GYS CALIWELD CGU 1.0 Manual
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GYS CALIWELD CGU 1.0 Manual

Calibration case
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VALIDATION CASE
EN
1 - 37
CALIWELD
www.gys.fr
N° V4_08/04/2021

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Summary of Contents for GYS CALIWELD CGU 1.0

  • Page 1 VALIDATION CASE 1 - 37 CALIWELD www.gys.fr N° V4_08/04/2021...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS S Y M B O L S ............................p 3 S A F E T Y I N S T RU C T IO N S .......................p 4-5 S TA N DA R D R E M I N D E R ......................p 6 T E C H N IC A L S P E C I F IC AT IO N S .....................p 7...

  • Page 3: Symbols

    CALIBRATION CASE CALIWELD SYMBOLS Warning ! Read the instructions manual before use. WARNING. DANGER. "WARNING. DANGEROUS VOLTAGE. Risk of electrocution." Complies with European Union directives. EAEC Conformity marking (Eurasian Economic Community). Material complies with British requirements. Material complies with Moroccan standards. 85-265 V Single phase power supply 50 or 60 Hz ~ 50/60Hz...

  • Page 4: Safety Instructions

    CALIBRATION CASE CALIWELD IP 67 Closed carry case : the product is dust proof and water proof for 30 min up to 1 m deep. SAFETY INSTRUCTIONS Only use this device for its intended use, otherwise the warranty may be void. Inspect the case before using the device: •...
  • Page 5 CALIBRATION CASE CALIWELD WELDING FUMES AND GASES The fumes, gases and dust created when welding are a health hazard. It is required to ensure adequate ventilation or extraction for fumes and gases. Using an air fed welding helmet is recommended in case of insufficient ventilation in the workplace.

  • Page 6: S Ta N Da R D R E M I N D E R

    CALIBRATION CASE CALIWELD NORMATIVE REMINDER According to the EN1090 standard, a welding generator must undergo a control of its welding parameters. This check allows us to issue a «Valida- tion report». The following validation procedure is based on the reference standards EN 50504 and EN 60974-14. The objective of this procedure is to ensure a correct welding result that is reproducible over time.

  • Page 7: T E C H N Ic A L S P E C I F Ic At Io N S

    CALIBRATION CASE CALIWELD TECHNICAL FEATURES The CALIWELD case is a device which allows: - to issue a validation report (certificate which attests the proper functioning of the product - Validation mode). - to check the welding values (current / voltage or energy, wire speed and gas - Multimeter mode and Oscilloscope). Power supply voltage: 85 V to 265 V (±...

  • Page 8: Ac C E S S O R I E S A N D C O N N E C T Io N S D E S C R I P T Io N

    CALIBRATION CASE CALIWELD DESCRIPTION OF ACCESSOIRES AND CONNECTIONS Picture Name - Description Duty cycle Ref: 060531 - Measuring cable 2 m CALIWELD VM1- Texas connection 70.24 Insulated Texas/Dinse connection for safe voltage measurement + insulated «banana» plug for (25°C) connection to CALIWELD case. 316 A@60% 120 V Max Ref: 060524 - Measuring cable 2 m CALIWELD ECM1 - Euro connection / CGU1.0...

  • Page 9: Set Up

    CALIBRATION CASE CALIWELD SET UP 1. Minimal configuration Windows 7 operating system Free disk space 10 Go Minimum resolution: 600 x 800 px RAM : 2 Go 1 USB port 2. Software and hardware installation Refer to quick start procedure (appendix, p.25). 3.

  • Page 10: Software Operation

    CALIBRATION CASE CALIWELD SOFTWARE OPERATION File menu - Preferences : ◊ Identity: information on the validation authority: name, address, postcode, town, te- lephone, e-mail, logo. ◊ Instrument: information on resistive load and case, type, serial number, report number, verification date. ◊...

  • Page 11: Detail

    • Infos : Indicates information about the programme : Program version / Date of last update / Da- tabase version / Manufacturer’s address GYS / Contact email of the manufacturer GYS. • Caliload 330 : access to the adjustment table (MIG/MMA/TIG) of the resistive load.

  • Page 12: Multimeter Mode

    CALIBRATION CASE CALIWELD MULTIMETER MODE Fig.1: Multimeter mode interface. DESCRIPTION The multimeter page opens when the software is launched. This mode offers the possibility to see each measurement channel, to record the dis- played values and to record weld seams. It also allows the calculation of the welding energy. The 4 measuring channels are: the current channel the tension channel...

  • Page 13: Recording

    CALIBRATION CASE CALIWELD Off Mode The «Off» mode allows to take a measurement at a time «t» by clicking on the disk. Manual mode The choice of the manual mode implies that the user chooses when to perform his welding points. Start the manual recording of points by clicking on the button .

  • Page 14: History, Saving & Printing

    CALIBRATION CASE CALIWELD RECORDING & PRINTING HISTORY History All recordings are available with several information in a history (up to 99 recordings). To get there, click on the «disabled» box under the heading «Acquisition» and then click on «Open» in the «Recording» menu. The measurement history gives the following information: Backup number, backup date and time, weld bead duration if recording >...

  • Page 15: Oscilloscope Mode

    CALIBRATION CASE CALIWELD OSCILLOSCOPE MODE Fig.5: Oscilloscope page DESCRIPTION (Fig.5: oscilloscope page) The oscilloscope mode allows you to select two measurement channels, view them and save them on a chart. This additional mode allows to focus on a precise channel and to compare it to another channel thanks to its chart. The elements which are included in the Oscilloscope mode page (Fig.5) are: - A chart.

  • Page 16: Recording

    CALIBRATION CASE CALIWELD RECORDING Manual recording To start a new manual recording, tick the «manual» box in the «measurement recording» menu. The START box appears ( fig. 5) and changes to a STOP box when the recording starts. To start recording the measurements, either activate the machine by using the remote control ( fig.5),or by welding, and then press the button each time that a recording is required.
  • Page 17 CALIBRATION CASE CALIWELD Fig.10: Recording list To open a previous recording, click on it to select it and click on the button To delete a recording, click on it to select it and click on the button To delete all recordings, click on the button...

  • Page 18: Validation Mode

    IN THE CASE OF A SCENARIO ALREADY AVAILABLE The scenarios for the GYS and IMS machines are already stored on the software. If the user has one of these models, he will be able to use the relevant scenario available on the software and on the website (the product updates are available on the GYS website www.gys-welding.com). The database can be imported or directly modified in the software (Warning : the imported database will replace the existing scenarios.

  • Page 19: In The Case Of A Scenario Creation

    CALIBRATION CASE CALIWELD IN THE CASE OF A SCENARIO CREATION Data are entered manually. In this case, click on «Add/Modify Scenario» The «Scenario» window pops up : Fig.12: Scenario page To create a new scenario : - From an existing scenario: open the page «Add/Modify Scenario» of the existing scenario and then save the modified scenario under another name (according to the model or manufacturer of the machine).

  • Page 20: Start

    CALIBRATION CASE CALIWELD How to fill in the list of points ? • Start by filling in the «Product» and «Information» sections. • Then select the channels to be measured in the section . If the machine has a digital display indicating the value of the selected channel, tick the «Display»...

  • Page 21: History

    CALIBRATION CASE CALIWELD HISTORY The «History» button (n° fig. 14) allows to open the «Validation history» page. If the welding machine has already been validated with the software, it will be written in this history. It can be printed or deleted with the «Recording» menu. Fig.15: recording and printing «Validation history».

  • Page 22: Recording

    CALIBRATION CASE CALIWELD Fig. 16: Validation page Before starting the recording, several information must be filled on the validation page in the following sections: • «Miscellaneous» - temperature: the actual temperature is indicated, but can be changed if necessary, - the date, •...
  • Page 23 CALIBRATION CASE CALIWELD «Automatic Recording» To activate automatic recording, use the «settings» tab . Then tick the «Auto» box in the «Measurement recording» section. Fig.17 To change the settings of the auto- matic mode once the value capture has started, it is necessary to go to the manual mode (security so that the user does not change the set- tings during a measurement).
  • Page 24 CALIBRATION CASE CALIWELD Once 10 measuring points have been taken (when the 1b spot is done), click on the «finish» button (n° fig. 17) which now appears at the bottom right of the window. Fig.18: End of acquisition (last point 1b + box «Finish that appears») A «Comment»...
  • Page 25 CALIBRATION CASE CALIWELD Fig.21: generated report The information are displayed before opening the PDF file. Press the «Measure page» button. The rest of the report is displayed. The «Back» box allows to go back to the page 1 of the report. Click on «Record»...

  • Page 26: Appendices

    APPENDICES QUICK START PROCEDURE CHECKING A SETTING ON THE WELDING MACHINE HELP ORGANIZATION OF THE SOFTWARE FILE LIST OF PRODUCTS THAT REQUIRE SPECIAL CONFIGURATION VALIDATION CERTIFICATE EN50504 - EXPORT PDF CERTIFICATE OF VALIDATION EN60974-14 - EXPORT PDF REMINDER OF THE TOLERANCES OF THE EN 60974-14 STANDARD REMINDER OF THE TOLERANCES OF THE EN 50504 STANDARD EXTRACT FROM STANDARD 60974-4...
  • Page 28 CALIBRATION CASE CALIWELD CHECKING A SETTING ON THE WELDING MACHINE Extract from the resistive load note and from standard EN 50504 Before adjusting the product, you must: 3. Connect the welding machine to the resistive load with the grounding cable and the torch used. If not, use cables of the same dimension (length and cross section), 4.
  • Page 29 CALIBRATION CASE CALIWELD Correction of voltage drops in cables The verification of a welding machine is done at the output of the welding machine and not at the load terminals. The measurement results can be wrong because of the voltage drop in the cables induced by their resistors. It is then necessary to compensate the measurement with the values indicated in the table below to obtain the voltage at the terminals of the product.
  • Page 30 CALIBRATION CASE CALIWELD TROUBLESHOOTING List of error messages N° erreur Message Solution Update the security database. 1. Get the database security on the website 2. Copy - paste this database into the folder Validation case not allowed. C:\\ProgramFiles\caliweld\Ressources\database\ 3. Then in the software import the Security database (section “Database”...
  • Page 31 CALIBRATION CASE CALIWELD ORGANIZATION OF THE SOFTWARE FOLDER ( C:\\ProgramFiles\caliweld\) The software package includes: 1. C:\Users\...\AppData\Roaming\CaliWeld Important files for the user: csv : Calibration (backup folder of validation mode .csv files). History (backup folder of the history .csv files). Voltmeter (backup folder of the multimeter and related .csv files). pdf : Calibration (backup folder for PDF files of the validation).
  • Page 32 CALIBRATION CASE CALIWELD LIST OF PRODUCTS REQUIRING A SPECIFIC CONFIGURATION Brand Models / Ranges Settings NEOPULSE Set the station to «MAN, 2T» mode. Select the argon steel Co2 gas and indicate the wire diameter corresponding to the coil. PULSEMIG PROMIG / MAGYS For the thread speed, set the feeder to manual mode.
  • Page 33 CALIBRATION CASE CALIWELD CERTIFICAT DE VALIDATION NF- - EN 50504 numero: 202102000026B6C Autorité de validation Client GYS SAS No client 01234 Adresse 1 rue de la Croix des landes Nom client Code 53941 Service BE elec Ville SAINT BERTHEVIN Adresse...
  • Page 34 CALIBRATION CASE CALIWELD CERTIFICAT DE VALIDATION NF- - EN 60974 numero: 202102000025B6C Autorité de validation Client GYS SAS No client 01234 Adresse 1 rue de la Croix des landes Nom client Code 53941 Service BE elec Ville SAINT BERTHEVIN Adresse...
  • Page 35 CALIBRATION CASE CALIWELD Reminder of EN 60974-14 tolerances EN 50504 classe STANDARD MEASURE Mesure Tolerance Reference Validation range +/-10% Of the real value If between 25 and 100% of the maximum setting Voltage +/- 2.5% From the highest setting If less than 25% of the maximum setting +/-10% Of the real value If between 25 and 100% of the maximum setting...
  • Page 36 CALIBRATION CASE CALIWELD Reminder of EN 50504 tolerances EN 60974-14 classe STANDARD MEASURE Measure Tolerance Reference Validation range +/- 10% From the reference value If between 25 and 100% of the highest set value Voltage +/- 2.5% From the set value If less than 25% of the highest set value +/- 10% From the reference value...
  • Page 37 CALIBRATION CASE CALIWELD Extract from standard 60974-4 Test sequence on used arc welding equipment Periodic inspection and test After repair Visual inspection in accordance with 5.1 Visual inspection in accordance with 5.1 Electrical test: Electrical test: – protective conductor resistance in accordance with 5.2 –...

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