Kronos 250M - Welding machine GYS - Free user manual and instructions

USER MANUAL Kronos 250M GYS

INSTALLATION – FONCTIONNEMENT PRODUIT

ANOMALIES, CAUSES, REMÈDES

GENERAL INSTRUCTIONS These instructions must be read and fully understood before use. Do not carry out 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 1000m 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 protective gloves which provide 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 procedures. 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. 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 working 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. 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.EN

User manual KRONOS 250M Translation of the original instructions 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 variations and exposure to the sun. 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 from the rating plate. 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 cable cross-section according to the intended application. Always use dry and in-fact clothing to insulate yourself from the welding circuit. Alongside this, wear well-insulated footwear in all working environments. EMC CLASSIFICATION This Class A device is not intended for use in a residential environment where power is provided by the public low-voltage local supply network. Ensuring electromagnetic compatibilty may be di󰀩cult at these sites due to conducted, as well as radiated, radio frequency interference. Provided that the impedance of the public low-voltage supply network is less than Zmax = 0.354 Ohms at the common coupling point, this equipment complies with IEC 61000-3-11 and can be connected to public low-voltage electrical supply. It is the responsibility of the tter or operator of the equipment to ensure, by consulting the electricity distribution network provider if necessary, that the network impedance complies with impedance restrictions. 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 must be taken for people with medical implants. 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,20 User manual KRONOS 250M 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 transport the welding power source or wire feeder while welding. 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 operations are to be carried out. 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 measurements 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 shield should be connected to the welding power source to ensure that there is good electrical contact between the conduit and the welding power source enclosure. 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 linking 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. It is necessary to insulate the operator 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.EN

User manual KRONOS 250M Translation of the original instructions It is advisable to remove the wire spool before lifting or transporting the welding power source.

SETTING UP THE EQUIPMENT

• 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 is IP23S rated, meaning: - its dangerous parts are protected from being entered by objects greater than 12.5 mm and, - it is protected against rain falling at an angle of up to 60° from vertical, providing that any moving parts (fan) are stationary. This product can therefore be stored outdoors in accordance with the IP23 protection rating. 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! The power cables, extensions and welding cables must be fully uncoiled to prevent 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 cable. 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 best possible product performance. DESCRIPTION This machine is a single-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 (II)

1- Reel support Ø 200/300 mm 9- Negative polarity socket

2- Accessory box hatch 10- Euro connector (torche)

3- Cable support 11- Gas connector

4- Torch support 12- Mains cable (5 m)

5- HMI (Human Machine Interface) 13- Bottle holder 4 m

8- Polarity reversal cable22

User manual KRONOS 250M Translation of the original instructions HUMAN-MACHINE INTERFACE (HMI) HMI Please read the Interface User Guide (HMI) which forms part of the complete product literature. POWER SWITCH This machine is tted with a 16A socket type CEE7/7 which must be connected to a single-phase 230V (50 - 60 Hz) power supply tted with three wires and one earthed neutral. The absorbed e󰀨ective current (I1e󰀨) is indicated 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 machine is designed to work on a 230V -20% +15% power supply. It switches to protection mode if the power supply voltage is below 185V RMS or over 265V RMS. (An error code will appear on the display screen).

• Starting is done by pressing the START/STOP switch (On), and stopping is done by pressing the same switch (O󰀨). Warning! Never switch o󰀨 the power supply while the unit is under load.

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 230 V -20% +15% and a peak voltage of less than 400V. - 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 - Cross-section of the extension cable (Length < 45m) 230 V 2.5 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. Do not over tighten as this will cause the power source to overheat.

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 0.8/1.0EN

User manual KRONOS 250M 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 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: 10 = Ø 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.- Press the trigger of the torch to activate the motor, and the procedure will be displayed on the screen..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 1.0mm (I-A). The unit is supplied with Ø 0.8/1.0 rollers for steel or stainless steel as standard. The contact tip, the grooved roller, and the torch sheath are designed for this application. For operation on steel, a specic welding gas (Ar+CO2) is required. 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 check the gas ow rate on the manometer without unwinding the welding wire, press and hold push-button n°1 and follow the procedure on the screen. This check should be done periodically to ensure the best possible welding. Refer to the HMI manual.SEMI-AUTOMATIC ALUMINIUM WELDING (MIG MODE)The unit can weld aluminium wire from Ø 0.8 to 1.2mm (I-B). 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.VideoSEMI-AUTOMATIC WELDING IN CUSI AND CUAL (BRAZING MODE)The unit can weld Ø 0.8 and 1.0 mm CuSi and CuAl wire. 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.24 User manual KRONOS 250M Translation of the original instructions

SEMI-AUTOMATIC WELDING WITH CORED WIRE

The unit can weld ux-cored wire from Ø 0.9 to 1.2mm. The original rollers must be replaced by specic cored wire rollers (available as an optional extra). 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.

Polarity + Polarity - Gas-shielded MIG/MAG welding generally requires 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 (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 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 - FeAr 15% CO2

Choice of the material to be welded. Synergic welding parameters Wire diameter Ø 0.6 > Ø 1.2mm - Choice of wire diameter 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.EN

User manual KRONOS 250M Translation of the original instructions WELDING PROCESSES For more information on GYS pre-installed user settings and welding processes, scan the QR code:

• 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 %/s This idling current is the next phase after the current is lowered. The intensity (% of welding current) and the time (seconds) can be programmed. 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. Crater-ll feature s Downslope current. 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. 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. Spot welding s Set duration. Voltage V Control over the cord’s width. Upslope s Upslope current 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.

To check the gas ow rate on the manometer without unwinding the welding wire, press and hold push-button n°1 and follow the procedure on the screen. This check should be done periodically to ensure the best possible welding. Refer to the HMI manual.

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

• Connect the earth clamp to the positive (+) plug connector. Connect the optional TIG torch (ref. 046108) into the EURO connector of the power source and the polarity reversal cable into the negative (-) socket.

• 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 current26 User manual KRONOS 250M Translation of the original instructions RECOMMENDED COMBINATIONS (mm) Current (A) Ø Electrode (mm) Ø Nozzle (mm) Argon ow rate (L/min)

PROCESS SETTINGS Settings Settings Welding process Standard Smooth current Pulsed Pulsed current Spot welding Smooth tacking Spot-Pulse Pulsed tacking Trigger mode 2T, 4T, Valve Choice of trigger welding management mode. 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. SETTINGS

• Standard 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.

• Pulse 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 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-Pulse This method of welding is used to pre-assemble thin sheet metal workpieces prior to the actual welding process. 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.

User manual KRONOS 250M Translation of the original instructions

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󰀨. 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.

CONFIGURING THE SETTINGS

Units End current % This idling current is the next phase after the current is lowered. Starting current % This start-up bearing current is a warm-up phase before the current is raised. Welding current A Welding current. Cold current % Second welding current known as a «cold» welding current. Pulse duration s Manual or time-controlled spot pulse phase Spot duration s Either manual or a set time. Crater-ll feature s Avoids cratering at the end of welding and the risk of cracking, particularly in light alloys. Frequency frequency

Pulse frequency (setting guidelines): - If welding with manual ller metal, then the F(Hz) is synchronised to the ller action, - If the metal is thin and without ller (< 0.8mm), F(Hz) > 10Hz - If welding in position, then F(Hz) < 100Hz Rising current s Allows a gradual increase in welding current. Post-Gas s Duration of the gas protection after the arc is extinguished. It protects the workpiece and the electrode from oxidation during cooling. Pre-Gas s When the torch is bled and the gas shield is created before ignition. Stopping time s This idling time is a phase that comes after the current is lowered. Starting time s Starting time before the current is raised. Cold weather % Pulsed hot current (I) time balance 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.

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 button no. 1 and follow the on-screen procedure. Refer to the HMI manual.

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.28 User manual KRONOS 250M Translation of the original instructions PROCESS SETTINGS Welding processes Settings Settings Standard Pulsed Electrode type Rutile Basic The type of electrode determines the settings in order to optimise its weldability depending on the type of electrode used. Anti-Sticking ON-OFF 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). 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

• Standard 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.

• Pulse 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 screen. 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.

CONFIGURING THE SETTINGS

Units Arc Force Arc Force is an overcurrent administered to prevent sticking when the electrode or weld bead touches the weld pool. Welding current A The welding current is determined by the type of electrode chosen (see electrode packaging). Duration of Hot Start s 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. Pulse frequency Hz PULSE mode’s PULSING frequency. Percentage Hot Start % 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. Percentage I cold % Cold weather s 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.

ADJUSTING THE WELDING INTENSITY

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)

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.EN

User manual KRONOS 250M Translation of the original instructions

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 200.30 User manual KRONOS 250M Translation of the original instructions 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

the update. 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. : cables, clamps, etc.).

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

• Environment-related faults (such as pollution, rust and dust). In the event of a breakdown, please return the appliance to your distributor, along with: - dated proof of purchase (receipt, invoice, etc.), a note explaining the malfunction.DE

WAARSCHUWINGEN - VEILIGHEIDSINSTRUCTIES

MMA (SMAW) LASMODULE

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)

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 KRONOS 250M KRONOS 250T KRONOS 320T

WF 35 Software version This manual covers the following software versions:

The software version of the interface is displayed in the general menu: Système / Information12 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. MIG-MAG (GMAW/FCAW) TIG (GTAW)

Current welding process Schedule, Traceability 2 Current settings

Gas ow control (Hold down / long press) BP1 4 Current process settings BP1 5 Push-button no. 1 (BP1)

Navigation/setting thumbwheel Short press to conrm Long press = General menu 7 Push-button no. 2 (BP2) 8 Advanced settings BP2 9 Access to the JOB (long press) BP2

Current welding process Schedule, Traceability 2 Current settings 3 Gas purge (long press) BP1 4 Current process settings BP1 5 Push-button no. 1 (BP1)

Navigation/setting thumbwheel Short press to conrm Long press = General menu 7 Push-button no. 2 (BP2) 8 Advanced settings BP2 9 Access to the JOB (long press) BP2EN

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. MMA (SMAW)

Current welding process Schedule, Traceability 2 Current process settings BP1 3 Push-button no. 1 (BP1)

Navigation/setting thumbwheel Short press to conrm Long press = General menu 5 Push-button no. 2 (BP2) 6 Advanced settings BP2 7 Long press BP2 (Hold down) BP214 Using the machine interface 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.Processes SettingsSystemPortability Processes MIG-MAG (GMAW/FCAW) Semi-automatic, gas shielded welding TIG (GTAW) Gas shielded welding with a non-fusible tungsten electrode MMA (SMAW) Arc welding with a coated electrodeEN

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)). System Device name: Device name information and customisation options. Clock: Setting the time, date and format (AM/PM). Cooling unit (only for machines equipped with a cooling system) - OFF: the cooling unit is deactivated. - ON: the cooling unit is permanently active. - AUTO: automatic operation (activates during welding and deactivates 10 minutes after the end of welding) PURGE : function specically dedicated to the purging of the cooling unit or lling of the hoses, the protections are disabled (see the general instructions for safe purging of your product). Information Conguration data of the product’s system components: - Model - Serial number - Device name - Software version Press push-button no. 2: Exporting the machine conguration to the USB stick (not supplied) Productivity Product usage data : - Ignition time - Welding time - etc. Reset Resets the product settings: - Partial: defaults the values of the current welding process. - Total: all the machine’s conguration will be reset to the factory settings.16 Using the machine interface Traceability

*This feature is not activated as default. It can be activated via the online congurator, available on Planet GYS / Tools / Product conguration. To activate it, contact your distributor. This welding management interface is designed to trace/record all the steps of the welding operation, bead by bead, during manufacturing. This qualitative approach ensures a post-production welding quality that allows the analysis, evaluation, re- porting and documentation of the recorded welding parameters. 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 with a USB stick.

1- Start - Creation of traceability

• Customise the name of the job by pressing the thumbwheel.• Sampling interval:- Hold: No recording of current/voltage values (average along the wire) during welding. - 250 ms, 500 ms, etc. : recording of current/voltage values (average along the wire) every «X» milliseconds or seconds during welding.Press «REC» to start traceability Traceability display At the top left of the main screen, a red symbol is displayed to indicate that a record is being made for traceability. Stop - Stopping traceability To end tracking during a welding operation, the user must return to the Traceability block and select «Stop». Exporting The recovery of this information is done by exporting the data to a USB stick (not supplied).The CSV data can be processed with a spreadsheet program (Microsoft Excel®, Calc OpenO󰀩ce®, etc).The le name is linked to the machine name and serial number.

2- Start - Traceability management

The screen lists previously created jobs. Short presssing push-button no. 1 returns to the previous menuHolding down on push-button no.1 ( ) deletes the active job or all jobs.Holding down push-button no. 2 ( ) creates a new traceability.Short pressing push-button no. 2 ( ) allows you to see the details of each of the previously created jobs.EN

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. Calibration Calib. Cables Function dedicated to the calibration of welding accessories such as MIG torch, or electrode holder and ground clamp cables. The purpose of calibration is to compensate for variations in the length of the accessories in order to match the selected voltage value. Once started, the proceedure is illustrated with an animation on the screen. Important: The cable calibration must be repeated each time the torch, harness or ground cable is changed to ensure optimal welding performance. Gas ow control (MIG-MAG) In the main screen, holding down on button no. 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. Gas purge (TIG) 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 button no. 1 and follow the on- screen procedure.18 Using the machine interface Wire loading (MIG-MAG) To unwind the wire in the MIG/MAG torch without using gas, please follow the procedure below:1- Hold the trigger down in a non-welding position.2- When the process is shown on the display, you can release the trigger.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.If you wish to exit the animation without waiting for the wire to nish feeding, press the trigger briey. 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 for the MIG/MAG process and 100 for the TIG and MMA process. The storage is based on the current pro-cess 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. Short presssing push-button no. 1 returns to the previous menuHolding down push-button no. 1 ( ) deletes the selected Job or all the Jobs.Short pressing push-button no. 2 ( ) allows you to see the details of each of the previously created jobs. QuickLoad – Recall JOBs from the trigger when not welding. QuickLoad is a mode to recall jobs (20 max) outside of welding, and is 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.

1- New - Creating a QuickLoad

• Customise the name of the QuickLoad by pressing the thumbwheel.• Choose the number of jobs to be recalled, between 2 and 20.• Choose the trigger sensitivity: slow, normal or fast• Choice of Jobs to be recalledPress push-button no. 2 to conrm the creation of a QuickLoad.EN

The screen lists previously created QuickLoads. Short presssing push-button no. 1 returns to the previous menu Holding down push-button no. 1 ( ) deletes the selected QuickLoad or all the QuickLoads.Holding down push-button no. 2 ( ) allows the selected QuickLoad to be modied.Short pressing on push-button no. 2 ( ) allows you to see the details of each of the previously created QuickLoads. 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 errorMessages 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, electrode holder, etc.) COOLING UNIT FAULTCooling unit not detectedThe cooling unit is no longer being detected. Check the connection between the cooling unit and the power source. FLOW ERRORCooling circuit blockedCheck the continuity of the torch’s coolant ow.Check the fuse of the cooling unit. WATER LEVEL ERRORCheck the coolant levelFill the tank of the cooling unit to the maximum (recommended coo-lant: Ref. 062511) COOLING UNITThermal protectionWait a few minutes for the cooling unit 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. 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.

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 pressedRemove the torch and check to see if the message is still active.Check that the «Gas purge / Wire feed» switch is not blocked..Check 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.20 Using the machine interface

Overload, please check your settings Press and release the trigger to erase Check 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-up Please check your welding parameters Press and release the trigger to erase Check the power source settings and installation (welding wire, rol- lers, gas, torch, etc.) If the problem persists, update the software (via Planet GYS).

USB overload Disconnect your USB Change the USB stick.

An internal system error has occurred. Please restart your product Turn the product o󰀨 and on again. If the problem persists, update the software (via Planet GYS) - Calibration error Recalibrate the welding cables («Calibration» menu)

The product’s memory space is full. Delete Jobs to free up internal storage space.

File %s not supported Err %d Continue anyway? The data on the USB stick is corrupted. Check your data. - Unable to write to USB stick Free up some space on the USB key. If the problem persists, change the USB stick..

The USB stick is not recognised. The display of step 5 of the update procedure does not appear on the screen (see general instructions).

1- Insert the USB key into its socket.

2- Turn on the power source.

3- Hold down on the HMI thumbwheel to force the update.

If an error code which is not listed appears or your problems persist, contact your distributor.21