1 Mise à jour : 26/06/06 Réf 73502 MIG 7

INSTRUCTION MANUAL

FOR SEMI-AUTOMATICAL

WELDING MACHINES

IMS MIG PRO 41/35

EC MARKING

This product has been designed in respect of the Low Voltage Directives 73/23 EEC dated 19th February 1973 (amended 93/68/EEC) and the electromagnetic compatibility directives EMC 89/336/EEC dated 3rd May 1989, (amended 92/31/EEC, 93/68/EEC,1 91/263/EEC). This conformity is established in compliance with the standardized norms EN 50199 dated 1995 (Directive EMC), EN 60974-1 dated 1998, and amendments A1 dated 2000 and A2 dated 2003.

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Thank you for choosing our product! Before installing and using the product, or maintenance, please read carefully the following recommendations about safety norms in order to avoid accidents to the users and damages of the welding process. GYS can’t be responsible for the damages occurred to persons or things, which derive from the use of the machine in following circumstances: - Modification or neutralization of safety elements, - Non respect of the recommendations written in the manual instruction, - Modification of the characteristics on the product - Use of the accessories, which are different than the ones delivered by GYS,

- Non-respect of the regulating and particular dispositions where the machine is settled.

I/ SAFETY STANDARDS AND GENERAL PRECAUTIONS

GENERALITIES 1. Before disassembling the product’s body, plug out the lead cable

2. The operators must have the appropriate qualification.

3. The operations of servicing can only be controlled by qualified technicians.

4. The operator is responsible for respect of the car manufacturers’ recommendations, concerning the protection

of electrical and electronic procedures (car computer, car radio, alarm, air bag, etc…)

5. It is necessary to make a regular preventive maintenance.

ELECTRICITY

1. Check that the unity must be connected to the earth coupler and that the connection to the earth is in

good condition.

2. Check that the workbench is connected to the earth coupler.

3. Make sure that the operator has no contact with the metal parts to the welded without any protection or

wet clothes.

4. Avoid being in contact with welding part

5. Before controlling or repairing, please disconnect the unit directly to the level of the plug.

PROTECTION OF EYES AND BODY

1. During the welding process, the operator must be protected from the eventual flashes of the electrical arc with protection clothes like leather gloves, welding aprons, safety shoes, welding helmets or glasses for filtering

radiations and projections. As well during operations of rubbing and hammering, the operator must protect his

eyes.

2. All the protection board must be in good condition and maintained in place.

Never look at an arc of welding without any protection of your eyes.

Protect the environment near the product against projections and reflections.

SMOKES AND GAS

Welding operations can cause the emission of toxic smokes and harmful metallic dusts. Use the device in a sheltered place equipped with smoke aspirators. The operator must wear an anti smoke mask. The welding material must be degreased and cleaned in order to limit the toxic gas during the welding process.

FIRE

1. Check that the sparks don’t cause fire especially near inflammable material. 2. Check that fire extinguishers are not too far from the operator. 3. Leave the product in a place with air movers. 4. Don’t weld neither on container of combustibles and lubricants, even empty, nor on containers with inflammable material. 5. Don’t weld in an atmosphere full with inflammable gas or fuel steam.

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ELECTRO-MAGNETIC COMPATIBILITY

Near the spot-welding, check: - There is neither no other power supply cable nor control lines, nor phone cables, nor radio or TV reception appliances, nor watches, nor mobile phones, nor magnetic cards, nor computers or any other electronic appliance. - There are in the surroundings (minimum 3 meters of each point of the product) no persons using active medical appliances (pacemakers, acoustic prosthetics). Make supplementary protections if other products are used in the same environment.

II / CONNECTIONS OF POWER SUPPLY CABLES

Electricity :

Three phases 400V 50Hz. Use of the PHASE 1, PHASE 2, PHASE3 and EARTH CONNECTION on a three phases plug (Don’t use NEUTRAL).

Protection of the line : Fuse 25A curve D ou fuse 25A type aM III/ DESCRIPTION OF THE MACHINE

MIG PRO 41/35 : Higher part

Indicator of VOLTAGE or WIRE SPEED measurement

Potentiometer of instructions wire speed.

Selection indicator of value (wire speed or voltage).

Selection indicator of value (voltage or wire speed).

Yellow indicator of thermal switching

Button of WIRE quick: it allows for new coils loading to save gas.

Indicator of current measurement

Indicators of mode selection: 2 times, 4 times or spot

Button of gas drain: it allows to avoid impurity during bottle replacement or after a long immobilization.

Commutator On / Off Button of mode selection

Button of spot time adjustment

Poste MIG PRO 41 / 35

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MIG PRO 41/35 : Foreside (Lower part)

Generator wire feeder (connected to positive terminal).

Selection commutators of the output voltage.

Gas connection allows to lay in gas generator wire feeder type WF. The connection is situated near to the motor

Terminal – to use a superior current 200 A (position for an using in SPRAY ARC).

Operating connector for application with a separated wire feeder type WF.

Positive terminal for an application with a separated wire feeder type WF.

Commutator on wire feeder choice. Position I: generator wire feeder (origin). Position II: separated wire feeder WF 212, 324 or 344 W (in option).

Terminal – application on weak Thickness (current inferior to 200 A)

IV / COMMISSIONING

4-1) Mains connection See paragraph III.

4-2) Connection to gas bottle and gas choice

Screw down the regulator on gas bottle. This one is connected to MAGYS and GENEGYS by a pipe whose terminal end is fixated on the electronic valve behind the machine. You must use clamps to avoid escape of gas.

MIG PRO 41/35

Application with the wire feeder of the generator Application with a separated wire feeder typ WF

Screw down the gas connection from moto generator wire feeder on the gas connection

Screw off the pipe of moto generator wire feeder and screw down bank connection by integrating the pipe in the front side hole.

Gas choice::

STEEL MORE OR LESS ALLOYED

- Pure CO2 (not much used),

- Argon + CO2 (universal gas, often used),

- Argon + CO2 + O2 (not much used).

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STAINLESS STEEL

- Argon + CO2 (often used),

- Argon + H + CO2 +N (not much used).

ALUMINIUM - Pure argon (often used), - Argon + He (not much used).

4-3) Connection to earth cable For an application with a wire in normal polarity, you must connect the adapter earth clamp on the negative terminal and take care to swivel from a ¼ the adapter. The MIG PRO 41/35 can only works on normal polarity (+ on the torch ) if we use the wire feeder of the

generator.

4-4) Connection of the torch All torches are with a euro connection, which can be adapted on GYS machines.

4-5) Setting of rollers Choose those in function of the wire diameter used and the type of wire (See following board). MAGYS 410 machine is delivered with rollers double groove 0,8 / 1 for steel. Rollers double groove GYS Reference for MIG

PRO 41/35 and wire feeder WF 324

0,6 / 0,8

041738

0,8 / 1

042094

0,8 / 1 ALU

042148

0,9 / 1,2 NO GAZ

042124

1 / 1,2

042117

1 / 1,2 ALU

042162

1,2 / 1,6

041752

1,2 / 1,6 ALU 041776

4-6) Setting of wire reel Open the wire feeder compartment. Remove the swivel from the coil support. Take the coil and put it on the support with taking care to block with base spin, then screw down again the swivel. For an application with a 5Kg coil (or d=200), put the adapter between the support and the coil. For an application in steel wire place in position the capillary tube (for an application in aluminum see the paragraph VIII).

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Slump the wire in the moto wire feeder entrance. Release the clamping at maximum. Close the plate of the moto wire feeder. Press on « ADVANCED WIRE » (in foreside) and tighten little by little the clamping handle until the motor start to drive the wire. (it enables the economy of gas)

4-7) Brake adjustment from the coil support

You must block this one in function of the weight coil used. Too blocked: the motor is in difficulty and the WIRE risk not to drive. Release: the important coil inertia can drive the wire rolling after end welding. Open the gas. The machine is ready to operate.

V / INDICATIVE ADJUSTEMENTS

AJUSTMENT FOR MIG PRO 41/35 FOR STEEL USE

INDICATIVE ADJUSTMENT COMMUTATOR POSITION

WIRE SPEED SELF EXTENSION

Metal thickness

∅ WIRE to use

Adjustment Current obtain (A)

Metal thickness

∅ WIRE to use

Adjustment

1 0,8 A1-A2 40-80 1-2 2-4

1,5 0,8 A3-A4 80-110 2-4 4-6

2 0,8-1 A4-A5 100-130 3-5 6-8

3 0,8-1 A5-A6- 130-180 4-5 7-11

4-5 1-1,2 A7-B1 180-230 4-7 7-13

5-7 1-1,2 B1-B2-B3 220-300 4-8 7-15

>7 1,2-1,6 B3-B4-B5-B6-B7

300-410 5-10 9-18

1

4 3

2

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VI / UTILISATION EN ALUMINIUM

The torch installation for aluminum is fundamental. The essential precautions are the following:

- Don’t use the brass capillary tube in the euro adapter, but use the Teflon envelope, which must come until the moto-wire feeder roller. - In ALUMINIUM, use a contact tube of a diameter immediately superior to the section of the wire used. - Use ALU rollers identical with wire diameter.

VII / OPTION FOR MIG PRO 41/35

The MIG PRO 41/35 is an evolutive welding machine. From origin machine, we can only use this one with the

moto wire feeder. Then, we can advanced the product with separated wire feeder with equipping it with a WF

wire feeder and a contact batch from 5 or 10 meters.

When the machine is fully equipped, the choice of the moto wire feeder will be in function of the commutator

position in foreside.

Connection from a wire feeder WF to the generator

VIII / MAINTENANCE You must clean out and replace regularly nozzle and contact batch of all projections. Use a spray of anti-pearl aerosol. We advice you to clean the covering situated in the torch by blowing it with compressed air.

IX / ADJUSTMENTS OF WELDING CYCLES : PREGAZ, POSTGAZ, BURNBACK

The advanced electronic card allows to intervene on the welding parameters. To go on ADJUSTMENT mode, you have to (when the machine is working) press during 3 seconds on the button « MODE ». Then, every indicators switch off and the higher display indicate PRE and the lower display indicate the PREGAZ value. This value can be modified by pressing on + or -. If you press again on, you will adjust the POSTGAZ time (POS on the higher display). If you press a third time, you will adjust the late time to the fusion

Origin moto-wire feeder on the generator

Option wire feeder WF

To use a wire feeder WF, tip the commutator on the position II « wire feeder

WF »

Do not forget to transpose the gas connection situated behind the front panel

Gas pipe Control cable Power cable

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(BURNBACK) or the free wire length (Bur on the higher display). To come back in normal mode, you have to press again on MODE. If, by mistake, the modified parameters doesn’t correspond anymore to the user wishes, you can put back the welding parameters from the factory. For that, you must switch off the machine. Then, you have to press on the button MODE and + and switch on

the machine by pressing a long time buttons MODE and +. After that, the values PRE, POS and Bur clear out.

Now, you can release buttons. News parameters are also enter in the machine.

X / MAINTENANCE: symptoms, reason, solution

SYMPTOMS

POSSIBLE REASONS

SOLUTIONS

The welding wire debit is not constant

-some cracklings block up the opening. -The wire skids in the rollers.

-Clean out the contact batch or change it and replace the anti-adherence product. -Control the rollers pressure or replace it. -Wire diameter non-consonant with roller. -Covering wire guide in the torch non-consonant.

The unwinding motor doesn’t operate.

-Coil brake too block. -Others.

-Release the brake. -Check that the running button is on the position on. -Release the rollers.

Bad wire unwinding. -Covering wire guide dirty or damaged. - Coil brake too block.

-Clean out or replace. -Release the brake

No welding current. -Bad connection of the main connection. -Bad earth connection. -Power contactor inoperative.

-See the branch connection and look if the lap is fed by 3 phases. -Control the earth cable (connection and clamp state). -Control the torch gate.

The wire rubs down after the rollers.

-Covering Wire guide crushed. -Locking of the Wire in the torch. -No capillary tube. -Wire quick too important.

-Replace or clean out. -Check the covering and torch body. -Check the presence of capillary tube.

The welding cord is porous.

- The gas debit is insufficient. -Gas bottle empty. -Gas quality non-satisfying. -Air circulation or wind influence. -Gas nozzle too foul. -Bad wire quality. -Bad quality of the area state to weld (rust, etc…)

-From 15 to 20 L / min. -Replace it. -Replace it. -Avert air blast, protect welding area. -Clean the gas nozzle or replace it. -Use adapted wire for MIG-MAG welding. -Clean the bases metal.

Very important flashing particles.

-Arc power too low or too high. -Bad earth connection. -Protecting gas insufficient.

-See welding parameters. -Control if it is possible to have a better earth connection. -Adjust gas debit.

No gas in torch outlet - Bad gas connection - (On MAGYS 410) see if the gas junction near to the motor is correctly connected.