING LIQUID while the pump is running. Meet the minimum coolant level. Failure to do so may result in permanent damage to the cooling system pump.

Ensure that the cooling unit is switched o󰀨 before disconnecting the torch’s uid inlet and/or outlet pipes. Coolant is harmful and irritates the eyes, mucous membranes and skin. Hot liquid can cause burns.

Danger of burns from hot liquid. Never drain the cooling unit after use. The liquid inside the machine is boiling hot, wait for it to cool before draining.

In «AUTO» mode, the cooler pump starts running when welding is started. When welding stops, the pump continues to run for a further 10 minutes. During this time, the liquid cools the welding torch bringing it back to room temperature. Leave the power source plugged in for a few minutes after welding to allow it to cool. In the MIG-MAG process, the cooling system is activated by default (AUTO). To use an air-cooled MIG-MAG torch, it is necessary to switch the cooling system o󰀨. Please refer to the interface manual to do this. SEMI-AUTOMATIC STEEL/STAINLESS STEEL WELDING (MAG MODE) This machine can weld steel and stainless steel wire from Ø 0.6 to 1.6 mm (II-A). The machine is designed for use with Ø 1.0 mm steel wire (Ø 1.0/1.2 roller) as standard. The contact tip, the sheave groove and the welding torch sheath are designed for this use. Use a torch no longer than 3 m to weld 0.6 diameter wire. The contact tip as well as the spools of the motorised wire feed roller should be replaced by a 0.6 grooved model (ref. (réf. 061859). In this case, position it so that the marking 0.6 is visible. To do this using steel requires a specic welding gas (Ar+CO2). The amount of CO2 may vary depending on the type of gas used. Use 2% CO2 for stainless steel. It is necessary to connect a gas pre-heater to the gas cylinder when welding with pure CO2. For specic gas issues, please contact your gas distributor. The gas ow rate for steel is between 8 and 15 litres per minute depending on the surroundings. SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE) The equipment can weld aluminium wire from Ø 0.8 to 1.6 mm (II-B). The use of aluminium requires a specic, pure, argon gas (Ar). Seek advice from a gas distributor for a wide selection of gases. he gas ow rate of aluminium is between 15 and 25 l/min depending on the surrounding environment and the welder’s experience. The di󰀨erences between steel and aluminium processing are as follows: - Use specic rollers for aluminium welding. - Put minimum pressure on the motorised reel’s pressure rollers so as not to crush the thread. - Use a capillary tube (to guide the wire between the motorised wire feeder rollers and the EURO connector) for steel/stainless steel welding only. - Use a special aluminium torch. This aluminium torch has a Teon coating to reduce friction. DO NOT cut away the coating at the tip of the connector! This coating is used to guide the wire from the rollers. - Contact tips: use a SPECIAL aluminium contact tip that matches the wire’s diameter. When using red or blue sheathing (aluminium welding), it is recommended to use the 91151 (II-C) accessory. This stainless steel sheath guide improves the centering of the sheath and facilitates the ow of the wire. Video SEMI-AUTOMATIC WELDING IN CUSI AND CUAL (SOLDERING MODE) The machine can weld CuSi and CuAl wire from Ø 0.8 to 1.6 mm. In the same way as with steel, a capillary tube must be set up and a torch with a steel sheath must be used. When braze welding, pure argon (Ar) should be used.

SEMI-AUTOMATIC «NO GAS» WIRE WELDING

This equipment can weld wire without gas protection (No Gas) from Ø 0.9 to 2.4 mm. Welding ux-cored wire with a standard nozzle can lead to overheating and damage to the torch. Remove the original nozzle from your MIG-MAG torch.EN

Polarity + Polarity - Gas-shielded MIG/MAG welding generally re- quires positive polarity. MIG/MAG welding without gas shielding (No Gas) generally requires negative polarity. In any case, refer to the wire manufacturer’s recommendations for the choice of polarity for your MIG-MAG torch. GAS SUPPLY - Fit a suitable pressure regulator to the gas cylinder. Connect it to the welding station with the pipe supplied. Attach the two hose clamps to prevent leaks. - Ensure that the gas cylinder is held securely in place with a chain attached to the power source. - Set the gas ow rate by adjusting the dial on the pressure regulator. NB: To adjust the gas ow rate more easily, use the rollers on the motorised spool by pulling the trigger on the torch (loosen the brake wheel on the motorised reel so that no wire is drawn in). Maximum gas pressure: 0.5 MPa (5 bar). This procedure does not apply to welding in «No Gas» mode. RECOMMENDED COMBINATIONS (mm) Current (A) Ø Wire (mm) Ø Nozzle (mm) Flow rate L/min MIG 0.8-2 20-100 0.8 12 10-12 2-4 100-200 1.0 12-15 12-15 4-8 200-300 1.0/1.2 15-16 15-18 8-15 300-500 1.2/1.6 16 18-25 MAG 0.6-1.5 15-80 0.6 12 8-10 1.5-3 80-150 0.8 12-15 10-12 3-8 150-300 1.0/1.2 15-16 12-15 8-20 300-500 1.2/1.6 16 15-18

MIG / MAG (GMAW/FCAW) WELDING MODE

Choice of the material to be welded. Pre-installed welding user settings Wire diameter Ø 0.6 > Ø 1.6 mm Choice of wire diameter ModulArc OFF - ON - - - - - Activating or deactivating the welding current’s modulation (Double Pulse)

GER 2T, 4T Choice of trigger welding management mode. Spot welding mode SPOT, DELAY - Selecting spot welding mode First Setting Thickness Start-up Speed

Choosing the main setting to be displayed (thickness of the workpiece, average welding current or wire speed). Power Hold Thermal coe󰀩cient See «Power» section on the following pages. Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual.32 Operating manual NEOPULSE 400 CW Translation of the original instructions WELDING PROCESSES For more information on GYS pre-installed user settings and welding processes, scan the QR code:

• SPOT WELDING This welding mode allows the pre-assembly of parts before welding. Spot welding can be done manually using the trigger or timed with a predened spot welding period. This spot welding makes reproduction and execution of non-oxidised weld points easier (accessible in the advanced menu).

• TIME LIMITS This is a welding mode similar to SPOT welding but with predened weld and dwell times, as long as the trigger is held down.

CONFIGURING THE SETTINGS

Units Wire speed m/min Amount of ller metal deposited and consequently the welding intensity and penetration. Voltage V Control over the cord’s width. Self - Lessens the welding current more or less. To be set according to the welding position. Pre-Gas s When the torch is bled and the gas shield is created before ignition. Post-Gas s Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from oxidation. Thickness mm The pre-installed user settings (syngergies) allow for a fully-automatic set-up. Working with di󰀨erent thicknesses automatically sets the appropriate thread tension and speed. Start-up A The welding current is set according to the type of wire used and the material to be welded. Arc length - Used to adjust the distance between the end of the wire and the weld pool (tension adjustment). Approach speed % Progressive yarn speed. Before priming, the wire moves slowly to create the rst contact without jolting. Hot Start % & s The Hot Start is an overcurrent used at the start that prevents the wire from sticking to the workpiece. The intensity (% of welding current) and the time (seconds) can be programmed. Crater Filler % This idling bearing current is a phase after the current is lowered. The intensity (% of welding current) and the time (seconds) can be programmed. Soft Start s Gradual current increase. The current is controlled between the rst contact and the welding process in order to avoid the possibility of violent ignitions or jolts. Uplsope s Upslope current Cold current % Second welding current known as a «cold» welding current. Pulse frequency Hz Pulse frequency Duty cycle % In pulsed mode, the hot current time is adjusted in relation to the cold current time. Downslope s Downslope current. Tack welding s Set duration. Time between two points s Time between the end of a point (excluding Post-Gas) and the start of a new point (including Pre-Gas). Burnback s Feature preventing the thread sticking to the bead. This is timed to coincide with the wire rising from the weld pool. Access to some welding settings depends on the welding process (Manual, Standard, etc.) and the selected display mode (Easy, Expert or Ad- vanced). Refer to the HMI manual.EN

Standard 2T process: IstartDstartI hot startT hotstartGas Pre-FlowCreep SpeedI blackoutT burn-backI burn-backGas post-Flow Soft-startT crater FillerI crater Filler When the trigger is pulled, the pre-gas starts. When the wire touches the workpiece, a pulse initiates the arc and the welding cycle starts. When the trigger is released, the wire feeding stops and a current pulse cleanly cuts the wire, followed by the post-gas. As long as the post-gas has not nished, pressing the trigger will allow a quick restart of the weld (manual chain stitch) without going through the HotStart phase. A HotStart and/or a crater ller can be added to the cycle. Standard 4T process: IstartDstartI hot startT hotstartI BlackoutT burn-backI burn-backGas post-Flow

Soft-start T crater FillerI crater FillerGas Pre-FlowCreep Speed In a standard 4T process, the timing of pre-gas and post-gas is managed automatically. HotStart and crater ller are both controlled by the trigger.34 Operating manual NEOPULSE 400 CW Translation of the original instructions Pulsed 2T process: IstartDstartI hot startT hotstartT upslopeGas Pre-FlowCreep SpeedT downslopeI blackoutT burn-backI burn-backGas post-Flow Soft-startT crater FillerI crater Filler When the trigger is pulled, the pre-gas starts. When the wire touches the workpiece, a pulse initiates the arc. Then, the machine starts with HotStart or upslope and nally, the welding cycle starts. When the trigger is released, the downslope initiates until it reaches crater ll. Then the STOP PEAK cuts the wire followed by the Post gas. Just as in Standard mode, the user can quickly restart the welding process during the post-gas phase without going through the HotStart phase. Pulsed 4T process: IstartDstartI hot startT hotstartT upslopeT downslopeI BlackoutT burn-backI burn-backGas post-Flow

Soft-start T crater FillerI crater FillerGas Pre-FlowCreep Speed In pulsed 4T mode, the timing of the pre-gas and post-gas is managed automatically. HotStart and crater ll are controlled by the trigger.EN

• DC TIG welding requires a protective gas shield (Argon).

• Connect the earth clamp to the positive (+) plug connector. Plug in the TIG torch (ref. 046108) iinto the power source’s EURO connector and the reverse cable into the negative (-) connector.

• Ensure that the torch is properly tted and that the consumables (vice grip pliers, collet bodies, di󰀨users and nozzles) are not worn out.

• The choice of electrode will depend on the current of the DC TIG process. ELECTRODE SHARPENING For optimum results, it is advised to use an electrode sharpened in the following way:

L = 3 x d for a low current. L = d for a high current PROCESS SETTINGS Welding processes Settings ADJUSTABLE SETTINGS Synergies (pre-installed user settings)

Standard - Smooth current Pulsed - Pulsed current Spot welding - Smooth tacking Tack - Pulsed tacking Type of materials Fe, Al, etc. - Choice of the material to be welded Tungsten elec- trode’s diameter

Choice of electrode diameter. Allows the renement of HF ring currents and pre-installed user settings (synergies). Trigger mode 2T - 4T - 4T LOG Choice of trigger welding management mode. E.TIG ON - OFF Constant energy welding mode with arc length correction. Power Hold Thermal coe󰀩cient - See «Power» section on the following pages. Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. WELDING PROCESSES

• DC TIG welding Specically designed for ferrous metals such as steel, stainless steel, copper and its alloys, as well as titanium.

• Synergic TIG welding No longer based on the selection of a DC current type and the welding cycle settings but intergrates welding rules/pre-installed settings based on real welding experiences. Therefore, this mode restricts the number of basic, adjustable settings to three: Type of material, welding thickness and welding position. ADJUSTABLE SETTINGS

• STANDARD WELDING The standard DC TIG welding process allows high quality welding on most ferrous materials such as steel and stainless steel, but also copper and its alloys including titanium. The various current and gas management possibilities allow you to perfectly control your welding operation, from priming to the nal cooling of your weld seam.

• PULSED WELDING This pulsed current welding mode combines high current pulses (I = welding pulses) with low current pulses (cold I, workpiece cooling pulses). The pulsed mode allows parts to be assembled while limiting temperature rises and warping. Ideal for on site use. Example: The welding current (I) is set to 100 A and % (cold I) = 50%, i.e. cold current = 50% x 100 A = 50. F(Hz) is set to 10 Hz, the signal period will be 1/10 Hz = 100 ms -> a 100 A pulse every 100 ms then followed by another at 50 A.

• SPOT WELDING This welding mode allows the pre-assembly of parts before welding. Spot welding can be done manually using the trigger or timed with a predened spot welding period. Spot welding allows for better reproduction and non-oxidised weld points.36 Operating manual NEOPULSE 400 CW Translation of the original instructions• TACK WELDING This welding mode also allows for the pre-assembly of parts before welding, but in two stages this time: the rst stage uses a pulsed DC current which concentrates the arc for better penetration. This is then followed by the second stage where a standard DC current is used to widen the arc and therefore the weld pool to secure the weld point.The variable times of the two welding stages allow for better reproduction and non-oxidised weld points.• E-TIG WELDING This mode allows for constant power welding by measuring arc length variations in real time to ensure consistent bead width and penetration. In cases where the assembly requires careful control of the welding energy, the E-TIG mode guarantees that the welder will respect the welding power regardless of the torch’s position in relation to the workpiece.Standard (constant current) E-TIG (constant power) 2 mm

Bouton principal T3T1 Bouton principal T2T4T3T1 Bouton principal T2T4 >0.5s<0.5s<0.5s T1 - The main button is pressed, the welding cycle starts (Pre-Gas, I_Start, upslope and welding).T2 - The main button is released, the welding cycle is stopped (downslope, I_Stop, Post-Gas).For two-button torches in T2 only, the secondary button is treated as the main button.

T3T1 Bouton principal T2T4 >0.5s<0.5s<0.5s T1 - The main button is pressed, the cycle starts from Pre-Gas and stops at the I_Start phase.T2 - The main button is released, the cycle continues to upslope and welding.T3 - The main button is pressed, the cycle goes to downslope and stops in the I_Stop phase.T4 - The main button is released, the cycle ends with the Post-Gas.NB: for torches, double buttons and double button + potentiometer=> «up/weld current» button turns on the potentiometer, the «down» button turns it o󰀨.EN

>0.5s<0.5s<0.5s T1 - The main button is pressed, the cycle starts from Pre-Gas and stops at the I_Start phase. T2 - The main button is released, the cycle continues to upslope and welding. LOG: this operating mode is used during the welding phase: - a quick press of the main button (<0.5 s) switches the current from I_welding to I_cold and vice versa. - if the secondary button is pressed, the current switches from I_welding to I_cold. - if the secondary button is left unpressed, the current switches from I_cold to I_welding. T3 - After holding down the main button (>0.5 s), the cycle goes into downslope and stops at the I_Stop phase. T4 - The main button is released and the cycle ends with Post-Gas. For dual button or dual trigger torches, the «high» trigger retains the same functionality as the single trigger torch . The «low» trigger is not active.

The presence of oxygen in the torch can lead to a decrease in mechanical quality and can result in less corrosion resistance. To ush the gas from the torch, press and hold the button #1 and follow the on-screen procedure.

CONFIGURING THE SETTINGS

Units Pre-Gas s When the torch is bled and the gas shield is created before ignition. Start-up time % This start-up bearing current is a warm-up phase before the current is raised. Starting time s Starting time before the current is raised. Rising current s Allows a gradual increase in welding current. Welding current A Welding current. Crater-ll feature s Avoids cratering at the end of welding and the risk of cracking, particularly in light alloys. End current % This idling bearing current is a phase after the current is lowered. Stopping time s This idling time is a phase that comes after the current is lowered. Thickness mm Thickness of the workpiece to be welded. Position - Welding positioning Post-Gas s Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from oxidation during cooling. Wave shape - Pulsed waveform. Cold current % Second welding current known as a «cold» welding current. Cold weather % Pulsed hot current (I) time balance Pulse frequency

Pulse frequency SET-UP TIPS: - If welding with a manual, ller metal, then F(Hz) is synchronised to the inputting of the wire. - If the metal is thin and without ller (< 0.8 mm), F(Hz) > 10 Hz - If welding in position, then F(Hz) < 100 Hz Spot welding s Either manual or a set time. Timed pulsed s Manual or timed pulsed hase Timed non-pulsed s Manual or timed smooth current phase Access to certain welding settings depends on the welding process (Standard, Pulsed, etc.) and the selected display mode (Easy, Expert or Ad- vanced).38 Operating manual NEOPULSE 400 CW Translation of the original instructions

MMA (SMAW) WELDING MODE

INSTALLATION AND GUIDANCE

• Plug the cables, electrode holder and earth clamp into the plug connections.

• Respect the electrical polarities and the strength of the welding power indicated on the electrode boxes.

• Remove the coated electrode from the electrode holder when the welding power source is not in use.

• The equipment is tted with 3 inverter-specic features: - Hot Start provides an overcurrent at the beginning of the welding process. - Arc Force creates an overcurrent which prevents the electrode from sticking to the weld pool. - The Anti-Stick technology makes it easier to unstick the electrode from the metal. PROCESS SETTINGS Welding processes Settings ADJUSTABLE SETTINGS Standard Pulsed Electrode type Rutile Basic Cellulosic The type of electrode determines the settings in order to optimise its weldability depending on the type of electrode used. Anti-Sticking OFF - ON The anti-stick feature is recommended to safely remove the electrode in the event of it sticking to the workpiece (the current is cut o󰀨 automati- cally). Power Hold Thermal coe󰀩cient See «Power» section on the following pages. Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual. WELDING PROCESSES

• STANDARD WELDING This standard MMA welding mode is suitable for most welding applications. It enables welding with all types of coated, rutile, basic and cellulosic electrodes, as well as on all materials: steel, stainless steel and cast iron.

• PULSED WELDING The pulsed MMA welding mode is suitable for upright (PF) applications. The pulsed setting keeps the weld pool cold while promoting material transfer. Without pulsing, vertical upward welding requires a «Christmas tree» movement, i.e. a di󰀩cult triangular movement. Thanks to Pulsed MMA welding, it is no longer necessary to perform this movement. Depending on the thickness of your workpiece, a straight upward movement should su󰀩ce. However, if you want to enlarge your weld pool, a simple sideways movement similar to downheld welding is su󰀩cient.. In this case, you can set the frequency of your pulsed current on the display monitor. This method o󰀨ers greater control of the vertical welding operation.

CHOOSING COATED ELECTRODES

• Rutile electrodes: very easy to use in any position.

• Basic electrodes: it can be used in all positions and is suitable for safety work due to its increased mechanical properties.

• Cellulosic electrodes: a very powerful arc with a high melting speed, its ability to be used in all positions makes it especially suitable for pipeline work.

Hot Start is an overcurrent at the ignition stage which prevents the electrode from sticking to the workpiece. The intensity (% of welding current) and the time (seconds) can be programmed. Duration of Hot Start s Welding current A The welding current is determined by the type of electrode chosen (see electrode packaging). Arc Force % Arc Force is an overcurrent administered to prevent sticking when the electrode or weld bead touches the weld pool. Percentage I cold % Cold weather s Pulse frequency Hz PULSE mode’s PULSING frequency. Access to some welding settings depends on the selected display mode: Settings/Display mode: Easy, Expert, Advanced. Refer to the HMI manual.EN

The following settings correspond to the applicable current range depending on the type and diameter of the electrode used. These ranges are quite large as they depend on the usage and the welding position. electrode Ø (mm) Rutile E6013 (A) Basic E7018 (A) Cellulosic E6010 (A)

It is advisable to set the Arc Force to the middle position (0) to start welding and then adjust it according to the results obtained and individual welding preferences. Note: The adjustment range of the Arc Force is specic to the type of electrode chosen. GOUGING During gouging, an electric arc burns between the gouging electrode and the metal workpiece, heating the workpiece to fusion. This weld pool is «cleaned» with compressed air. Gouging requires an electrode holder with a compressed air connection (ref. 041516) and gouging electrodes: Type Quantity Ampere ref.

6.5 x 305 mm 50 400 A 086081

PROCESS SETTINGS Units Welding current A The welding current is determined by the diameter and type of gouging electrode (max. 400 A). (refer to the electrode packaging). Access to some interface functions is not available in Gouge mode (JOB, etc.). POWER A method developed for welding with DMOS-regulated energy control. As well as displaying the energy of the weld bead after welding, this mode allows the setting of the thermal coe󰀩cient according to the standard used: One for ASME standards and 0.6 (TIG) or 0.8 (MMA/MIG-MAG) for European standards. The energy displayed is calculated taking into account this coe󰀩cient.

OPTIONAL PUSH-PULL TORCH

Reference number Wire diameter Length Cooling type 038738 0.8 > 1.2 mm 8 m Air 038141 0.8 > 1.2 mm 8 m Liquid 038745 0.8 > 1.6 mm 8 m Liquid A push-pull torch can be connected to the power source via the socket (I-13). This type of torch allows the use of AlSi wire even in Ø 0.8 mm with a torch length of 8 m. This torch can be used in all MIG-MAG welding modes. The Push-Pull torch is detected by simply pulling the trigger. When using a push-pull torch with potentiometer, the highest control range setting can be set using the interface. The potentiometer can then range anywhere between 50% and 100% within this setting.

OPTIONAL REMOTE CONTROL

• RC-HA2 Analogue remote control (ref. 047679): An analogue remote control can be connected to the power source via the socket (I-13). This controller acts on the voltage (rst potentiometer) and the wire speed (second potentiometer). These settings are then inaccessible from the power source’s interface.

• RC-HD2 Digital remote control (ref. 062122): A digital remote control can be connected to the power source via the NUM-1 Kit (option ref. 063938). This remote control is designed for MIG/MAG, MMA and TIG welding processes. It enables the welding unit to be controlled remotely. An ON/OFF button is used to switch the digital remote control on or o󰀨. When the digital remote control is switched on, the HMI power source displays the cur- rent and voltage values. As soon as the HMI is switched o󰀨 or disconnected, the HMI power source is reactivated.40 Operating manual NEOPULSE 400 CW Translation of the original instructions

Dust lter (PN. 063143) with a lter neness of 270 µm (0.27 mm). Please note that the use of this lter reduces the duty cycle of your machine’s power source. To avoid the risk of overheating due to blocked air vents, the dust lter should be regularly cleaned. Unclip and clean with compressed air. ADDITONAL FEATURES The manufacturer GYS o󰀨ers a wide range of features that are compatible with your product. To check them out, scan this QR code.

DEFECTS: CAUSES & SOLUTIONS

SYMPTOMS POSSIBLE CAUSES SOLUTIONS

The ow of the welding wire is not constant. Clogs blocking the opening. Clean the contact tube or replace it with non- stick material. The wire slips in the roller. Reapply the non-stick product. One of the rollers is spinning. Check the tightness of the roller screw. The torch cable is twisted. The torch cable should be as straight as possible. The reel motor is not working. Reel brake or roller is too tight. Loosen the brake and rollers. Incorrect wire unwinding. Dirty or damaged wire guide. Clean or replace. Roller pin key is missing. Reposition the pin in its slot. Reel brake is too tight. Loosen the brake. No current or wrong welding current. Improper connection of mains plug. Check the plug connection and verify that the plug is connected to the power supply. Poor earth connection. Check the earthing cable (its connection and the condition of the clamp). No power. Check the torch trigger.EN

Operating manual NEOPULSE 400 CW Translation of the original instructions The wire jams after passing through the rollers. Crushed wire guide sheath. Check the sheath and torch. Wire jamming in the torch. Replace or clean. No capillary tube. Check that the capillary tube is present. Wire speed too high. Reduce the wire speed. The weld bead is porous. The gas ow is insu󰀩cient. Adjustment range from 15 to 20 L / min. Clean the base metal. Gas cylinder empty. Replace it. Unsatisfactory gas quality. Replace it. Air circulation or wind inuence. Avoid draughts and protect the welding area. Gas nozzle is too clogged. Clean or replace gas nozzle. Bad wire quality. Use a wire suitable for MIG/MAG welding. Condition of the welding surface is too poor (rusted, etc.). Clean the workpiece before welding. The gas is not connected. Check that the gas is connected to the power source’s inlet. Excessive sparks. Arc voltage is too low or too high. See welding settings. Poor earth connection. Check and position the earth clamp as close as possible to the area to be welded. Insu󰀩cient gas protection. Adjust the gas ow. No gas coming from the torch. Poor gas connection. Check the connections of gas inlets. Check that the solenoid valve is working. Error while downloading. The data on the USB stick is incorrect or corrupted. Check your data. Backup error. You have exceeded the maximum number of backups. You need to delete some programs. The number of backups is limited to 500. Automatic deletion of JOBS. Some of your JOBs have been deleted because they were incompatible with the new pre-installed user settings (synergies).

Push Pull torch detection error. - Check Push Pull torch connection. USB key error. There is no JOB detected on the USB stick. - The product’s memory space is full. Free up some space on the USB key. File error. The le does not match the pre-installed user settings (synergies) downloaded to the product. The le was created with pre-installed user settings (synergies) that are not present on the machine. WARRANTY CONDITIONS The warranty covers any defects or manufacturing faults for two years from the date of purchase (parts and labour). The warranty does not cover:

• Any other damage caused by transportation.

• General wear of parts (eg. : cables, clamps, etc.).

• Damage caused by misuse (incorrect power supply, the dropping or dismantling of equipment).

STD DYNAMIC STD IMPACT STD ROOT COLD PULSE PULSE

WAARSCHUWINGEN - VEILIGHEIDSINSTRUCTIES

MMA (SMAW) LASMODULE

Warning ! Read the user manual before use.

Undulating current technology based source delivering direct curent.

Suitable for welding in an environment with an increased risk of electric shock. However this a machine should not placed in such an environment.

Direct welding current

Open circuit voltage

Duty cycle according to standard EN 60974-1 (10 minutes – 40°C).

Corresponding conventional welding current

Conventional voltage in corresponding loads.

Three-phase power supply 50 or 60Hz

Maximum rated power supply current (effective value).

Maximum effective power supply current.

Device complies with euro- peans directives, The EU declaration of conformity is available on our website (see cover page).

Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).

Equipment in conformity with Moroccan standards. The declaration Cم (CMIM) of conformity is available on our website (see cover page).

The device is compliant with standard EN60974-1 and EN60971-10 class A device.

This product is compliant with standard EN 60974-2.

This product is compliant with standard EN 60974-5.

This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin !

This product should be recycled appropriately

EAEC Conformity marking (Eurasian Economic Community).

Temperature information (thermal protection)

Fan cooled hardware.

Protected against access to dangerous parts of solid bodies with diam >12.5 mm and protected against rain directed at 60° to the vertical

Maximum coolant level

Minimum coolant level

This interface (HMI) manual forms part of the complete documentation. A general manual is included with the product. Read and follow the general manual’s instructions, particularly the safety instructions! Only for use with the following products: NEOPULSE 220 C

The software’s version can be found on the main menu: Information / MMI2 Using the machine interface Using the device The main screen contains all the necessary information for the entire welding process, including the pre-, mid- and post-welding phases (the interface may change slightly depending on the selected process). (4) (8) (7) (1) (2) (6) (5) (3) (1) User name / Traceability (2) Push button n°1 : Main menu or return to the pre- vious menu (3) Push button n°2 : Current Welding Process Settings (4) Navigation buttons (5) Push button n°3 : Settings (6) Push button n°4 : Job or Validation (7) Current settings (8) Voltage, Current and Power Readings Main menu The main menu screen is displayed when the product is rst started. Navigating between the different sections is done using the dials and buttons. Processes Parameters System Portability Calibration Information (1) (2) (3) (1) Back (2) Validation (3) The current section’s computer iconEN

Processes Access to some welding processes depends on the product: MIG-MAG (GMAW/FCAW) Semi-automatic welding, in a protective gas atmosphere TIG (GTAW) Arc welding with non-stick electrode, in a protective gas atmosphere MMA (SMAW) Arc welding with coated electrode Gouging Air-arc gouging allows a groove to be cut in the metal Settings (User settings) Display mode - Easy: reduced display and functionality (no access to the welding cycle). - Expert: full display, allows the user to adjust the timing of the different welding cycle phases. - Advanced: full display, allows the user to adjust all the welding cycle settings. Language Choice of the interface language (English, French, German, etc). Units of measurement Choice of measurement units: International (SI) or Imperial (USA). Material naming European standard (EN) or American standard (AWS). Brightness Adjusts the interface screen’s brightness (setting from 1 [very dark] to 10 [very bright]). User Code Customise the user’s access code to safely lock the machine (default 0000). Tolerance I (current) Current tolerance control: OFF : Freely adjustable, the current setting is not limited. ± 0A : no tolerance, current limitation. ± 1A> ± 50A : The setting range at which the user can adjust their current. Tolerance U (voltage) Voltage tolerance control: OFF : freely adjustable, the voltage setting is not limited. ± 0.0V : no tolerance, voltage limiting. ± 0.1V> ± 5.0V : setting range at which the user can vary the voltage. Tolerance (wire speed) Wire speed setting tolerance (m/min): OFF : freely adjustable, wire speed setting is not limited. ± 0.0m/min : no tolerance, wire speed control. ± 0.1m/min> ± 5.0m/min : setting range at which the user can vary the wire speed.4 Using the machine interface Using the machine’s System Naming Device Interface Information about the device’s name and the option to customise it can be reached by pressing on the interface. Clock Setting the time, date and format (AM/PM). Cooling unit - OFF : The cooling unit is switched off. - ON : The cooling unit is permanently switched on. - AUTO : automatic control (activated during welding and deactivated 10 minutes after welding has ended) PURGE : a function designed to purge the cooling unit or to lling beams, during which the safeguards are disabled (see the cooling unit manual to purge your product safely). Reset Pressing ‘Reset’ will reset the machine’s settings: - Partial: will reset the default value of the present welding process. - Total: Will reset all the device’s conguration data to the factory settings. Locking This machine’s interface screen can be locked to protect any work in progress and prevent unintentional or accidental changes. The current settings window can still be modied with the settings chosen in the Settings menu (see previous page). All other functions are inaccessible. To unlock the interface, press push button #1 and enter your 4-digit user code (default 0000).EN

Users The user mode enables the machine to be shared between several users. The rst time that the machine is started, it will be in Admin mode. The administrator can create user proles. Each user has his own setup (mode, setting, process and JOBs etc.) and this cannot be modied by another user. Each user needs a personal four-digit code in order to sign in to the machine.

• The administrator has access to the entire general menu.

• Users have access to a simplied interface. Users do not have the ability to delete information (Tracking, Jobs, User proles, etc). User conguration interface (reserved for the administrator). The left side of the screen lists the users. The administrator has the ability to sort these users by name or by date by quickly pressing button n°2. Pressing this button for a prolonged time will delete the active user(s) instead (although the Admin account cannot be deleted). On the right side of the screen, you can see the details of all the users previously created with the following information: Avatar, Name, Team No. and Tolerance (%). Creating a user prole Press button n°3 to create a new user. - User : Customise the user’s name by pressing push button n°3. - Avatar : Choice of avatar colour - Team : Assignment of the team number (10 max) - User code : personal access code (default 0000) - Current setting tolerance I: OFF : freely adjustable, the current setting is not limited. ± 0.0A : no tolerance, limiting the current (not recommended). ± 0.A> ± 50A : Setting interval at which the user can vary their current. - Voltage setting tolerance U: OFF : freely adjustable, the voltage setting is not limited. ± 0.0V : no tolerance, limiting the voltage (not recommended). ± 0.1V> ± 5.0V : setting range at which the user can vary the voltage. - Wire speed setting tolerance (m/min) : OFF : freely adjustable, the wire speed setting is not limited. ± 0.0m/min : no tolerance, limiting the wire speed (not recommended). ± 0.1m/min > ± 5.0m/min : the range of settings at which the user can vary the wire speed. It is not possible to change the admin name or avatar for the «Admin» user. Changing a user prole Select the user on the left side of the screen and press the push button n°4. Selecting users If one or more user proles are created, the user block displays all of the machine’s users. Select the user of your choice and press to conrm the choice.You will be asked for an unlock code. The «Close» feature locks the machine on the user’s choice so that no other settings are accessible. This screen remains the same when the machine is switched on (OFF -> ON switch). User display The active avatar and username are displayed at the top left of the screen. Unlocking code Each user prole is protected by a personal, four-digit code. The default code will be 0000 if not changed. After failing to correctly enter your personal code three times, the interface will be blocked and you will be asked for an unlock code. This code is made up of six digits and cannot be changed. It is: 314159.6 Using the machine interface Using the machine’s Tracking interface This welding management interface allows you to track/record every step of the welding operation, bead by bead, during any industrial operation. This quality-driven approach ensures high post-production welding quality through analysis, evaluation, reporting and documentation of the recorded welding settings. This feature allows for the accurate and fast collection and storage of data required under EN ISO 3834. This data can be recovered and exported to a USB stick.

1- Start - Creating a tracking system

• Personalise the site’s name by pressing push button n°3.• Sampling interval :- Hold : No recording of current/voltage values (average along the wire) during welding. - 250 ms, 500 ms, etc. : Recording of the current/voltage values (average along the wire) every «X» milliseconds or se- conds during welding.• Options - OFF : simple tracking• Options - ON : full trackingPass counter (ON/OFF) Weld counter (ON/OFF)Temperature (ON/OFF) : Temperature of the part to be welded at the beginning of the weld bead. Length (ON/OFF) : Length of the wire (units of measurement are displayed according to the choices made in Set- tings/Units of Measurement).Variable(s): allows you to add additional personalised information (weight, notes, wire speed, etc.).Press to start tracking. Tracking display At the top left of the screen, the job name and the bead number are displayed (the bead number goes up automatically and cannot be changed). Identication - Options ON At the end of each bead, an identication window appears: Pass N°, Weld N°, Part temperature and/or Bead length. Validation Conrmation can be done on the HMI or by pressing the torch’s trigger. Stop - Stop tracking To stop tracking during a welding process, the user must return to the Tracking block and select «Stop». Export The recovery of this information is done by exporting the data to a USB stick.The CSV data can be processed with a spreadsheet program (Microsoft Excel®, Calc OpenOfce®, etc).The le name is linked to the machine name and serial number.

2- Start - Tracking management

The left-hand side of the screen lists previously created work sites. The user has the possibility to sort these worksites by name or by date by quickly pressing button n°2. Holding down this button will delete the active job or all jobs. The right-hand side of the screen shows the details of each of the previously created jobs with the following information: sampling frequency, number of recorded welds, total welding time, welding energy supplied, setup of each weld (process, timestamp, welding time and welding U-I).Creation of a tracking system(see previous paragraph) Rec Start the active site’s tracking systemEN

Portability Import Setup. Upload the machine settings from a USB memory stick (directory: Removable Disk\PORTABILITY\CONFIG) to the machine. Press and hold to delete the settings on the USB stick. Export Conguration Export the machine settings to a USB stick (directory: Removable Disk\PORTABILITY\CONFIG)

Import Job Importing Jobs to the machine according to the processes available in the USB key’s Removable Disk directory. Export Job Exporting jobs from the machine to a USB stick according to the processes (directory: Removable Disk\PORTABI- LITY\ JOB) . Caution, older jobs on the USB stick may be deleted. To prevent data loss during data import or export, do not remove the USB ash drive or turn off the machine. The le name is linked to the machine name and serial number. Calibration Calib. Speed Feature designed to calibrate the speed of the motorised reel. The purpose of calibration is to compensate for varia- tions in reel speed in order to adjust the displayed voltage measurement and to rene the energy calculations. The procedure, once started, is explained with an animation on the screen. Calibration of the motorised reel speed must be done regularly to ensure optimal welding. Calib. The Cable Feature is also dedicated to the calibration of welding accessories such as the torch, cable and electrode holder, as well as the cables and earth clamp. The purpose of calibration is to compensate for the accessories’ length changes in order to adjust the displayed voltage measurement and to rene the energy calculations. The process, once started, is explained with an animation on the screen. Important : The cable calibration must be repeated each time the torch, harness or earth cable is changed to gua- rantee optimal welding. Information Setup data of the product’s system components: - Model - Serial number - Device name - Software version - Job and Synergies (preinstalled user settings) used. Pressing any push button will exit the information screen.8 Using the machine interface Job memories and reminders Can be accessed via the «JOB» icon on the main screen. The settings in use are automatically saved and remembered the next time you turn on the machine.In addition to the current settings, it is possible to save and remember so-called «JOB» settings.There are 500 JOBS for the MIG/MAG and TIG processes, as well as 200 for the MMA process. Data storage is based on the current process settings, the current settings and the user prole. Job This JOB mode enables JOBs to be created, saved, remembered and deleted. Quick-Load – Recall JOBs from the trigger when not welding. Quick Load is a non-welding JOB recall mode (20 max) and only possible in MIG-MAG and TIG processes.From a list of previously created JOBs, JOB recalls are done by short trigger presses. All trigger modes and welding modes are supported. Error codes The following table shows a non-exhaustive list of messages and error codes that may appear. Carry out these checks and controls before contacting an authorised GYS technician. If the user needs to open the product, they must turn off the power supply by unplugging the electrical plug and waiting two minutes for safety.Error codes Messages Solutions OVER VOLTAGE FAULTCheck the electrical installationHave your electrical installation checked by an authorised person. UNDERVOLTAGE FAULTCheck the electrical installation005 Earth current fault.There is a stray current. Check the wiring of the welding accessory (torch, earth clamp, electrode holder, etc.) COOLING UNIT FAULTThe cooling unit can no longer be detected.Check the connection between the undetected cooling unit and the power source. FLOW RATE FAULTBlocked cooling systemCheck the continuity of the coolant ow to the torch. WATER LEVEL FAULTCheck the water levelFill the cooling unit’s tank to the maximum (with coolant ref. 062511) COOLING GROUP Thermal protectionWait a few minutes for the cooling unit to cool down.Take care not to exceed the recommended duty cycle for the welding current being used.Ensure that air inlets and outlets are not obstructed. GENERATORThermal protectionWait a few minutes for the power source to cool down.Ensure that the recommended duty cycle for the welding current used is not exceeded. Thermal protection Ensure that the air inlets and outlets are not obstructed.Installing a dust lter (ref. 063143). Please note that the dust lter reduces the duty cycle.

Fan Fan faultFan Switch off the power supply by unplugging the electrical plug and check the fan. Ensure that the fan is not blocked. TRIGGERThe trigger is pressed.Remove the torch and check that the message is still applicableCheck that the «Gas purge / Wire feed» switch is not obstructed or stuck.Check that the MIG/MAG torch trigger is not obstructed or stuck.EN

MOTOR Unable to reach the required speed Check the pressure settings of the motorised reel rollers. Check that the ller wire is not blocked in the torch sheath. If it is Impossible to reach the requested speed, calibrate the speed of the motorised wire reels (Menu «Calibration»).

If overloaded, please check your settings. Release the trigger to clear Check the power source’s settings and the machine’s installation (ller wire, rollers, etc.) If the problem persists, carry out an update (Via Planet GYS).

Welding start problem Please check your welding parameters Press and release the trigger to clear. Check the power source’s settings and the machine’s installation (ller wire, rollers, etc.) If the problem persists, carry out an update (Via Planet GYS).

USB overload Unplug your USB. Change the USB stick.

An internal system error has occurred. Please restart your machine Restart your machine by turning the machine off and on again. If the problem persists, carry out update (via Planet GYS) - Error during motor calibration Recalibrate the motor reel speed (Menu «Calibration») - Error during calibration Recalibrate the welding cables (Menu «Calibration») - No more memory space in the machine Delete Jobs to free up the internal storage space.

Unsupported les %s Err %d Continue anyway? The data on the USB stick is corrupted. - Unable to save to the USB stick Free up space on the USB stick. If the problem persists, change the USB stick.

Number of attempts exceeded. Unlock code required Enter unlock code: 314159 - Wrong user code Wrong user code If the personal code is wrong, enter the correct code. By default, this code is 0000. If an unlisted error code appears or your problems persist, contact GYS Customer Service. Warning icons The alert icons at the top right of the screen provide you with more information about your product. Warning Meaning Alert meaning the machine is in Demonstration mode. Check your electrical installation (mains voltage). Blocked cooling system. Check the continuity of the torch’s coolant ow. End-of-life interface battery. Change the battery (CR2032) and update the [product’s date and time (System / Clock). The fan is not running at the right speed. Check the fan’s condition.DE