GYS TRIMIG Welding Machines

Introduction

This manual provides comprehensive instructions for the GYS TRIMIG series of semi-automatic welding units. These machines are designed for MIG/MAG welding of steel, stainless steel, and aluminium. They feature a synergic wire speed function for quick and easy adjustment and operate on 400V three-phase power, with DV models also supporting 230V three-phase.

Product Range

• TRIMIG 200-4S
• TRIMIG 250-4S DV 230/400V
• TRIMIG 300-4S & 300 G
• TRIMIG 350-4S DUO DV 230/400V
• TRIMIG 350 G DV 230/400V

Electricity Supply

Ensure the power supply and its protection (fuse/circuit breaker) are compatible with the device's maximum current requirements. The power socket must be easily accessible. Use extension cables with a minimum wire section of 4 mm². Products are supplied with a 16A or 32A plug (EEC RS/015) and require a 400V (3PH) earthed power socket, protected by a 16A circuit breaker and a 30mA differential. For 230V three-phase models (250-4S DV, 350 G DV, 350-4S DUO DV), modification of the terminal board connection by qualified personnel is necessary if the installation is 230V. This modification requires a 16A or 25A circuit breaker and a 30mA differential.

Device Presentation

The welding units consist of several key components:

• On/Off Switch: Powers the unit.
• Power Settings: Two switches with 7 positions for adjusting welding voltage, proportional to workpiece thickness.
• Control Panel: For welding settings (manual or automatic mode).
• European Standard Torch Connection: Standard connection for welding torches.
• Thermal Protection Light: Indicates when the unit requires a cool-down period after intensive use.
• Torch Support: For resting the welding torch.
• Power Cable: Typically 5 meters long.
• Earth Cable Connector: For connecting the earth clamp.
• Gas Bottle Support: Accommodates one gas bottle (up to 10m³).
• Fastening Chain: Secures the gas bottle.
• Reel Support: For wire spools (Ø 200 mm or 300 mm).
• Gas Connector: Specific connector for gas supply (e.g., 350-4S DUO DV).
• Torch Cable Support: Manages the torch cable.
• Wire Feeder Solenoid Valve: Controls gas flow to the torch.
• Wire Feeder Gas Connection: Connects gas to the torch.
• Wire Feeder Control Cable Connector: Connects the wire feeder control.
• Wire Feeder Power Cable Connector: Connects power to the wire feeder.
• Selection Switch Potentiometer: (On 300G and 350 G DV models) Adjusts welding parameters.

Figure II illustrates the device components and assembly.

Welding Modes

Semi-Automatic Welding (MIG/MAG)

The TRIMIG series supports welding of steel, stainless steel, and aluminium using either Metal Active Gas (MAG) or Metal Inert Gas (MIG) processes.

Steel / Stainless Steel (MAG Mode)

• TRIMIG 200-4S: Welds Ø 0.6/0.8/1mm steel and stainless steel wires. Recommended wire size: Ø 1.0 mm with appropriate roller and contact tip.
• TRIMIG 250-4S DV: Welds Ø 0.8/1/1.2mm steel and stainless steel wires. Recommended wire size: Ø 1mm with appropriate roller and contact tip.
• TRIMIG 300-4S, 300 G, 350-4S DUO DV, 350 G DV: Welds Ø 0.8/1/1.2mm steel and stainless steel wires. Recommended wire size: Ø 1mm with appropriate roller and contact tip.

Gas: Argon + CO2 (Ar+CO2) mixture is required. CO2 percentage varies with application. Gas flow: 10-20 L/min.

Aluminium (MIG Mode)

• TRIMIG 200-4S: Welds Ø 0.8mm and 1mm aluminium wires.
• TRIMIG 250, 300, 350: Welds Ø 1mm and 1.2mm aluminium wires.

Gas: Pure Argon (Ar) is required. Consult gas distributor for specific requirements. Gas flow: 15-25 L/min.

Important Notes for Aluminium Welding:

• Set roller pressure to minimum to avoid crushing the wire.
• Remove the capillary tube before connecting the aluminium torch.
• Use a special aluminium torch with a Teflon sheath for reduced friction.

Figure III illustrates welding modes and material compatibility.

Reel and Torch Assembly

Instructions involve opening the machine door, positioning the wire reel on its support, adjusting the reel brake, and fitting double groove rollers (Ø 0.8/1 or Ø 1/1.2). For first use, release wire guide screws, place rollers, tighten screws, and position the wire guide close to the roller. Drive roller adjustment involves loosening a knob, starting the motor, and tightening the knob until the wire moves. A common adjustment scale is 3-4 for steel and 2-3 for aluminium. Ensure the wire guide is correctly positioned and does not touch the roller.

Figure IV details the reel and torch assembly process.

Control Panel and Modes

The control panel allows selection of welding modes and wire speed.

Welding Mode Selection:

• 2T: Two-stage welding.
• 4T: Four-stage welding.
• SPOT: Spot welding with adjustable spot diameter.

Wire Speed Selection:

A wire speed regulator allows adjustment from 1 to 15 m/minute.

Manual Mode:

Wire speed is set manually by adjusting the potentiometer. The arc quality is often judged by sound: stable arc with low crackling is ideal. Too low speed results in discontinuous arc; too high speed causes crackling and wire push-back.

Synergic Mode:

In this mode, the device automatically controls wire speed based on selected parameters: wire type, wire diameter, and power setting. The potentiometer should be set in the "OPTIMAL SYNERGIC" zone. Wire speed can be fine-tuned using the +/- adjustment. The last welding configuration is automatically saved.

Figure V illustrates the control panel and mode selections.

Duty Cycle

The welding units have a "constant current" output characteristic. Duty cycles are specified according to EN60974-1 (at 40°C on a 10-minute cycle):

Note: Duty cycle tested at room temperature (40°C) and determined by simulation. These are Class-A devices for industrial/professional environments.

Maintenance

Maintenance should only be performed by qualified personnel. Ensure the machine is unplugged and the ventilator has stopped. Regularly remove dust from the unit and check electrical connections. Inspect the power supply cord for damage and replace if necessary. Ensure ventilation holes are not blocked. Check welding cables and earth clamp before each use.

Safety Precautions

Arc welding can be dangerous. Follow these safety guidelines:

• Arc Radiation: Use a welding helmet with appropriate filters (EN169 or EN 379).
• Environment: Weld 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 an earthed power supply. Do not touch high-voltage parts. Ensure the power supply is suitable.
• Handling: Do not place or carry the unit over people or objects.
• Burns: Wear protective (fire-proof) clothing, gloves, and apron. Keep bystanders 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. Use in a well-ventilated environment with artificial extraction if indoors.
• Additional Precautions: Special care is needed in areas with increased risk of electric shock, poorly ventilated rooms, or presence of flammable materials. Welding in raised positions should only be done with safety platforms.
• Pacemakers: Consult a doctor before using the device.
• Pipe Freezing: Do not use the unit to unfreeze pipes.
• Gas Bottles: Handle with care to avoid damage to the bottle or valve.

Troubleshooting

Common issues and their solutions:

Electrical Diagrams

Detailed electrical diagrams are provided for specific TRIMIG models (TRIMIG 200-4S, 250-4S, 300-4S, 300 G, 350-4S DUO DV, 350 G DV). These diagrams illustrate the internal circuitry, component connections, and configuration settings via various switch and connector tables.

Key tables from the diagrams include:

• TRIMIG 200-4S: POS (Position) switch settings for various connections (e.g., 1-2, 3-4, etc.).
• TRIMIG 250-4S: Similar POS switch settings and input/output configurations.
• TRIMIG 300-4S: POS switch settings and input/output configurations.
• TRIMIG 300 G: POS switch settings and input/output configurations.
• TRIMIG 350-4S DUO DV 230-400V: POS switch settings and input/output configurations.
• TRIMIG 350 G DV 230-400V: POS switch settings and input/output configurations.

Spare Parts

A comprehensive list of spare parts is available, categorized by model and part number. This includes components like chains, cable supports, handles, wire speed knobs, control keyboards, switches, wire feeders, cables, wheels, diode bridges, transformers, fans, contactors, and solenoids. The parts list specifies compatibility across different TRIMIG models (200, 250, 300, 350) and includes part numbers for ordering.

Warranty Information

The warranty is valid for 1 year from the date of purchase, covering manufacturing defects (parts and labour). It does not cover issues arising from incorrect voltage, misuse, drops, disassembly, transport damage, or normal wear and tear. For warranty claims, return the unit with the completed certificate and a description of the fault. GYS provides after-sales service for repairs after the warranty period, subject to quotation acceptance.

Declarations of Conformity

GYS declares that the TRIMIG welding machines comply with European directives, including the Low Voltage Directive (2006/95/CE) and the EMC Directive (2004/108/CE). Compliance is based on harmonized standards such as EN60974-1, EN 50445, and EN60974-10. CE marking was applied in 2013.

Symbols and Icons

The manual uses various symbols to denote electrical units, welding processes, and safety warnings:

• A: Amperes (Current)
• V: Volts (Voltage)
• Hz: Hertz (Frequency)
• S: MIG/MAG Welding (Metal Inert Gas / Metal Active Gas)
• IP21: Protection against fingers and vertical water drops.
• D: Continuous welding current (DC).
• 3~50Hz: Three-phase power supply (50 Hz).
• U0: Rated no-load voltage.
• U1: Rated supply voltage.
• I1max: Rated maximum supply current (effective value).
• I1eff: Maximum effective supply current.
• EN60974-1: Compliance with the standard for welding units.
• X(40°C): Duty cycle at 40°C.
• Safety Symbols: Warnings regarding arc radiation, electric shock, fire hazards, fumes, and proper disposal.

Accessories

Various accessories are available for the TRIMIG series, including different wire types, diameters, gas nozzles, contact tips, and cable sets, specified for each model and wire size.