GYS SAM-1A Smart Automation Module

1. General Information

Revision History

2. Warnings - Safety Regulations

General Advice

This user's manual contains information on the operation of the device and the precautions to be taken for the safety of the user. Please read it carefully before using the machine for the first time and keep it for future reference.

⚠️ These instructions must be read and understood before any operation.

Any modification or maintenance not specified in the manual must not be undertaken.

The manufacturer shall not be liable for any damage to persons or property arising from use not in accordance with the instructions in this manual.

If you have any problems or uncertainties, please consult a qualified person to handle the appliance correctly.

This device may only be used for ticket printing and/or data transmission within the limits indicated on the device and in the manual. The safety instructions must be observed. In case of improper or dangerous use, the manufacturer cannot be held responsible.

The device is intended for indoor use. It should not be exposed to rain.

Regulation

The device complies with the European directives. The declaration of conformity is available on our website (see cover page).

Material conforms to UK requirements. The UK Declaration of Conformity is available on our website (see cover page).

This material is subject to separate collection in accordance with the European Directive 2012/19/EU. ♻️ Do not dispose of in domestic waste!

A recyclable product that is subject to sorting instructions.

Electrical Safety

When working on the product, be sure to secure the area by not allowing anyone who is not familiar with the safety instructions in this user manual to enter the area. This device should preferably be installed by a professional according to the installation rules in force in the particular country. If this is not possible, it is recommended that you read these rules before proceeding.

Electrostatic Damage Warning

⚡ Static electricity can damage electronic equipment. Use an earthed, antistatic wrist strap, ankle strap or equivalent safety device to prevent electrostatic discharges (ESD) when installing this product.

Electrostatic damage can irreparably impair the power source and/or the entire product. To protect electronic components from electrostatic damage, place this product on an antistatic surface, such as an antistatic discharge mat, antistatic bag or disposable antistatic mat.

3. Product Overview

Introduction

This document contains information on how to set up and connect the SAM-1A gateway in a PLC or automated network. The Smart Automation Module (SAM-1A) is a communication tool between compatible GYS welding power sources and programmable logic controllers (PLCs).

A SAM-1A connection converts GYS devices' internal communication language into digital or analogue input/output signals. The settings can be changed by using pre-loaded JOBs saved in the power source.

The power source/SAM-1A module assembly can be reassigned to a new system without requiring any modifications to the system (integrating it into a new machine, replacing a PLC or automating a process, etc.).

The SAM-1A (PN. 071940) enables additional applications on compatible power sources. The module allows access to parameters of the welding generator for control by the PLC or robot.

Compatible Products

Contents / Spare Parts

The product package includes:

• Electronic board (E0101C)
• Cable bundle 300 mm (F0035)
• RJ45 cables (300 mm, 750 mm)
• Connectors (20 points, 4 points)
• 3 points strap

Electronic Board Support Brackets and Connector Support Plates

Diagrams show various support brackets and plates for electronic boards and connectors, specific to models like NEOPULSE 320 C / 400 CW, NEOPULSE 400 G / 500 G, KRYPTON, TITAN, and EXAGON FLEX.

4. Installation

Installation Warning

⚠️ ELECTRIC SHOCKS CAN BE FATAL

Only experienced personnel authorised by the manufacturer may install the equipment. During installation, ensure that the power source is disconnected from the mains.

Kit Installation

The document shows QR codes linking to installation guides for different product series (EXAGON / NEOPULSE / TITAN / TITANIUM 400, TITANIUM 230 AC/DC, TITANIUM 321 AC/DC, KRYPTON 401 DC).

Access to internal areas beyond those outlined in this manual is prohibited and voids the warranty as well as all other forms of support. Indeed, these interventions can be damaging to the power source's internal electronic parts and/or components.

5. SWO Feature (Safe Welding Off)

Function Description

The "Safe Welding Off" function primarily prevents the current or voltage source from starting. It acts directly on the power source in a very short time.

This function is also used to safely stop the power source in the event of an emergency stop. This avoids a sudden power supply interruption to the power source if a problem arises. It should be remembered that a break in the power supply downstream of a loaded power source is dangerous and can damage the equipment.

Electrical Safety

The "Safe Welding Off" function does not offer electrical isolation; therefore, before any work is carried out on the power source, it must be electrically isolated by switching off the power supply and locally isolating the power source (padlock procedure).

SWO Activation and Wiring

Two switches (DIP 1 and DIP 2) on the SAM-1A board are provided to set the security function and other features. To activate the security function, switch DIP 1 to ON and DIP 2 switch 3 to ON. Wiring is done via a terminal block (X5) on the SAM-1A electronic board.

Principle Diagram: A diagram illustrates the connection of an EMERGENCY STOP button, power supply (24Vdc), and the terminal block X5 with inputs/outputs.

Electrical Characteristics of Terminal Block X5 Inputs/Outputs

6. Input/Output Assignments

Connector X20 Technical Specifications

Power Supply: The inputs/outputs (24 V) can be supplied either internally by the SAM-1A or by an external 24 V power supply. The SAM-1A is set up for internal power supply as standard. To use an external power supply, switch the jumper on the three-pin power connector and apply 24 V to the X20 connector (pin 10). A 3-point strap is supplied with the product.

Digital Inputs/Outputs

Digital Inputs: The SAM-1A has four digital inputs (MMI_LOCK, Start_Process, Start_Gaz, Wire_Feed) detailed with their connector pins (X20-18 to X20-16) and status (0/1) for multimeter mode, process control, gas valve, and wire feed.

Digital Outputs: The SAM-1A has four digital outputs (Error, Authorised_Start, Arc_Detect, Welding_Process, Main_Current) detailed with their connector pins (X20-6 to X20-13) and status (0/1) for error status, welding permission, arc detection, and welding phase.

Analogue Inputs/Outputs

Analogue Outputs: The SAM-1A provides two analogue outputs for voltage and current measurement. Voltage (M_Weld_Voltage, X20-5) ranges from 0-10V (0-50V measurement). Current (M_Weld_Current, X20-15) ranges from 0-10V (0-500A measurement).

DIP 2 Settings

A table details the DIP 2 switch settings for MIG and TIG processes, covering modes like JOB (without settings, current settings, wire-speed settings), Manual Mode, and Tracking Mode. Each setting configures parameters such as Arc_LEN, Weld_Current, Self, and JOB number.

7. Welding Processes

Schematic Diagrams

The document includes schematic diagrams illustrating different welding cycles:

• Diagram of a Welding Cycle (Job Mode init): Shows the sequence of functions like Authorised Start, Start Process, and Welding Process controlled by CPU and SAM.
• Schematic Diagram of a Welding Cycle in Tracking Mode (TIG): Details the timing of functions like Authorised Start, Start Gas, Welding Current, and Welding Process.
• Schematic Diagram in Case of an Error: Illustrates how functions like Average Cycle Current, Error State, Authorised Start, and Gas ON behave during an error condition.

8. Maintenance

Updates

It is recommended to check for software updates on the GYS SAV website before first use. A single update can update all connected products (generator, remote control, wire-feed reel, SAM, etc.).

Update Process:

1. Disconnect all devices from the network.
2. Connect a USB key with the latest updates to the specific USB port and start the device.
3. The screen will indicate if a new version is detected. Wait for completion and restart the product after removing the USB key.

⚠️ Before upgrading, check the changes made by the new firmware update. In the event of a major software update, changes may be required to the PLC's software programming.

Defects List

Refer to the after-sales section of the website www.gys.fr for a list of defects.

9. Appendices

Appendix 1: SAM-1A Settings using NEOPULSE/PULSEMIG

Details digital and analogue inputs/outputs, analogue input functions (JOB modes, Manual Mode), how to find JOB numbers and synergy values, and provides examples of diagrams.

Appendix 2: SAM-1A Settings using TITAN/TITANIUM

Details digital and analogue inputs/outputs, analogue input functions (JOB modes, SAM-1A settings, Tracking Mode), how to find JOB numbers, and provides examples of diagrams.

Appendix 3: SAM-1A EXAGON FLEX Settings

Details SAM-1A I/O, analogue inputs/outputs, analogue input functions (CV mode - Generator settings, CV mode - SAM-1A settings), and provides examples of diagrams.

The document includes detailed tables for input/output configurations and parameter settings for various welding processes and modes.

Warranty Conditions (France)

The warranty covers manufacturing defects for two years from the date of purchase (parts and labour).

The warranty does not cover:

• Damage caused by transport.
• Normal wear and tear of parts (e.g., cables, clamps).
• Incidents due to misuse (incorrect wire feeding, dropping, dismantling).
• Environmental failures (pollution, rust, dust).

In case of breakdown, return the appliance to your distributor with proof of purchase and a note explaining the breakdown.

Electronic Board Diagram

A detailed diagram of the SAM-1A electronic board is provided, showing component locations and connector pin assignments (X20, Power supply, DIP 1, DIP 2, X5).