Exafeed 4L - Welding machine GYS - Free user manual and instructions

USER MANUAL Exafeed 4L GYS

INSTALLATION – FONCTIONNEMENT PRODUIT

INTERFACE HOMME MACHINE (IHM) (FIG-2)

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 caused due to non-compliance with the instructions featured in this manual . In the event of problems or uncertainties, please consult a qualied person to handle the installation properly. Read the welding machine’s instruction manual before using the wire feeder. ENVIRONMENT This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. The operator must respect the safety precautions that apply to this type of welding. In case of inedaquate or unsafe use, the manufacturer cannot be held liable for damage or injury. This equipment must be used and stored in a place protected from dust, acid or any other corrosive agent. Operate the machine in an open, or well-ventilated area. Operating temperature: Use between -10 and +40°C (+14 and +104°F). Store between -20 and +55°C (-4 and 131°F). Air humidity: Lower or equal to 50% at 40°C (104°F). Lower or equal to 90% at 20°C (68°F). Altitude: Up to 1000 meters above sea level (3280 feet).

INDIVIDUAL PROTECTIONS AND OTHERS

Arc welding can be dangerous and can cause serious and even fatal injuries. Welding exposes the user to dangerous heat, arc rays, electromagnetic elds, noise, gas fumes, and electrical shocks. People wearing pacemakers are advised to consult with their doctor before using this device. Protect yourself and others. Ensure the following safety precautions are taken: In order to protect you from burns and radiations, wear clothing without cus. 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. Use sucient welding protective gear for the whole body: hood, gloves, jacket, trousers... (variable depending on the application/ operation). Protect your eyes during cleaning operations. Do not operate whilst wearing contact lenses. It may be necessary to install reproof welding curtains to protect the area against arc rays, weld spatters and sparks. Inform the people around the working area to never look at the arc ray or the molten metal, and to wear protective clothes. 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 . Stay away from moving parts (e.g. engine, fan...) with hands, hair, clothes etc... Never remove the safety covers from the cooling trolley when the machine is plugged in - The manufacturer is not responsible for any accident or injury that happens as a result of not following these safety precautions. The pieces that have just been welded are hot and may cause burns when manipulated. During maintenance work on the torch, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. The cooling trolley must be on when using a water cooled torch in order to ensure that the liquid does not cause any burns. ALWAYS ensure the working area is left as safe and secure as possible to prevent damage or accidents.

WELDING FUMES AND GAS

The fumes, gases and dust produced during welding are hazardous. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gases away from the work area. An air fed helmet is recommended in cases of insucient 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. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to degrease the workpiece before welding. Gas cylinders must be stored in an open or ventilated area. The cylinders must be in a vertical position secured to a support or trolley. Do not weld in areas where grease or paint are stored.15 EXAFEED 4L

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. Be careful of spatter and sparks, even through cracks. It 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, the power supply 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 o. Always keep cylinders in an upright position securely chained to a xed 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 or deadly accidents. Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, earth cable, cables, electrodes) because they are connected to the welding circuit. Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged. Do not touch the torch or electrode holder and earth clamp at the same time. Damaged cables and torches must be changed by a qualied and skilled professional. Make sure that the cable cross section is adequate with the usage (extensions and welding cables). Always wear dry clothes in good condition, in order to be insulated from the electrical circuit. Wear insulating shoes, regardless of the environment in which you work in. ELECTROMAGNETIC INTERFERENCES The electric currents owing through a conductor cause electrical and magnetic elds (EMF). The welding current generates an EMF eld around the welding circuit and the welding equipment. 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 enroll the cables around your body; – never position your body between the welding cables. Hold both welding cables on the same side of your body; – connect the earth clamp as close as possible to the area being welded; – do not work too close to, do not lean and do not sit on the welding machine – do not weld when you’re carrying the welding machine or its wire feeder. People wearing pacemakers are advised to consult their doctor before using this device. Exposure to electromagnetic elds while welding may have other health eects which are not yet known. TRANSPORT AND TRANSIT OF THE WIRE FEEDER The wire feeder is equipped with handles for easy transportation. Be careful not to underestimate the machine’s weight. The handle cannot be used to hang the machine from other equipment. Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item. Do not place/carry the unit over people or objects. The removal of the wire reel from the machine is recommended before undertaking any lifting operation. The machine is tted with non-insulated lifting eye bolts, they are designed for wire feeder maintenance and not for wire feeder lifting during welding operations. If they are used during welding, the eye bolts must be insulated from the building’s earth.16 EXAFEED 4L

Stray welding currents/voltages may destroy earth conductors, damage electrical equipment or cause components to warm up which may cause a re. - All welding connections must be rmly secured, check regularly ! - Check that the metal piece xation is strong and without any electrical problems ! - Attach or hang all the electrically conductive elements,such as the trolley in order to insulate them - Do not place any electrical equipment such as drills on top of the welding machine without insulating them ! - Always place welding torches or electrodes holders on an insulated surface when they’re not in use ! INSTALLATION Rules to follow :

• The wire feeder must be switched on with all access panels closed.

• Put the wire feeder on a oor with a maximum incline of 10°.

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

• The equipment’s protection level is IP23, which means : - Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and, - Protection against the rain inclined at 60° towards the vertical. These devices can be used outside in accordance with the IP23 protection index. The manufacturer does not incur any responsability regarding damages to both objects and persons that result from an incorrect and/or dangerous use of the machine . MAINTENANCE / RECOMMENDATIONS

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

• Ensure the wire feeder is disconnected from the welding machine, and wait for two minutes before carrying out maintenance work.

• 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 connection cable between the wire feeder and the machine. If damaged, the connection cable cable must be replaced.

• Warning ! If the welding machine is transported/handled by another solution than the one recommended by the manufacturer; the wire feeder casing must be insulated from the transporting/handling solution. Rules to follow :

• The wire feeder must be switched on with all access panels closed.

INSTALLATION – PRODUCT OPERATION

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. It is recommended to use the welding cables supplied with the unit in order to obtain the optimum product settings. Risk of injury due to moving parts! The wire feeders contain moving parts that may catch hand, hair, clothes or tools which can lead to injuries! Take extra care.

• Do not place your hand on mobile/pivoting/wire feeding parts of the machine!

• Make sure that all panels remain closed when in use ! HARDWARE DESCRIPTION (FIG-1)

1- Lifting ring 9- Water connector

2- Connection cable access 10- Water connector

3- Reel support 11- Remote control cable connector

4- Wire feeding motor 12- Connection cable control connector

5- Rocker switch Wire inch / Gas purge 13- Gas connector

6- Transport handles. 14- Power relay connector

7- Man to Machine Interface 15- Water connector

8- EURO connector 16- Water connector

6- Disruption of normal operations indicator 16- 2T indicator

7- Voltage adjustment knob: 17- 4T indicator

The EXAFEED 4L wire feeder has been solely designed to operate with the EXAGON 400 CC/CV welding machine (ref. 010925).The connection between these two elements is done via one of the following connection cables :Cooling Length Section Reference Air 5m 70mm² 047587 10m 70mm² 04759495mm² 047600 15m 95mm²03834920m 038431Liquid1.8m 70mm² 0372435m 70mm² 047617 10m 70mm² 04762495mm² 047631 15m 95mm²03844820m 038455

CONNECTIONS AND RECOMMENDATIONS

The connection between the welding machine and the wire feeder must be done while the power supply is o.Connection cable on the wire feeder :- Open the connection cable’s access panel (FIG 1 - n°2)- Pass the cable through the opening at the back of the wire feeder - Lock the connection cable on the wire feeder by twisting it clockwise by 1/4 then lock the support using the screw supplied with the connection cable. - Perform the connection.Connection cable on welding machine :- Connect the earth clamp on the positive (+) or negative (-) terminal depending on the wire type.- Connect the connection cable on the remaining terminal for power.- Connect the command connector on the 10 pin DIN connector located between the welding machine’s power connectors. WIRE REEL INSTALLATION (FIG-4)

• Remove the torch shroud (FIG-4, F) and contact tip (FIG-4, E). Open the door of the machine.FIG-4, A :
• Place the reel on the driving pin of the reel support. For a 200 mm (10kg) wire reel, tighten the wire reel support to the maximum.

• Set the brake (FIG-4, 2) to prevent wire entanglement when the weld stops. In general, do not excessively tighten the brake, which would cause the motor to overheat.FIG-4, B :
• Set the rollers that t the intended use of the machine. The supplied rollers are double groove rollers (Ø1/ and Ø1.2). The indication on the visible side of the roller is the diameter in use. For a Ø1.2 mm wire, use the Ø1.2 groove. For aluminium welding, use suitable rollers (U groove). FIG-4, C :To change the wire, proceed as follows :
• Untighten the wheels (FIG-4, 4) at the maximum and lower them, insert the wire, then close the wire feed motor and tighten the wheels according to the instructions.• Start the motor by pressing the torch trigger (FIG 1 - n°5)
• Make the wire come out of the torch by 5 cm, then put a suitable contact tip at the end of the torch (FIG-4, E), as well as the shroud (FIG-4, F). Remarks :• A torch liner that is too narrow may cause wire feeding problems as well as motor overheating.• The torch connector must also be securely tightened to prevent overheating.
• Check that neither the MIG/MAG wire nor the wire reel are in contact with the machine’s mechanical parts, otherwise there si a danger of short-circuit.

MODE SELECTION ON THE WELDING MACHINE

On the machine, press the button several times until the LED light switches on below the symbol . Both display show and the knobs are inactive, all controls are now operated from the wire feeder’s interface (FIG-2).

WELDING PARAMETERS SETTINGS

1. Setting the welding voltage :

Adjust the welding voltage using the main knob depending on the work to be carried out. The voltage setpoint is indicated on the left side display.

2. Setting the wire speed :

Adjust the wire speed using the right knob depending on the work to be carried out. The speed setpoint is indicated on the right side display.18 EXAFEED 4L

While pressing the button , turn the knob , the index shows a value from -9 à +9. The lower the inductance level, the harder and more guiding the arc. The higher the inductance and the softer the arc with little splatter.

these settings are only available in Spot / Delay mode. (2)

the Hotstart settings are only available in Spot / Delay mode. (3)

the CraterFiller settings are only available in Spot / Delay mode. (5)

During welding, the machine measures and displays the welding current and voltage. After the weld, the average current and voltage values are displayed during 30 seconds, as soon as a knob or a button is pressed, the welding parameters are displayed. Depending on the operation (short-circuit, globular or spray-arc), the average voltage can slightly dier from the setpoint voltage.

SAVE AND LOAD WELDING SETTINGSS

The current settings are automatically saved and loaded at start up.On top of the current settings, it is also possible to save and load settings per each mode.There are 50 memory slotsThe saved settings include :- voltage, wire speed and inductance,- advanced settings.- 2T / 4T / SPOT DELAY modeSave new settings :- Hold buttons and during 3 seconds. appears, release the buttons.- Turn one of the two knobs . Validate by pressing the button .- The display indicates a memory set (01 to 50) while blinking.- Turn the knob to select the memory set in which the desired settings will be saved. Validate by pressing the button - The settings are saved / the menu exit is instantaneous.Load existing settings :- Hold buttons and during 3 seconds. appears, release the buttons.19 EXAFEED 4L

- Turn one of the two knobs . Validate by pressing the button .- The display indicates a memory set (01 to 50) while blinking. - Turn one of the two knobs to select the memory slot containing the settings to load. Validate by pressing the button . The settings are loaded / the menu exit is instantaneous.Quick Load mode: Easy recall of saved welding parameters : When the « Quick load » mode is active, the user can sequentially recall previously saved welding parameters, by briey pressing/releasing the trigger. Slots 2 to 50 can store customisable welding parameters. (Example : Setting 5 will allow the user to recall, using he trigger, programs 01 to 05). WELDING CYCLES 2T mode: Burnback Start Hotstart (1) Welding Crater Filler (2) Voltage Wire speed Gas Released Held Trigger (1)

If the Hotstart phase feature is deactivated, the welding starts immeditately after the arc ignition (Start). (2)

If the Crater Filler feature is deactivated, the wire is drawn back immediately after the trigger is released.20 EXAFEED 4L

4T mode: The 4T mode allows the user to manage various steps with the trigger The behaviour varies depending on the activation / deactivation of the Hots- tart and Crater Filler features. Burnback Start Hotstart (1) Welding Crater Filler (2) Voltage Wire speed Gas Released Held Trigger (1)

if the Hotstart feature is active, the Hotstart phase lasts until the trigger is released. If the Hotstart feature is deactivated, the pregas phase lasts while the trigger is held (no graph). (2)

if the Crater Filler feature is active, the Crater Filler phase lasts while the trigger is held. If the Crater Filler is deactivated, the postgas phase lasts while the trigger is held (no graph).Spot / Delay mode: The Spot / Delay is a 2T mode to weld beads of a specic length (Spot settings expressed in seconds) with a specic spacing (Delay settings expressed in seconds). If the Delay setting is set to 0.0 seconds then a single weld bead will be welded, you will have to release and press the trigger again to weld another weld bead. REMOTE CONTROL A remote control (ref. 047679) can be connected to the EXAFEED wire feeder via the connector (FIG-1, 5). The remote control acts on the voltage (1st potentiometer) and the wire speed (2nd potentiometer). Thus these settings cannot be accessed on the wire feeder’s interface. LOCKING CONTROLS That feature can lock the knobs and keypad to prevent accidental changes in the settings.Operation :Press the button for 3 seconds, the display shows and goes back to current display. The LED (FIG-2, n°13) switches on. No button is enabled, the knobs can adjust the voltage and wire speed (value at +/- of the percentage, dened by the «tol» setting) (see the welding machine’s instruction manual). To unlock the commands, press the button for 3 seconds, the display shows then goes back to current display. The LED (FIG-2, n°13) switches o.21 EXAFEED 4L

Load settings and menu exitSave settings and menu exitConfirm Quick load mode and back to main menuReset all settings for all processesAccess to advanced settingsMenu configurationExit settings menuWelding MMI outputButtons' releasePresent valueValidate tolerance settings and back to root menuPresent value22 EXAFEED 4L

settings available only in Spot / Delay mode (2)

settings avaiable only if Hot start mode is active (H.S. set to On). (4)

settings available only if Crater Filler is active (C.F. set to On) WARRANTY The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).The warranty does not cover:• Transit damage.• Normal wear of parts (eg. : cables, clamps, etc..).• Damages due to misuse (power supply error, dropping of equipment, disassembling).• Environment related failures (pollution, rust, dust).In case of failure, return the unit to your distributor together with:- The proof of purchase (receipt etc ...)- A description of the fault reported24 EXAFEED 4L

WAARSCHUWING - VEILIGHEIDSINSTRUCTIES

INTERFACE HUMAN MACHINE (IHM) (FIG-2)