GYS TRIMIG Semi-Automatic Welding Machines

Description

Thank you for choosing this product. Please read this instruction manual carefully before installing and using the product and keep it in a safe place for future reference. The TRIMIG units are semi-automatic welding units, ventilated for semi-automatic welding (MIG or MAG), and capable of welding steel, stainless steel, and aluminium. Adjustment is quick and easy with their "synergic wire speed" function. They operate on a 400V three-phase power supply, and/or 230V three-phase for the DV models.

Electricity Supply

The absorbed current (I1eff) is indicated on the device for use at maximum settings. Ensure the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed during use. The device must be placed so that the power socket is always accessible. Do not use an extension cable with a wire section smaller than 4 mm². These products are supplied with a 16A or 32A plug type EEC RS/015. They should be plugged into a 400V (3PH) power socket WITH earth and protected by a 16A circuit breaker and 1 differential 30mA.

For 230V 3-phase power supply (Trimig 250-4S DV, 350 G DV, 350-4S DUO DV): WARNING: This device is pre-built for 400V three-phase. If your electrical installation is 230V three-phase, you must modify the connection on the terminal board. This modification must be undertaken by qualified personnel. Refer to the technical diagram inside the product. The plug must be protected by a 16A or 25A (for 350 models) circuit breaker and 1 differential 30mA.

Device Presentation (Figure II)

Figure II illustrates the main components of the TRIMIG welding units. It shows the machine's housing, wheels, control panels, and various connection points.

• [1] On / Off switch
• [2] Power Settings: 2 switches with 7 positions for adjusting welding voltage output, proportional to workpiece thickness.
• [3] Control panel: For welding settings (manual or automatic mode).
• [4] European standard torch connection.
• [5] Thermal Protection light: Indicates when a cool-down period is necessary after intensive use.
• [6] Torch support.
• [7] Power Cable (5m).
• [8] Earth cable connector.
• [9] Gas bottle support (max 1 bottle of 10m³).
• [10] Fastening chain for bottles (ensure it is fastened securely, see IV-1).
• [11] Reel support Ø 200 mm/300mm.
• [12] Gas connector (350-4S DUO DV).
• [13] Torch Cable support.
• [14] Wire feeder solenoid valve 2.
• [15] Wire feeder gas connection for torch 2.
• [16] Wire feeder control cable connector.
• [17] Wire feeder power cable connector.
• [18] Selection switch potentiometer (only on 300G and 350 G DV).

Welding Modes

Reel and Torch Assembly (Figure IV)

Figure IV illustrates the steps for assembling the wire reel and torch. This includes opening the machine door, positioning the wire reel on its support (potentially using an adapter for 200mm reels), adjusting the reel brake to prevent tangling, and setting the wire feeder rollers and guide.

CHOICE OF REELS

*Consider Teflon sheath and special aluminium contact tip.

Gas Coupling

Fit the regulator/flowmeter to the gas bottle and connect the gas pipe to the connector. Use the provided collars to prevent gas leaks. Ensure proper maintenance of the gas cylinder.

Control Panel (Figure V)

Figure V shows the control panel layout. Key functions include:

• [2] Welding mode selection: 2T (two-stage), 4T (4-stage), SPOT (spot welding with adjustable diameter).
• [4] Wire speed selection: Regulator for wire speed, varying from 1 to 15 m/minute.
• [5] SPOT/DELAY setting potentiometer.
• [1] Manual Mode: Wire speed is manually adjusted by the user via potentiometer [4].
• [3] Synergic Mode: Position potentiometer [4] in the "OPTIMAL SYNERGIC" zone. In this mode, the device automatically determines optimum wire speed based on Voltage, Wire diameter, and Power mode. Speed can be fine-tuned with +/- adjustment.

Operating Modes

Advice and Thermal Protection

• Do not lift the TRIMIG by its handles, torch support, or top. Ensure weight is fully supported at the bottom. Do not connect the gas bottle during lifting.
• Always respect basic welding safety rules.
• Do not block or cover ventilation holes.
• Leave the device plugged in after welding for proper cooling.
• Thermal Protection: If the machine overheats, the warning light illuminates, and the machine stops. Cooling takes a few minutes.

Duty Cycle and Welding Environment

The welding unit operates as a "constant current" type. Duty cycles are indicated per standard EN60974-1 (at 40°C on a 10 min cycle):

Note: Duty cycles were tested at room temperature (40°C) and determined by simulation.

These are Class-A devices, designed for industrial or professional environments. Electromagnetic compatibility may be difficult to ensure in other environments.

These devices comply with IEC 61000-3-12, provided the short-circuit power (Ssc) at the interface is ≥ 3.9MVA (2.8MVA for Trimig 200-4S). Users must ensure connection to a suitable power supply.

Maintenance

• Maintenance should only be performed by qualified personnel.
• Ensure the machine is unplugged and the ventilator has stopped before maintenance (DANGER: High Voltage and Currents).
• GYS recommends removing the steel cover 2-3 times a year to remove dust and check electrical connections.
• Regularly check the power supply cord; replace if damaged by the manufacturer or qualified personnel.
• Ensure ventilation holes are not blocked for adequate air circulation.
• Before each use, check welding cables of the torch and earth clamp for exposed conductive metal.

Safety

Arc welding can be dangerous. Protect yourself and others. Follow these precautions:

• Arc radiation: Use a helmet with filters compliant with EN169 or EN 379.
• Environment: Use in a clean/dry environment (pollution factor ≤ 3), on a flat surface, at least one meter from the workpiece. Do not use in rain or snow.
• Electric shock: Use only with an earthed power supply. Do not touch high-voltage parts. Ensure the power supply is suitable.
• Falls: Do not place or carry the unit over people or objects.
• Burns: Wear protective (fire-proof) clothing (cotton, overalls, jeans), gloves, and a fire-proof apron. Keep others at a safe distance and prevent them from looking directly at the arc. Use fire-proof protection walls.
• Fire risks: Remove flammable products from the work area. Do not work in the presence of flammable gases.
• Fumes: Do not inhale welding gases and fumes. Use in a well-ventilated environment with artificial extraction if indoors.
• Additional Precautions: Welding in rooms with increased risk of electric shocks, poorly ventilated rooms, or presence of flammable/explosive material requires approval by a "responsible expert" and trained personnel for emergencies. Technical protection as per CEI/IEC 62081 must be implemented. Welding in raised positions should only be done with safety platforms.
• People wearing pacemakers should consult their doctor before use.
• Do not use the welding unit to unfreeze pipes.
• Handle gas bottles with care to avoid damage to the bottle or valve.

Troubleshooting

This table lists common symptoms, their potential reasons, and solutions:

Electrical Schematics

Pages 9 through 14 contain detailed electrical schematics for the TRIMIG 200-4S, TRIMIG 250-4S, TRIMIG 300-4S, TRIMIG 300 G, TRIMIG 350-4S DUO DV, and TRIMIG 350 G DV models. These diagrams are intended for qualified technicians for installation, maintenance, and troubleshooting purposes.

Spare Parts

The following tables list available spare parts for the TRIMIG welding machines, categorized by model and part number.

Warranty Conditions

CONDITIONS DE GARANTIE FRANCE

The warranty is valid only if the form is correctly completed by the seller. The warranty covers any manufacturing defect or fault for 1 year from the date of purchase (parts and labor). The warranty does not cover voltage errors, incidents due to misuse, drops, disassembly, or any other transport damage. The warranty does not cover normal wear and tear of parts (e.g., cables, clamps, etc.). In case of breakdown, return the appliance to GYS (port refused), enclosing: The present warranty certificate validated by the seller. An explanatory note of the breakdown. After the warranty period, our After-Sales Service provides repairs after acceptance of a quote.

Contact SAV: Société GYS - 134 Bd des Loges, BP 4159 - 53941 Saint-Berthevin Cedex. Fax: +33 (0)2 43 01 23 75 - Tel: +33 (0)2 43 01 23 68.

HERSTELLERGARANTIE (Manufacturer Warranty)

The manufacturer's warranty applies exclusively to manufacturing or material defects reported within 12 months of purchase (proof of purchase required). Upon acknowledgment of the warranty claim by the manufacturer or its representative, a free repair or replacement of parts will be provided to the buyer. The warranty period remains unchanged by warranty services performed. Exclusion: The warranty does not apply to defects caused by improper use, drops, hard impacts, unauthorized repairs, or transport damage incurred during shipping for repair. Wear parts (e.g., cables, clamps, etc.) and signs of use are not covered. The device must be sent exclusively through the dealer with proof of purchase and a brief description of the fault. Repair will only proceed after written acceptance of the submitted cost estimate. In case of warranty service, GYS covers only the return shipping costs to the dealer.

Declarations of Conformity

These welding units are manufactured in compliance with European directives, including the Low Voltage Directive (2006/95/CE) and the EMC Directive (2004/108/CE). Conformity is established by adherence to harmonized standards such as EN60974-1, EN 50445, and EN60974-10. CE marking was applied in 2013.

FR: GYS atteste que ces postes de soudure sont fabriqués conformément aux exigences des directives Basse tension 2006/95/CE du 12/12/2006, et aux directives CEM 2004/108/CE du 15/12/2004. Cette conformité est établie par le respect des normes harmonisées EN60974-1 de 2005, EN 50445 de 2008, EN 60974-10 de 2007. Le marquage CE a été apposé en 2013.

EN: The equipment described on this manual is conform to the instructions of low voltage 2006/95/CE of 12/12/2006, and the instructions of CEM 2004/108/CE of the 15/12/2004. This conformity respects the standards EN60974-1 of 2005, EN 50445 de 2008, EN60974-10 of 2007. CE marking was added in 2013.

DE: GYS erklärt, dass die synergisch geregelten Schweißanlagen TRIMIG 200-4S/ 250-4S DV/ 300-4S/ 300 G/ 350-4S DUO DV/ 350 G DV richtlinienkonform mit Niederspannungsrichtlinie 2006/95/CE −12.12.2006 und EMV- Richtlinien 2004/108/CE – 15.12.2004 elektromagnetische Verträglichkeit- hergestellt wurden. Diese Geräte stimmen mit den harmonisierten Normen EN60974-1 von 2005, EN 50445 von 2008, EN60974-10 von 2007 überein. CE Kennzeichnung: 2013.

ES: GYS certifica que estos aparatos de soldadura son fabricados en conformidad con las directivas baja tensión 2006/95/ CE del 12/12/2006, y las directivas compatibilidad electromecánica 2004/108/CE del 15/12/2004. Esta conformidad está establecida por el respeto a las normas EN60974-1 de 2005, EN 50445 de 2008, EN 60974-10 de 2007. El marcado CE fue fijado en 2013.

RU: GYS заявляет, что сварочные аппараты произведены в соответствии с директивами Евросоюза 2006/95/ СЕ о низком напряжении от 12/12/2006, а также с директивами СЕМ 2004/108/CЕ от 15/12/2004. Данное соответствие установлено в соответствии с согласованными нормами EN60974-1 2005 г, EN 50445 2008 г, EN 60974-10 2007 г. Маркировка ЕС нанесенна в 2013 г.

Declaration date: 01/02/2013. Signatory: Nicolas BOUYGUES, Président Directeur Général, Société GYS.

Symbols and Icons Explanation

This section explains common symbols and icons used in the manual and on the equipment:

Accessories

The following tables list available accessories for the TRIMIG welding machines.

Trimig 200-4S

Trimig 250-4S DV 230-400V

Trimig 300-4S / 300 G / 350-4S DUO DV / 350 G DV