GYS AUTO E1 / E2 / E3 MIG/MAG Welding Machine

General Information

This document provides instructions for the GYS AUTO E1, E2, and E3 MIG/MAG welding machines. It covers assembly, operation, safety, and maintenance.

Model Numbers: E1, E2, E3

Version: V2

Date: 30/07/2024

For more languages, visit www.gys.fr.

Assembly Instructions

The following steps detail the assembly of the welding machines. Specific hardware (screws) are indicated in the diagrams.

Base Assembly (Diagrams 1-4)

The base assembly involves attaching various components to form the main structure of the welding machine. This typically includes securing parts using screws such as M6x12 and M6 (x8).

Wheel and Holder Assembly

E1 Model: Assembly involves attaching wheels and a gas bottle holder. Screws like M5x12 (x4) and M5 (x4) are used for smaller components, while M8x12 (x8) and M6 (x8) are used for larger structural parts like the base and wheel mounts.

E2 / E3 Models: Assembly includes mounting wheels and a gas bottle holder. This uses screws like M6x12 (x3) for the rear wheel assembly and M6x12 (x4) for other parts.

Bracket Assembly (E2/E3)

For E2/E3 models, a specific bracket assembly (KUN STYRKE 077300) is shown, using screws M6x12, M6x40, and M6. The diagrams illustrate the step-by-step process of attaching these brackets.

Gas Bottle Holder Installation

E1: Accommodates a 4 m³ gas bottle.

E2 / E3: Accommodates a 4 m³ gas bottle or two 4 m³ gas bottles.

The diagrams show how to secure the gas bottles to the machine chassis.

Update Procedure

The machine can be updated using a USB drive. The software is available on the GYS website.

1. Press the STOP button.
2. Insert the USB key.
3. Press the START button.
4. The screen will display "System Update V1.02", "Please Wait", and "Check File Integrity".
5. Remove the USB key after the update is complete.

Gas Connection

General: Connect a suitable pressure regulator to the gas cylinder. Use the provided hoses and hose clamps to prevent leaks. Ensure the gas cylinder is securely fastened. Adjust gas flow using the regulator dial. For easier adjustment, operate the wire feeder rollers by pressing the torch trigger (release the wire feeder brake knob to avoid wire retraction). Maximum gas pressure: 0.5 MPa (5 bar). This procedure does not apply to "No gas" welding.

E1: Requires a 1-meter gas hose.

E2 / E3: Requires a 2-meter gas hose. For E3, the gas pipe should be cut into 4 parts of desired length.

Gas Connection Types

Type I:

• A (Steel): Shows connections for steel wire, including steel sheath, steel core, and wire guides.
• B (Aluminum): Shows connections for aluminum wire, featuring a Teflon sheath for reduced friction, and specific guides.
• C (Shield Gas): Indicates the use of shield gas.

Type II (Machine Layouts): Diagrams show the overall layout of E1, E2, and E3 machines with numbered components. Refer to the parts list for identification.

Safety Warnings and Recommendations

General Instructions: Read and understand all instructions before operation. Do not modify the equipment. The manufacturer is not liable for damages resulting from improper use.

Environment: Use only for welding operations within specified limits. Avoid dusty, acidic, or flammable environments. Ensure adequate ventilation. Operating temperature: -10 to 40°C (14 to 104°F). Storage temperature: -20 to 55°C (-4 to 131°F). Humidity: Max 50% at 40°C, Max 90% at 20°C. Altitude: Up to 1000m.

Protection of Individuals and Others: Arc welding can cause severe injury or death. Protect yourself and others by wearing appropriate protective clothing (flame-retardant, insulating, dry), gloves, and eye protection. Use hearing protection if noise levels are high. Keep body parts, hair, and clothing away from moving parts (fan). Do not remove protective covers while the machine is active. Welded parts are hot; allow them to cool before handling.

Welding Fumes and Gases: Welding fumes and gases are hazardous. Ensure adequate ventilation or use a fresh air mask. Check extraction efficiency against safety standards.

Fire and Explosion Risk: Keep flammable materials at least 11 meters away. Have fire-fighting equipment ready. Avoid welding near grease or paint. Do not weld in closed containers or pipes unless properly prepared. Do not direct grinding work towards the power source or flammable materials.

Gas Cylinders: Store cylinders upright in well-ventilated areas, secured to prevent falling. Close the cylinder between uses. Keep away from heat sources, flames, arcs, and electrical circuits. Never weld on a pressurized cylinder. Open cylinder valves carefully.

Electrical Safety: Ensure the electrical network is properly grounded. Use the correct fuse size. Electric shock can be fatal. Never touch live parts. Disconnect power and wait 2 minutes before opening the unit. Ensure cables and torches are in good condition.

EMC Classification: This Class A equipment is not intended for residential areas due to potential radio frequency interference.

Electromagnetic Emissions: Welding current produces electromagnetic fields (EMFs) that can interfere with medical implants like pacemakers. Take precautions for individuals with implants. Minimize EMF exposure by keeping welding cables together, positioning yourself away from the circuit, not wrapping cables around the body, and connecting the return cable close to the workpiece.

Recommendations for Welding Area Evaluation and Installation

The user is responsible for proper installation and use. Evaluate the welding zone for potential electromagnetic interference from other equipment, radio/TV receivers, computers, safety-critical equipment, and the health of nearby individuals (e.g., pacemaker users). Ensure compatibility of other equipment in the environment. Consider the time of day for welding activities.

Reducing Electromagnetic Emissions: Connect to the public supply network as recommended. Shield power cables in metal conduits. Perform routine maintenance. Ensure all access doors are closed and locked during operation. Keep cables short and close to the ground. Consider equipotential bonding of metal objects in the area. Ensure the workpiece is properly grounded. Selective shielding of cables and equipment can reduce interference.

Transport and Handling: Do not use cables or torch to move the machine. Move it in an upright position. Do not drag it over people or objects. Never lift a gas cylinder and the welding machine simultaneously. Remove the wire spool before lifting or transporting.

Equipment Installation: Place the welding power source on a floor with a maximum inclination of 10°. Ensure adequate ventilation and access to controls. Do not use in environments with conductive metal dust. Protect from rain and direct sunlight. The equipment has an IP21 protection class (protected against solid objects >12.5mm and vertical water drops).

Maintenance and Advice

Maintenance should only be performed by qualified personnel. Annual maintenance is recommended. Disconnect power and wait 2 minutes before working on the equipment. Regularly clean dust with a blower. Check electrical connections. Inspect power cables for damage and replace if necessary. Keep ventilation openings clear. Do not use the machine for thawing pipes, charging batteries, or starting engines.

Installation - Product Operation

Installation should be performed by authorized personnel only. Ensure the generator is disconnected from the mains. Parallel or series connection of generators is prohibited. Use the provided welding cables for optimal performance.

Description: The material is a ventilated "synergistic" semi-automatic welding station for MIG or MAG welding. It is recommended for steel, stainless steel, and aluminum, as well as brazing. Adjustment is simple and fast due to its integrated "synergistic" mode.

Description of Materials (II)

Detailed lists of parts for E1, E2, and E3 models are provided, including:

• Spool holders (Ø 200/300 mm)
• Accessory hatch
• Cable support
• Torch holder
• HMI (Human-Machine Interface)
• START/STOP switch
• Ground clamp cable
• Euro connector (torch)
• Storage compartment
• Gas connection
• Power cable
• Gas bottle holder (4m or 2x4m)
• USB port
• Wire feeder motor
• Gas feed-through

Human-Machine Interface (HMI)

Refer to the HMI manual for detailed information.

Power Supply - Start: The equipment uses a 16A CEE7/7 plug and requires a single-phase 230V (50-60Hz) electrical installation with a grounded neutral. The effective absorbed current (I1eff) is indicated on the unit. Ensure the power supply and its protections (fuse/breaker) are compatible. The power source operates within 230V -20% to +15%. It enters protection mode if voltage is below 185Veff or above 265Veff. Start by pressing the START/STOP button; stop by pressing it again. Do not turn off the station while it is charging.

Connection to Generator: The equipment can operate with generators if the auxiliary power meets requirements: alternating voltage of 230V -20% to +15%, peak voltage less than 400V, and frequency between 50-60Hz. High voltage spikes from generators can damage the unit.

Use of Electric Extension Cord: Extension cords must match the equipment's voltage requirements in length and cross-section, complying with national regulations. For 230V input, a 2.5 mm² cord is recommended for lengths under 45m.

Spool Installation: Remove the torch nozzle and contact tube. Open the generator compartment. Place the spool on its support, aligning the drive pin. Adjust the brake wheel to prevent wire backlash. Do not overtighten the brake, as it can overheat the motor.

Wire Feeding: To change rollers, loosen the knob, unlock the rollers by unscrewing the fixing screws, and install the appropriate motor rollers. Ensure the rollers match the wire diameter and material (V-groove for steel, U-groove for aluminum). Check the inscription on the roller. Install the wire by feeding it through the wire feeder and tightening the knob. Activate the motor by pressing the torch trigger.

Wire Installation Notes: A too-narrow sheath can cause wire feeding problems and motor overheating. Ensure the torch connection is tight. Prevent wires or spools from touching mechanical parts to avoid short circuits.

Risk of Injury from Moving Components: Wire feeders have moving parts that can cause injury. Do not touch rotating or moving components. Ensure covers are securely closed. Do not wear gloves when feeding or changing wire spools.

Semi-Automatic Welding (Steel/Stainless Steel - MAG Mode): The equipment supports steel and stainless steel wire from Ø 0.6 to 1.0 mm. It comes with Ø 0.6/0.8 rollers for steel/stainless steel (E1/E2) and Ø 0.6/0.8 and Ø 0.8/1.0 rollers for steel/stainless steel (E3). Requires specific welding gas (ArCO2 for steel, 2% CO2 for stainless steel). Gas flow for steel is 8-15 L/min. Use the optional flow meter for measurement.

Semi-Automatic Welding (Aluminum - MIG Mode): Supports aluminum wire from Ø 0.8 to 1.2 mm. Comes with Ø 0.8/1.0 rollers for aluminum (E2/E3). Requires pure argon (Ar) gas. Gas flow for aluminum is 15-20 L/min. Use specific rollers, minimal pressure on drive rollers, a special aluminum torch with a Teflon sheath, and a special aluminum contact tip. The optional accessory 90950 (IC) with stainless steel guide is recommended for aluminum welding.

Semi-Automatic Welding (CuSi and CuAl - Brazing Mode): Supports CuSi and CuAl wire from Ø 0.8 to 1.0 mm. Use a steel sheath torch and pure argon (Ar) gas.

Troubleshooting

The manual includes a table detailing symptoms, possible causes, and remedies for common issues such as inconsistent wire feed, no power, poor welding current, porous weld beads, excessive spatter, no gas, download errors, backup problems, USB key issues, and update problems.

Example: If the welding bead is porous, possible causes include insufficient gas flow, empty gas cylinder, poor gas quality, or draft. Remedies include adjusting gas flow (15-20 L/min), cleaning the gas nozzle, or ensuring proper ventilation.

Parts List and Diagrams

Detailed diagrams and part lists are provided for E1, E2, and E3 models, showing the location of components such as spool holders, HMI, switches, connectors, wire feeders, wheels, fans, and circuit boards. Circuit diagrams are also included, illustrating the electrical connections.

Technical Specifications

Pictograms and Symbols

The manual uses various pictograms to convey important information:

• i: Information symbol, indicating that the user manual should be read.
• Warning Symbol: Indicates potential hazards or important safety precautions.
• MIG/MAG Welding Symbol: Represents the MIG/MAG welding process.
• S: Often indicates a specific setting or mode, like "Synergic".
• U0: Represents Open Circuit Voltage.
• I2: Represents Welding Current.
• V: Represents Voltage.
• Hz: Represents Frequency.
• m/min: Represents wire feed speed in meters per minute.
• U1: Represents primary power supply voltage.
• I1max: Represents maximum supply current.
• I1eff: Represents maximum effective supply current.
• CE Marking: Indicates conformity with European directives.
• UKCA Marking: Indicates conformity with UK requirements.
• EAC Marking: Indicates conformity with Eurasian Economic Community standards.
• IP21: Indicates protection against solid objects >12.5mm and vertical water drops.
• Fan Symbol: Indicates a fan for cooling.
• START Button: Power On.
• STOP Button: Power Off.

Warranty Conditions

The warranty covers manufacturing defects for 2 years (parts and labor). It does not cover damage from transport, normal wear and tear, improper use, or environmental damage. For warranty claims, return the unit to the dealer with proof of purchase and a descriptive note.

Contact Information

GYS has offices in France, Italy, UK, China, Germany, and Iberica. Contact details are provided for each location.

GYS France: 1, rue de la Croix des Landes - CS 54159, 53941 Saint-berthevin Cedex, France. www.gys.fr, +33 2 43 01 23 60, service.client@gys.fr

GYS UK: Unit 3, Great Central Way, CV21 3XH - Rugby - Warwickshire, United Kingdom. www.gys-welding.com, +44 1926 338 609, uk@gys.fr

GYS Italia: Via Porta Est, 7, 30020 Marcon - VE, Italia. www.gys-welding.com, +39 041 53 21 565, italia@gys.fr

GYS China: 6666 Songze Road, Qingpu District, 201706 Shanghai, China. www.gys-china.com.cn, +86 6221 4461, contact@gys-china.com.cn

GYS GmbH: Professor-Wieler-Straße 11, 52070 Aachen, Deutschland. www.gys-schweissen.com, +49 241 / 189-23-710, aachen@gys.fr

GYS Iberica: Avenida Pirineos 31, local 9, 28703 San Sebastian de los reyes, España. www.gys-welding.com, +34 917.409.790, iberica@gys.fr