GYS 032903 User manual
M1 GYS AUTO
T1 GYS AUTO
T1 GYS AUTO DV
T3 GYS AUTO
T3 GYS AUTO DV
FR 6-10 / 27-36
EN 11-14 / 27-36
DE 15-18/ 27-36
ES 19-22 / 27-36
RU 23-26 / 27-36
75560 - V5 - 12/03/2014 www.gys.fr
2
M1 - T1 & T3 GYS AUTO
I - M1 & T1
II - T3
III
11
14 7
8
1
12
10
2
3
5
4
9
14 7
3
1
5
4
4
9
12
10
8
15
AB
Fig 4-C :
13
13 17
16
Fig 4-B :
2
11
23
M1 - T1 & T3 GYS AUTO
IV
V
VI
1
2
3
5
4
13
2
4
56
4
M1 - T1 & T3 GYS AUTO
VII
M1 - T1 - T3 GYS AUTO
T3 GYS AUTO
Visser toutes les vis du support bouteilles
Tighten all the screws of the gas bottle stand
• Prémonter les vis manuellement
sans les bloquer
• Pre-install the screws manually
without blocking them
Vis/Screws
M5x12 (x8)
Ecrous/Nuts
M5x8 (x8)
3
2
1
4
45
M1 - T1 & T3 GYS AUTO
T3 GYS AUTO (option ref. 032958 / 032972)
M5x12 (x4)
5 6
10 11
M1 - T1 & T3 GYS AUTO EN
DESCRIPTION
Thank you for choosing our product! In order to take the most of your Mig welder please read the following
instructions carefully:
These welding are recommended to weld steel, stainless steel, aluminium and for the “MIG Brazing” of high-tensile
strength steels with CuSi and CuAl wires (ideal for car body repairs). Its adjustment is easy and fast thanks to its
« synergic wire speed » function. They work on a 380V 3-phase power supply or 220V/380V 3-phase for the T1 GYS
auto DV and T3 GYS auto DV. The M1 GYS AUTO works on a 230V single phase power supply.
ELECTRICITY SUPPLY
The absorbed current (I1eff) is indicated on the device, for the maximum use conditions. Check that the power supply
and its protections (fuse and/or circuit breaker) are compatible with the current needed at use. In some countries, it
might be necessary to change the plug to allow the use at maximum conditions. The device must be placed in such way
that the power socket is always accessible.
- These welding, are supplied with a 16A plug of RS-015 CEE.
- The M1 GYS AUTO has to be connected to a 230 V (50Hz) earthed power supply with a a circuit breaker 16A and 1
differential 30mA.
- The T1 GYS auto, T3 GYS auto, T1 GYS auto DV and T3 GYS auto DV have to be connnected to a 380 V (50Hz) ear-
thed power supply with a a circuit breaker 10A and 1 differential 30mA. Do not use an extension cord which has a wire
section inferior to 2.5 mm².
- For the T1 GYS auto DV and T3 GYS auto DV only, 220V 3-phase power supply:
this device is pre-built in 380V three-phase. If your electrical installation is in 220V 3-phase, you have to modify the
connection on the terminal board. This modication has to be realized by a competent person. (see the electrical dia-
gram at the end of the manual)
CONTROLS AND FEATURES (FIG 1 & 2)
1- switch On-Off
2- 7 positions power adjustement switch : aloows adjust-
ment of the welding voltage at the generator output. The
adjustment of the output voltage is proportional to the
thickness of the material to weld. (refer to page 6)
3- welding settings adjustement keyboard (manual or
automatic mode)
4- European standard torch coupling
5- spool on gun coupling command
6- thermal protection light : informs when a short break
is necessary following intensive use.
7- torch support
8- supply cable (2m M1GYS AUTO, 3m T1GYS, 6m
T3GYS).
9- out earth cable for T1GYS and M1GYS AUTO, earth
cable with a 200A clamp for T3GYS
10- gas bottles support (max 1 bottle 4m³ for M1GYS
AUTO and max 2 bottles 4m³ for T1GYS, T3GYS).
11- fastening chain for bottles
12- reel sopport 200/300 mm
13- solenoid valve torch 1
14- torch cable support
T3GYS:
15- reel support 200 mm
16- solenoid valve torch 2
17- solenoid vavle for spool gun
SEMI-AUTOMATIC WELDING FOR STEEL/STAINLESS STEEL (MAG MODE)(FIG 2)
These welding can weld 0.6/0.8 and 1.0mm steel and stainless steel wires (g 2A). The device is capable of working
with Ø 0.8 mm steel wire (contact tube Ø 0.8, roller Ø 0.6/0.8 and Ø 0.8/1.0). If you need to use Ø 0.6mm wire, you will
have to change the contact tube, and ensure that the reversible rollers in the wire feeder are posititioned correctly (so
that the writing that states “0.6mm” is visible when in place). For Steel or Stainless Steel, you will need to use specic
gas - Argon + CO2 (Ar + CO2). The proportion of CO2 will vary depending on usage. The gas ow in steel is between 8
and 12L / min depending on the environment and experience of the welder. For the specic requirements, seek advice
from your gas distributor.
SEMI-AUTOMATIC WELDING FOR ALUMINIUM (FIG 2)
These welding can weld 0.8 and 1mm aluminium wires (g 2B).
To weld aluminium, neutral gas “pure argon” (AR) is required. When choosing gas, ask a gas distributor for advice.
The gas ow in aluminium should be between 15 and 25 L / min depending on the environment and experience of the
welder.
Things to note when welding with Aluminium:
-Set the pressure rollers of the wire feeder on the wire at the minimum pressure so as not to pinch the wire
- Remove the capillary tube before connecting the aluminium torch
- When welding aluminium use a special aluminium torch with Teon sheath to reduce friction. Do not cut the sheath
near the connector! It is used to guide the wire from the rollers. (diagram 3-B )
12
M1 - T1 & T3 GYS AUTO EN
- Contact Tip: Use a contact tip SPECIAL aluminium corresponding to the diameter of the wire.
- Contact Tip: Use the specic Aluminium contact tip corresponding to the diameter of the wire.
SEMI-AUTOMATIC BRAZING WELDING FOR HIGH-TENSILE STRENGTH STEELS
These welding are recommended by car manufacturers to braze-weld high-tensile strength plates with a cuprosilicium
CusI3 wire or cuproaluminium CuAl8 wire (Ø 0.8 mm and Ø 1 mm). The welder must use a neutral gas: pure argon (Ar).
For specic gas requirements, seek advice from your gas distributor. The gas ow required s between 15 and 25 L / min.
GAS CONNECTION (FIG 3)
Connect the manometer (owmeter) to the gas bottle (manometer not supplied with the product).For use with one
or two bottles of gas.
To connect two bottles of gas to three torches, split the pipe into 3 pieces and attach a 3-way “Y” connector. (g 3-C )
To link a single bottle of gas with 3 torches, cut the pipe into 4 pieces and attach two 3-way “Y” connectors.
Connect each bottle to the solenoid valves in the following order:
-T1 solenoid valve to the top left (g 3B:13)
-Spool gun solenoid to the top right (g 3B:17)
-T3 solenoid valve to the bottom (g 3B:16)
To avoid any gas leaks, always use the collars supplied with the product.
PROCESS OF REELS AND TORCHES ASSEMBLY (FIG 4)
Open the device trapdoor.
- Place the reel on the driving pin (g 4:2) of the reel support.
- Adjust the reel brake (g 4:3) to avoid the reel inertia tangling the wire when welding stops. In general, do not tighten
too much!
- The electrical roller (g 4:4) is a double groove roller (0,6/ 0,8 and 0,8/1). The indication on the visible side of the
roller is the diameter in use. For a 0,8 wire, use the 0,8 groove.
- For the rst use:
- Release the xing screw of the wire guide.
To set the adjusting knob of the pressing rollers (g 4:5), proceed as follow: loosen the knob fully, start the motor by
pressing the torch trigger, tighten the adjustment knob whilst pressing the trigger. Bend the wire where it comes out of
the nozzle and hold it in place to stop its progress. The setting is correct when the guide roller slides over the wire even
when it is blocked at the end of the torch. A common adjustment is the rollers command (g 4:5) on the scale 3 for steel
and 2 for aluminium.Nb: for the aluminium wire put a minimum pressure in order not to crush the wire.
CHOICE OF REELS
possible settings:
type l Torche 1
T1,T3,M1 Torche 2
T3 Spool gun
T3
Gaz
acier
Ø 300 x
argon
+
CO2
Ø 200 x x
Ø 100 x
inox Ø 200 x x
Ø 100 x
CuSi3 Ø 200 x x
argon
pur
CuAl8 Ø 200 x x
Alu
AlMg5
Ø 300 x*
Ø 200 x* x*
AlSi5 Ø 100 x
AlSi12 Ø 100 x
CuSi3: Recommandation OPEL & MERCEDES
CuAl8: Recommandation Peugeot/Citroën/Renault
AlSi12: Recommendation for automotive aluminium from metal sheet of 0,6mm to 1,5 mm of thickness.
* Consider Teon sheath and special aluminium contact tip
12 13
M1 - T1 & T3 GYS AUTO EN
«MANUAL» MODE (FIG 5)
1-welding mode choice:
- Normal (2T): standard two-stage welding
- Delay: intermittent welding modes for an optimised
operating procedure.
- Spot:spotwelding with ajustable spot diameter
2- Wire speed settings: wire speed tting potentiometer.
The speed varies from 1 to 15L/minute.
3- Spot/delay potentiometer tting
4- Manual mode: In manual mode, the wire speed is
determinated by the user by adjusting the potentiometer
(2).
5- Synergic mode: position the potentiometer (2) in the
middle of the «optimal synergic» zone. In this mode, the
device determines the optimal wire speed according to 3
parameters:
- Voltage
- Wire diameter
- The power mode.
It’s possible to adjust the wire speed +/-.
In position Normal(2T), 2 modes are proposed to ease
the settings of the device: Manual or Synergic.
«MANUAL» MODE (FIG 5)
To set your device, proceed as follow:
- Choose the welding voltage using the 7 positions switch
Example: position 1 for 0,6mm metal sheets and position 7 for 4 mm metal sheets.
- Adjust the wire speed with the potentiometer(2).
Advice:
The wire speed adjustment is often determinated « with the noise »: the arc must be stable and have a low
crackling. If the speed is too low, the arc is not continuous. If the speed is too high, the arc crackles and the wire
pushes back the torch.
«SYNERGIC» MODE (FIG 5)
This function will set the wire speed automatically.
For this:
Position the wire speed potentiometer (2) in the middle of the« Optimal synergic » zone.
-Select:
-The wire type (5)
-The wire diameter (5) The power mode (7 position switch), to select the right position in accordance with the thic-
kness of the part to weld, please refer to the table (g 6)
From this combination, they determines the optimal wire speed and the device is ready to weld. It is also possible
to adjust the wire speed if necessary by adjusting potentiometer (2) + or – manually. A memory of the last welding
conguration is done (wire diameter, wire type, mode).
GAS choice (only for steel welding) :
In synergic mode, it's determines the welding settings in accordance with the gas used. By default, in steel welding
the machine is set in « Argon + CO2 ».
To change the gas and set the machine in C02 mode or come back in Argon + CO2 mode, process as explained:
1-Press « Type » for 5 seconds until the keyboard switches off the release.
2-Within 5 seconds, choose the required setting with the key « choose mode ».
-Normal (2T) => Argon + CO2 (default setting)
-Delay => CO2 100%
3-The conrmation is done either by the « Type » key, or by waiting for 5 seconds.
4-Once conrmed, the machine reverts to the normal functioning mode but the modication is registered even when
the machines is switched off.
SPOT MODE (FIG 5)
This function allows spot welding. To adjust the length of each spot, use the potentiometer (3).
DELAY MODE (FIG 5)
Allows intermittent welding, the delay can be adjusted through the potentiometer (3).
This function allows welding very thin steel or aluminium metal sheet, limiting the risk of piercing and distortion
(especially for aluminium welding).
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M1 - T1 & T3 GYS AUTO EN
SPOOL GUN (OPTION)
Spool gun description and functionning
- The spool on gun torch must be installed on the torch T1 connector.
- The spool on gun works either in « Manual » mode or either in « Synergic » mode.
- In « manual » or « Synergic » mode, only the wire speed adjustment knob on the torch (4) is active (the wire speed
potentiometer of the device is not active).
-« Synergic » mode:
-Place the wire speed knob on the torch (4) at the middle of its area then adjust if necessary.
-For more information on the « Synergic » mode, refer to page 9.
1- Hood Opening/closing knob
2- Reel holding nut
3- Reel locknut (do not tighten too much)
4- Rollers tension adjusting screw
5- Wire speed adjusting knob
Assembly process
Reel :
- Open the hood (1)
- Remove the reel holding nut (2) (NB. : no reversed screw)
- Tighten the locknut (3) to bulge the reel axis (do not tighten too much)
- Insert the reel-To insert the wire in the rollers, apply pressure on the «roller tension setting screw »
Torch:
- Pull out the wire of the T1 torch in winding up the reel.
- Pull out the T1 torch
- Plug the power connector of the spool on gun on the T1 connector.
- Plug the control connector of the spool gun-Place the switch on T1 position.
FACTEUR DE MARCHEDUTY CYCLE AND WELDING ENVIRONMENT
- The welding unit describes an output characteristic of «constant current» type. The duty cycles following the norm
EN60974-1 (at 40°C on a 10mn cycle) are indicated in the table here below:
X/60974-
1 à 40°C(T
cycle=10min)
I max 60%(T cycle=10min) 100%(T cycle=10min)
T1 GYS AUTO 25% à 150A 110A 90A
T3 GYS AUTO 25% à 150A 110A 90A
M1 GYS AUTO 15% à 140A 80A 60A
Note: The warming test was done at room temperature and the duty cycle at 40°C were determinated by simulation.
- These are A-class devices. They are designed to be used in an industrial or professional environment. In a different
environment, it can be difcult to ensure electromagnetic compatibility, due to conducted disturbances as well as
radiation.
- This device complies with IEC 61000-3-12, provided that the power of the short-circuit Ssc is equal to or greater
than 1.8MVA at the interface between the machine and the mains power network. It is the responsibility of the instal-
ler or user of the equipment to ensure if necessary by consulting the operator of the mains electricity, that the equip-
ment is only connected to a power supply where the power of short-circuit ssc is equal to or greater than 1.8MVA.
ADVICE AND THERMAL PROTECTION
- Respect the basic rules of welding.
- Leave the air holes of the device open to allow air circulation.
- Leave the device plugged after welding to allow its cooling.
- Thermal protection: The light turns on and the cooling duration is a couple of minute according to the area
temperature.
This manual suits for next models
5
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