Auto E3 - Welding machine GYS - Free user manual and instructions

USER MANUAL Auto E3 GYS

02-07 / 38-47 / 78-88

INSTALLATION – FONCTIONNEMENT PRODUIT

ANOMALIES, CAUSES, REMÈDES

GENERAL INSTRUCTIONS These instructions must be read and fully understood before use. Do not undertake any alterations or maintenance work that is not directly specied in this manual. The manufacturer shall not be liable for any damage to persons or property resulting from use not in accordance with the instructions in this manual. 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 the event 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. Ensure good air circulation when in use. Temperature range: Use between -10 and +40°C (+14 and +104°F). Store between -20 and +55°C (-4 and 131°F). Air humidity: Lower 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 source of heat, light radiation from the arc, electromagnetic elds (caution to those using pacemakers) and risk of electrocution, as well as noise 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. Inform people in the welding area not to stare at the arc rays or molten parts and to wear appropriate clothing for protection. 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 hands, hair and clothing away from moving parts (the ventilation fan, for example). 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. It is important to secure the work area before leaving it in order to protect people and property.

WELDING FUMES AND GAS

The fumes, gases and dusts emitted by welding are harmful to health. Su󰀩cient ventilation must be provided and an additional air supply may be required. An air-fed mask could be a solution in situations where there is inadequate ventilation. Check the extraction system’s performance against the relevant safety standards. Caution: Welding in conned spaces requires safety monitoring 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

User manual E1 - E2 - E3 GYS AUTO Translation of the original instructions Cylinders should be stored in open or well-ventilated areas. They should be stored in an upright position and kept on a stand or trolley. Welding should not be carried out near grease or paint.

RISK OF FIRES AND EXPLOSIONS

Fully shield the welding area, ammable materials should be kept at least 11 metres away. Fire ghting equipment should be kept close to wherever the welding activities are being undertaken. 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. Welding in closed containers or tubes is to be avoided. If the containers or tubes are open, they must be emptied of all ammable or explosive materials (oil, fuel, gas residues, etc.). Grinding work must not be directed towards the source of the welding current or towards any ammable materials. GAS CYLINDERS Gas escaping from cylinders can cause su󰀨ocation if there is too high a concentration of it in the welding area (ensure good ventilation). The machine must be transported in complete safety: gas cylinders must be closed and the welding power source turned o󰀨. They should be stored upright and supported to limit the risk of falling. Close the cylinder between uses. Beware of temperature changes and sun exposure. The cylinder must not come into contact with ames, arcs, torches, earth clamps or any other sources of heat or ignition. Be sure to keep it away from electrical and welding circuits. 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. An electric shock can be the source of a serious accident, whether directly or indirectly, 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 use high-quality, dry 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 complies with the IEC 61000-3-12 standard. 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 - securing them with a clamp if possible;

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

• never wrap the welding cables around your body,

• 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.20 User manual E1 - E2 - E3 GYS AUTO Translation of the original instructions 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 moved 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 transportation 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 machine benets from an IP21 protection index, which means: - its dangerous parts are protected from being entered by objects greater than 12.5 mm and, - Protection against vertically falling drops 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.

INSTALLATION - USING THE PRODUCT

Only experienced personnel, authorised by the manufacturer, may carry out the machine’s set-up. During set-up, ensure that the power source is unplugged 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 optimum product settings. DESCRIPTION The unit is a semi-automatic «synergic» welding unit, ventilated for welding (MIG or MAG). This machine is recommended for welding steel, stainless steel, aluminium and the brazing. Its adjustment is quick and easy with its «synergic» mode. DESCRIPTION OF THE EQUIPMENT (II)

1- Reel support Ø 200/300 mm 8- Euro connector (torche)

2- Accessory box hatch 9- Storage space

3- Cable support 10- Gas connector

1- Gas connector (torch 1) 10- Euro connector (torch 1)

2- Gas connector (torch 2) 11- Euro connector (torch 2)

3- Reel support Ø 200 mm (torch 1) 12- Bulkhead connector for gas

4- Reel support Ø 200/300 mm (torch 2) 13- Mains cable (6.25 m)

5- Cable support 14- Bottle holder 4 m3 or 2 x 4 m3

6- Torch support 15- USB hatch

7- HMI 16- Wire-feed motor (torch 1)

2- Gas connector (torch 2) 12- Euro connector (torch 1)

3- Gas connector (torch 3) 13- Euro connector (torch 2)

4- Reel support Ø 200 mm (torch 1) 14- Euro connector (torch 13

5- Reel support Ø 200 mm (torch 2) 15- Bulkhead connector for gas

6- Reel support Ø 200 mm (torch 3) 16- Mains cable (6.25 m)

7- Cable support 17- Bottle holder 4 m3 or 2 x 4 m3

8- Torch support 18- USB hatch

HUMAN-MACHINE INTERFACE (HMI) HMI Please read the Interface (HMI) manual which is part of the equipment’s user literature. POWER SWITCH The material is supplied with a 16A plug type CEE7/7 and must only be used on a single-phase electrical installation 230V (50-60 Hz) with 3 wires including one connected to earth. The absorbed e󰀨ective current (I1e󰀨) is shown on the device for optimum operating conditions. Check that the power supply and its safeguards (fuse and/or circuit breaker) are compatible with the electric current being used. In some countries, it may be necessary to change the plug to allow the use at maximum settings.

• The power source is designed to operate on 230 V -20% +15%. The machine goes into protection mode if the supply voltage is below 185 Ve󰀨 or above 265 Ve󰀨. (an error code will appear on the display screen).

• The power is switched on by pressing the START/STOP switch (On), conversely switching o󰀨 is done by pressing the same switch (O󰀨). Warning! Never disconnect the machine from the power supply while the machine is charging.

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, and the RMS value must be 230 V -20% +15%, with peak voltage below 400V, - The frequency must be between 50 and 60 Hz. It is imperative to check these requirements, as many generators generate high voltage peaks that can damage these machines.

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 Extension lead cross section (<45m) 230 V 2.5 mm²

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

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. Do not over tighten as this will cause the power source to overheat.LOADING THE FILLER WIRE

To change the rollers, do the following:- Loosen the knob (a) to the maximum and lower it. - Unlock the rollers by removing the retaining screws (b)- Fit the appropriate drive rollers for your application and retighten the retaining screws. The rollers supplied are double groove rollers :- steel Ø 0.6/0.8 (E1 + E2 + E3)- steel Ø 0.8/1.0 (E3)- aluminium Ø 0.8/1.0 (E2 + E3).- Check the inscription on the roller to ensure that the rollers are suitable for the wire diameter and the wire material (for Ø 1.0 wire, use the Ø 1.0 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: 1.0) : groove to be used

To install the wire, follow the steps below:- Loosen the knob to the maximum and lower it. - Insert the wire, then close the motor reel and tighten the knob as shown.- Operate the motor via the trigger of the torch.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’s spool.SEMI-AUTOMATIC STEEL/STAINLESS STEEL WELDING (MAG MODE)This machine can weld steel and stainless steel wire from Ø 0.6 to 1.0 mm (I-A).E1 / E2 : The unit is supplied with Ø 0.6/0.8 rollers for steel or stainless steel as standard. E3 : The unit is supplied with Ø 0.6/0.8 and Ø 0.8/1.0 rollers for steel or stainless steel as standard. The contact tip, the sheave groove and the welding torch sheath are designed for this use. 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. For stainless steel, use a 2% CO2 mixture. When welding with pure CO2, it is necessary to connect a gas pre-heater to the gas cylinder. 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. To measure the gas ow rate at the torch outlet, it is recommended to use the optional ow meter (ref. 053939).24 User manual E1 - E2 - E3 GYS AUTO Translation of the original instructions SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE) This machine can weld aluminium wire from Ø 0.8 to 1.2 mm (I-B) (Ø 1.2 mm, non-intensive welding). E2 / E3 : The unit is supplied as standard with Ø 0.8/1.0 rollers for aluminium. For use with aluminium, pure argon gas (Ar) is required. Seek advice from a gas distributor for a wide selection of gases. The gas ow rate for aluminium is between 15 and 20 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. - Only use the capillary tube (for guiding the wire between the feed rollers and the EURO connector) for steel/stainless steel welding (I-B) - 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 (for aluminium welding), it is recommended to use the accessory 90950 (I-C). 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 1.0 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. For brazing, pure argon (Ar) should be used.. GAS SUPPLY Bulkhead connector : E2 / E3 - Fit a suitable pressure regulator to the gas cylinder. Connect to the machine with the hose(s) sup- plied, see diagram on page 6. Fit the 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 (L/min) MIG 0.8-2 20-100 0.8 12 10-12 2-4 100-200 1.0 12-15 12-15 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

MIG / MAG (GMAW/FCAW) WELDING MODE

Welding processes Settings Settings Manual Synergies (pre-installed user settings) Torque material/gas - Fe Ar 15% CO

User manual E1 - E2 - E3 GYS AUTO Translation of the original instructions Using the trigger 2T, 4T Choice of trigger welding management mode Spot mode Spot, Spot-Delay Selecting the spot mode First Setting Thickness Start-up Speed

Choosing the main setting to be displayed (thickness of the workpiece, average welding current or wire speed). Access to some of the welding parameters depends on the selected display mode: Settings/Display mode: Easy or Expert. Refer to the HMI ma- nual. WELDING PROCESSES For more information on GYS pre-installed user settings and welding processes, scan the QR code: 2 WELDING MODES (EASY)

• Welding (continuous)

• Stitch Welding This function allows the assembly of very thin sheet metal while limiting the risk of piercing and deformation of the material. Chain-stitch welding is done manually with the trigger. SPOT MODE (EXPERT)

• Spot 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.

• Spot-Delay This is a welding mode similar to Spot welding but with predened weld and dwell times, as long as the trigger is held down. This function allows welding very thin steel or aluminium metal sheet, limiting the risk of piercing and distortion (especially for aluminium welding).

CONFIGURING THE SETTINGS

Units Burnback - Feature to help prevent the wire sticking to the bead. This is timed to coincide with the wire rising from the weld pool. Crater Filler - This idling current is the next phase after the current is lowered. Delay s Time between the end of a point (excluding Post-Gas) and the start of a new point (including Pre-Gas). Thickness mm The pre-installed user settings (syngergies) allow for a fully-automatic set-up. Changing the thickness setting automatically sets the appropriate wire tension and speed. Hot Start - The Hot Start is an overcurrent used at the start that prevents the wire from sticking to the workpiece. Current A The welding current is adjusted according to the type of wire used and the material to be welded. I Start - Adjustment of the ignition current. Arc length - Used to adjust the distance between the end of the wire and the weld pool (tension adjustment). Pre-Gas s When the torch is bled and the gas shield is created before ignition. Tack welding s Set duration. Post-Gas s Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from oxidation. Self-Induction Coil - Lessens the welding current more or less. To be set according to the welding position. Voltage V Control over the cord’s width. Approach speed - Progressive yarn speed. Before priming, the wire moves slowly to create the rst contact without jolting. Wire speed m/min Amount of ller metal deposited and consequently the welding intensity and penetration. Access to some of the welding settings depends on the selected welding process (Manual, Standard, etc.) and the selected display mode (Easy, Expert or Advanced). Refer to the HMI manual.26 User manual E1 - E2 - E3 GYS AUTO Translation of the original instructions

In the main screen, a long press on button N°1 allows you to adjust the gas ow on the manometer without unwinding the supply wire. Once started, the proceedure is illustrated with an animation on the screen. The gas ow setting should be checked periodically to ensure optimal welding.

DEFECTS: CAUSES & SOLUTIONS

SYMPTOMS POSSIBLE CAUSES SOLUTIONS

The ow rate of the welding wire is not constant. Clogs blocking the opening. Clean the contact tube or replace it with non- stick material. The wire is slipping on the rollers. 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 unwinding mechanism is not working. The spool’s brake or roller is too tight. Loosen the brake and rollers. Incorrect unwinding of the wire. Dirty or damaged wire guide. Clean or replace. Roller pin key is missing. Reposition the pin in its slot. Spool’s brake is too tight. Release the brake. No current or wrong welding current. Incorrect mains outlet connection. 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. The wire jams after passing through the rollers. Crushed wire guide sheath. Check the wire-guide sheath and body of the torch.. Wire blockage 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 the 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 200. Automatic deletion of JOBS. Some of your JOBs have been deleted because they were incompatible with the new pre-installed user settings (synergies).

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. Update problem The USB stick is not recognised. The visuali- sation of step 5 of the update procedure does not appear on the display.

1- Insert the USB key into its socket.

2- Turn on the power source.

3- Hold down on the HMI thumbwheel to force

Diameter Part Number (x2) Steel Aluminium ø 0.6/0.8 042087 - ø 0.8/1.0 042360 042377 ø 1.0/1.2 - 040915 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 during transport.

• The general wear and tear of parts (i.e. : clamps, etc.).

• Incidents caused by misuse (incorrect power supply, dropping or dismantling).

WAARSCHUWINGEN - VEILIGHEIDSINSTRUCTIES

7- IHM 16- Trainalo (torcia 1)

RYZYKO POŻARU I WYBUCHU

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.

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 60974-5.

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)

Protec- ted against access to dangerous parts of solid bodies with a diameter >12.5mm (equivalent to the nger of the hand) and against vertical drops of water.

Fan cooled hardware.

The safety disconnection device is a combination of the power socket in coordination with the electrical installation. The user has to make sure that the plug can be reached.

This interface (HMI) manual forms part of the complete item documentation. A general manual is included with the product. Read and follow the general manual’s instructions, particularly the safety instructions! For use and application to the following products only

Software version This manual covers the following software versions:

The software version of the interface is displayed in the general menu: Système / Information8 Using the machine interface Control of the power source The main screen displays all the information needed before, during, and after welding. The interface is adjustable with 2 di󰀨erent display modes: Easy or Expert. Easy Expert ThicknessWelding

Torch used (E2 / E3) Schedule 2 Current settings

Welding mode choice: Welding/Stitch Welding 5 Push-button no. 1 (BP1)

Navigation thumbwheel Short press to conrm Long press = General menu 7 Push-button no. 2 (BP2) 8 Current process settings

Torch used (E2 / E3) Schedule 2 Current settings

Long press BP2 Access to JOB Easy Mode: This streamlined display mode is ideal for achieving optimum weld quality. - 2 welding modes: Welding and Stitch Welding - 4 settings : Choice of welding material (synergies), ller wire diameter, thickness, and arc length. Expert Mode : This more extensive display mode is designed for more experienced welders. - Welding modes: Synergic or Manual - Trigger behaviour: 2T or 4T - Spot modes: Spot and Spot-Delay - Selection of the main setting to be presented on the display - Full adjustment of the welding cycle: Arc length, inductance, Pre-gas, Hot Start, Burn Back, Post gas, etcEN

General menu The navigation between the di󰀨erent sections is done with the thumbwheel.From the home screen, a long press on the thumbwheel takes you to the main menu.Briey pressing button no. 1 ( ) returns to the previous menu or accesses the main screen.Settings SystemPortability Settings Display mode - Easy: simplied display suitable for the vast majority of users.- Expert: comprehensive display suitable for more experienced welders. Allows you to adjust the durations of the di󰀨erent phases in the welding cycle. Language Choice of the interface language (French, English, German, etc). Units of measurement Choice of measurement units: International (SI) or Imperial (USA). Name of materials European standard (EN) or American standard (AWS). Luminosity Adjusts the brightness of the interface screen (setting from 1 (dark) to 10 (very bright)).10 Using the machine interface System Device name: Device name information and customisation options. Clock: Setting the time, date and format (AM/PM). Information Conguration data of the system components: - Model - Serial number - Device name - Software version Press push-button no. 2 : Exporting the machine conguration to the USB stick (not supplied) Reset Resets product settings: - Partial: defaults the values of the current welding process. - Total: all the machine’s conguration will be reset to the factory settings. Portability Import Cong. Loading the conguration from the USB stick (directory: Removable disk\Portability\Cong) to the machine. Holding down on the push-button no. 1 ( ) deletes the congurations on the USB stick. Export Cong. Export the machine conguration to the USB stick (directory : Removable disk\Portability\Cong). 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 the USB stick procedure (directory : Removable disk\Portability\Job). Caution, old 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 o󰀨 the machine. The le name is linked to the machine name and serial number. The USB stick is not included.EN

Gas ow control In the main screen, a long press on button N°1 allows you to adjust the gas ow on the manometer without unwinding the supply wire. Once started, the proceedure is illustrated with an animation on the screen. The gas ow setting should be checked periodically to ensure optimal welding. Wire loading To unwind the wire in the MIG/MAG torch without using gas, please follow the procedure below:

1- In the non-welding position, hold the trigger down without releasing it.

2- A procedure is shown automatically on the display.

3- The wire starts to feed. 3m of wire feeds at a speed of 5m/min by default. You can change these va-

lues with the thumbwheel. Job memory and recalls Accessible through 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 active settings, it is possible to save and recall «JOB» congurations.. There are 200 JOBS. The storage is based on the current process parameters, and the current settings. Job This JOB mode allows you to create, save, recall and delete JOBs.

1- Save As - Creating a Job

Customise the job name by pressing the thumbwheel. Conrm by pressing push-button no. 2. Display the current job At the bottom right of the screen, the job number is displayed. Stop the current job To close the current job, the user must return to the Job menu and select «Close».

2- Open - Jobs Management

The screen lists previously created Jobs. Holding down push-button no. 1 deletes the active job or all jobs. Short presssing push-button no. 1 returns to the previous menu Short pressing push-button no. 2 allows you to see the details of each of the previously created jobs..12 Using the machine interface Error codes The following table shows a non-exhaustive list of messages and error codes that may appear. Carry out these checks and inspections before calling in an authorised GYS technician. If the user needs to open the product, they must turn o the power supply by disconnecting the electrical plug from the socket, and wait two minutes for safety. Codes Error Messages Solutions

OVER-VOLTAGE FAULTCheck the electrical installationHave your mains supply checked by an authorised person. UNDER-VOLTAGE FAULTCheck the electrical installation005 Earth current faultPresence of a stray current. Check the cabling of the welding acces-sories (torch, ground clamp, etc.) POWER SOURCEThermal protectionWait a few minutes for the power source to cool down.Ensure that the recommended duty cycle for the selected welding current used is not exceeded.Ensure that air inlets and outlets are not obstructed.

Fan Fan default.Switch o󰀨 the power supply by unplugging the mains connector, and check that the fan is not blocked. TRIGGERA trigger is being pressedCheck that the trigger on the MIG/MAG torch is not blocked or stuck. MOTORUnable to reach the required speedCheck the pressure settings on the wire-feeding rollers.Check that the welding wire is not blocked in the torch liner. Overload, please check your settingsPress and release the trigger to eraseCheck the power source settings and installation (welding wire, rol-lers, gas, torch, etc.)If the problem persists, update the software (via Planet GYS). Problem with welding start-upPlease check your welding parametersPress and release the trigger to eraseCheck the power source settings and installation (welding wire, rol-lers, gas, torch, etc.)If the problem persists, update the software (via Planet GYS). USB overloadDisconnect your USBChange the USB stick. An internal system error has occurred.Please restart your productTurn the product o󰀨 and on again.If the problem persists, update the software (via Planet GYS)- The product’s memory space is full. Delete Jobs to free up internal storage space. File %s not supportedErr %dContinue anyway?The data on the USB stick is corrupted. Check your data.- Unable to write to USB stickFree up some space on the USB key.If the problem persists, change the USB stick.. If an error code which is not listed appears or your problems persist, contact your distributor.DE