Air Liquide DV YARD User manual

DV YARD

EN Instructions for Safety, Use and Mainteance

Cat. nr. : 8695-8033

Rev : 00

Date : 07/2014

www.airliquidewelding.com

Arc welding and plasma cutting may be dangerous for the operator and

persons close to the work area.

Please ensure you read the operating manual carefully before use.

3 - EN

CONTENTS

1 - GENERAL INFORMATION .....................................................................................................4

1.1 - PRESENTATION OF INSTALLATION....................................................................................... 4

1.2 - WELDING SET CONSTITUENT .............................................................................................. 4

1.3 - TECHNICAL SPECIFICATIONS............................................................................................... 4

1.4 - DIMENSIONS AND WEIGHT................................................................................................... 4

2 - SETTING UP...........................................................................................................................5

2.1 - PRECAUTIONS........................................................................................................................ 5

2.2 - UNPACKING THE SET............................................................................................................. 5

2.3 - WIRE FEEDER SLINGING....................................................................................................... 5

2.4 - WIRE FEED UNIT CONNECTION ........................................................................................... 5

3 - INSTRUCTIONS FOR USE ....................................................................................................6

3.1 - FEED ROOLS .......................................................................................................................... 6

3.2 - INTERCONNECTIONS ............................................................................................................ 6

3.3 - GAS.......................................................................................................................................... 6

3.4 - TORCH..................................................................................................................................... 6

3.5 - REVERSE POLARITY ............................................................................................................. 6

4 - HUB ASSEMBLY MOUNTING................................................................................................6

4.1 - PROCEDURE .......................................................................................................................... 6

5 - ALARMS .................................................................................................................................7

6 - MAINTENANCE......................................................................................................................7

6.1 - WIRE ROLLERS AND GUIDES ............................................................................................... 8

6.2 - WIRE-FEED PLATE WEAR PART ............................................................................................ 9

6.3 - SPARE PARTS ....................................................................................................................... 10

4 - EN

1 - GENERAL INFORMATION

1.1 - PRESENTATION OF INSTALLATION

The DV YARD can be adapted to most direct current ARC ( MMA )

power-sources , you must use it with 300 mm wire spool.

Its power supply is ensured directly by the arc voltage. It is

therefore very simple to implement and does not require any

auxiliary transformer.

Using the DV YARD, you can transform your ARC ( MMA ) power-

source into an authentic MIG-MAG welding source.

Air Liquide Welding recommend to use with CV power source for

best welding performances

When properly installed, the DV YARD will enable you to obtain

high-quality welds with a good visual appearance.

Optimum use of the system requires full knowledge of this manual;

it is important to follow all the instructions described in this

document.

1.2 - WELDING SET CONSTITUENT

The welding-set is comprise of:

■a wire feeder unit, with 5 m long earth cable and its clamp & 5 m

long gas hose,

■user and maintenance manual,

■safety instruction.

1.3 - TECHNICAL SPECIFICATIONS

- W000382134 : DV YARD : wire feeder without owmeter

- W000382135 : DV YARD FM : wire feeder with owmeter

DV YARD

W000382134

DV YARD FM

W000382135

Rollers plate 4 rollers

Input voltage range 14-48 VDC 15-110 OCV

Welding current range 50 – 425 A

Duty cycle 60% at 40 °C 425 A

Duty cycle 100% at 40 °C 330 A

Wire dia. usable 0.8 to 2.4 mm

Max. spool size spool capacity 300 mm 15/20 kg

Wire feed speed 1.2 -20 m / min

Designed to t through a manhole

Yes

Protection index IP 23 S*

Standard EN 60974 - 5 / EN 60974 - 10

Torch connection "European type"

*Protection index

Code letter IP Equipment protection

First number 2

Against the penetration of solid

foreign bodies

with Ø ≥ 12,5 mm

Second number 1

Against the penetration of vertical

drops of water with harmful eects.

Against the penetration of rain

(inclined up to 60° in relation to the

vertical) with harmful eects.

Indicates that the protection test

against detrimental eects due to

water penetration has been done with

all parts of the equipment at rest.

1.4 - DIMENSIONS AND WEIGHT

Dimensions

(LxWxH)

Net weight

Wire feeder unit DV YARD 600 x 220 x 420 mm 13.9 kg

GENERAL INFORMATION

5 - EN

2 - SETTING UP

2.1 - PRECAUTIONS

■Ensure to not pinch the cables and gas hoses

■Ensure correct installation of power connections.

■Do not leave liquid or hot material to be in contact with the cables.

■The stability of the system is supported up to angles of 10°.

■The connection of the wire feeder unit is to made while the power

source is o.

2.2 - UNPACKING THE SET

Remove the various items from their packaging.

2.3 - WIRE FEEDER SLINGING

For slinging the wire feeder, you must use the handle.

2.4 - WIRE FEED UNIT CONNECTION

1. Place the ¼ female turn on power cable, then connect cable to the

DV YARD terminal on the front.

2. Connect the other end of cable to + terminal of power source.

3. Connect power source - plug to the workpiece.

4. Connect the DV YARD earth clamp to the workpiece.

5. Connect the MIG torch on DV YARD

6. Place the gas hose on the regulator of gas installation (use specied

gas for MIG-MAG welding).

7. Adjust the gas ow and bleed the circuit ..

The DV YARD has a microprocessor based system that allows it to

automatically recognize whether the power source works in Constant-

Current (CC) or Constant-Voltage (CV) and to adapt accordingly without

any selector.

Adjust the power (voltage) on power source and the wire speed on DV

YARD according to the advice placed on DV YARD door. Close the wire

feed unit door and press the torch trigger. Let the wire appears at the torch

end, on the contact tip output.

Your installation is ready to weld.

SETTING UP

POWER SOURCE

6 - EN

3 - INSTRUCTIONS FOR USE

3.1 - FEED ROOLS

Before connecting the electrical and gas supplies, ensure that the

equipment is set for the correct type and size of wire to be used, Check

that the diameter stamped on the feed roll is the same than the diameter

of the wire used.

3.2 - INTERCONNECTIONS

While the machine is switched o, connect the wire feeder to the power

source with the t connection cable, It is advisable to layout the lead as

straight as possible.

3.3 - GAS

Connect the gas hose placed on the rear of the wire feeder with the gas

manometer of the gas cylinder.

PRESSURE REDUCER

GAS TUBE

3.4 - TORCH

Check that the contact tip mounted on the torch head is t for the wire

used, Remove the contact tip and using the torch button to feed the wire

till it comes out of the torch itself, Ret the contact tip and ensure it is well

tightened.

3.5 - REVERSE POLARITY

For some ux cored wire without gas or specics and recharging -

Connect the power cable from the negative terminal of the MMA power

source and the input of DV YARD.- Connect the cable with clamp on the

positive terminal of the MMA power source and the pieces to be welded.

4 - HUB ASSEMBLY MOUNTING

4.1 - PROCEDURE

■Remove the hand nut from the hub assembly wire guide.

■Place the wire reel on the hub so that the wire will be drawn o from

the top.

■Release the end of the wire, but do not allow the wire to loose, cut o

the kinked portion of the wire removing any deformation.

This must be done each time that the wire is referred through the

equipment.

■Adjust the hub assembly by using the screw inside the hub assembly

wire guide, so as the prevent the wire reel over-run once the motor of

the wire feeder stop. Do not tighten the hub assembly too much.Too

much pressure will cause excessive drag.

■By the tting lever release the pressure roll

revolving on ball

bearing and lift it. Thread the wire through the tting inlet guide

and feed it out of the central adaptor.

■Lower the pressure roll

, ret it into the initial position by the

lever

, adjusting the pressure with the knob. Minimum pressure

is sucient so as not to allow the feeding rolls to slip. Excessive

pressure will cause wire deformations and entanglements inside

the liner (in case of aluminium wires) and generally early wear-and-

tear of the wire feeding motor bushing. A scanty pressure will cause

welding uneven or irregular.

■Connect the torch to the tting adaptor and ensure that the wire is

positively fed inside the torch lead liner. Remove the nozzle from

the torch extremity and unscrew the contact tip. Feed the wire till it

comes out of the torch.

■Ret the contact tip keeping in mind that it must have the same

diameter of the wire diameter used.

4.2 - SLOPE UP start welding.

The operator can choose 4 positions for SLOPE UP start welding:

Keep pressed recall A/V button and in the same time press Test gas

button , on the front panel you can read this number 111 , 222, 333, 444

these numbers suggest a dierent time for a small delay for start welding.

1 step 111 short time 0,4 s

2 step 222 medium time 0,75 s

3 step 333 long time 1,2 s

4 step 444 long time 1,6 s

INSTRUCTIONS FOR USE - HUB ASSEMBLY MOUNTING

7 - EN

5 - ALARMS

1. Alarm for big current, I out up to 550 A for 1 second, feeder stop to

work for 5 seconds on the display you can read 666.

2. Alarm for minimum voltage, when the minimum welding voltage is

less than 12 V the feeder stop to work for 5 seconds; on the display

you can read 777.

When you want to work at lower voltage this condition help you to

nd right parameters because to start welding is necessary increase

the current or reduce the speed wire until you nd a good welding.

3. Alarm for high temperature, when the temperature inside the feeder

for any reasons become too high the feeder stop to work until the

temperature return to the nominal value; on the display you can read

888.

4. Alarm for high voltage, maximum work voltage is 100 V so when the

voltage go up to this value the feeder stop to work. On the display

you can read 999.

6 - MAINTENANCE

Routine maintenance

Disconnect power before maintaining.

Maintain more often during severe condition.

3 Months

Replace Damaged or Unreadable Labels.

Replace Damaged Gas Hose.

Repair or Replace Cracked Cables and Cords.

6 Months

Clean Drive Rolls.

Blow Out Or Vacuum Inside.

ALARMS - MAINTENANCE

8 - EN

6.1 - WIRE ROLLERS AND GUIDES

CONTROLS

1. Digital voltmeter and ammeter

2. Wire feed speed adjustment

ܟProvides continuously variable wire feed speed control. The

wire speed is directly proportional to welding current so that

increasing the wire speed increases the current and vice- versa.

3. 2T/4T switch

4. Recall A/V

Push on the key “Recall” allows to see the last parameters

used (I/U) after welding.

5. Central European connector

ܟAllows an easy connection to the welding torch simultaneously

carrying power, torch button connection, gas and liner

connections.

6. Connecting Gas Hose

7. Connecting Weld Cable

MAINTENANCE

9 - EN

6.2 - WIRE-FEED PLATE WEAR PART

REP DESCRIPTION PART NO.

1 PCB FR 109 W000382445

2 KOHM POTENTIOMETER W000382446

2A LARG KNOB W000382447

2B SMALL KNOB W000382455

3 POLE SWITCH W000382450

4 CENTRAL ADAPTER W000382451

5 CONTACTOR W000382452

6 PCB FR 459 W000382453

724 V AC GAS VALVE W000382454

8 WELDING CONNECTOR W000382456

9 REEL HUB ASSY W000382457

10 24V 70W LEFT MOTOR W000382458

11 POLE SWITCH W000382459

12 FLOWMETER W000382470

13 FUSE HOLDER W000382472

13A FUSE 4A DELAY W000382460

MAINTENANCE

10 - EN

6.3 - SPARE PARTS

MAINTENANCE

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