GYS CALIWELD CGU 1.0 Bedienungsanleitung

N° V4_08/04/2021

EN 1 - 37 VALIDATION CASE

CALIWELD

www.gys.fr

TABLE OF CONTENTS

SYMBOLS..........................................................................................................................................p 3

SAFETY INSTRUCTIONS.......................................................................................................p 4-5

STANDARD REMINDER.............................................................................................................p 6

TECHNICAL SPECIFICATIONS.............................................................................................p 7

ACCESSORIES AND CONNECTIONS DESCRIPTION................................................p 8

SET UP................................................................................................................................................p 9

SOFTWARE OPERATION...................................................................................................p 10-11

MENU BAR DETAIL..................................................................................................................p10

STATUS BAR DETAIL................................................................................................................p 11

MULTIMETER MODE............................................................................................................p 12-14

DESCRIPTION.........................................................................................................................p 12

START....................................................................................................................................p 12

RECORDING............................................................................................................................p 13

HISTORY, SAVING & PRINTING.................................................................................................p 14

OSCILLOSCOPE MODE.......................................................................................................p 15-17

DESCRIPTION.........................................................................................................................p 15

ZOOM.....................................................................................................................................p 15

RECORDING............................................................................................................................p 16

SAVING & PRINTING................................................................................................................p 17

VALIDATION MODE.............................................................................................................p 18-24

DESCRIPTION.........................................................................................................................p 18

IN THE CASE OF AN EXISTING SCENARIO.................................................................................p 18

IN THE CASE OF A SCENARIO CREATION.................................................................................p 19

START....................................................................................................................................p 20

HISTORY.................................................................................................................................p 21

RECORDING............................................................................................................................p 22

APPENDICES...........................................................................................................................p 26-37

CALIBRATION CASE CALIWELD EN

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

~ 50/60Hz

15 VA max Single phase power supply 50 or 60 Hz

VVoltage measuring point

ACurrent measuring point

nWire speed measuring point

Gas input measuring point

Gas output measuring point

Taking back remote control

Input point of the measurement ow

Output point of the measurement ow

Case power indicator

USB connections indicator

USB 2.0

USB connector

Earth clamp

HF PROTECTION Electronics protected against HF of TIG machines

IP 30 Open carry case : the product is protected against external objects larger than 2.5 mm. However, it is not

waterproof.

CALIBRATION CASE CALIWELD EN

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:

• Look for potential defects or cracks.

• Check carefully the insulation of the terminals.

Do not use the product in the vicinity of explosive gases, fumes or in a wet/humid environment.

Do not work on your own.

The use of this device is limited to the indicated measurement categories, voltage and intensity.

Be aware of local and national safety requirements, and make sure to comply. Use personal protective equipment (rubber glo-

ves, mask and heat proof clothing) in order to prevent injuries from electrocution and explosions caused by electrical arcs when

dangerous live conductors are exposed.

Use measuring categories (CATII), accessories with the right voltage and intensity (sensors, measuring leads and adaptors)

suitable for the device for all measurements.

Avoid contact with voltage higher than >30 V AC, 42 V AC peak or 60 V DC.

Only use the current sensors, measuring leads and adaptors supplied with the machine.

Turn the product o if it is damaged.

Do not use the device if it is damaged.

Do not use the device if it is not working properly.

Only use the sensors, measuring leads and accessories which match the measurement category, voltage and intensity of the

device.

Only use cables whose voltage is suitable for the device.

Never apply a voltage exceeding the nominal value between the terminals, or between a terminal and the earth.

Measure a known voltage (prior to the test) to make sure that the device is working correctly.

Use the terminals, the mode and the range matching the measures you wish to take.

Do not use damaged measuring leads. Check for insulation defects, exposed metal parts and wear indicator on measuring leads.

Check the continuity of the measuring leads by testing a known voltage.

Do not create contact between the sensors and a voltage source when the measuring leads are connected to the current terminals.

This product should be disposed of in an appropriate recycling facility. Do not throw away in a household bin.

This product should be recycled appropriately.

CALIBRATION CASE CALIWELD EN

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 insucient

ventilation in the workplace.

Check that the extraction is eective by checking it against recommended safety standards.

Caution, welding in small spaces requires surveillance from a safe distance. In addition, the welding of certain materials containing

lead, cadmium, zinc, mercury or beryllium may be particularly harmful.

Do not weld in areas where grease or paint are stored.

GAS CYLINDERS

Gas leaking from the cylinders can lead to suocation if present in high concentrations around the work area.

Transport must be done safely: cylinders closed and device switched o. They must be stored vertically and held

by a support to limit the risk of falling.

The same recommendations apply for the storage of the cylinders. They must also be stored in open and ventilated

areas.

Gas cylinders must be stored in an open or ventilated area. The cylinders must be in a vertical position and fastened to a support

or trolley.

Close the cylinder in between using it. Be wary of temperature variations and sun exposure.

The cylinder must not be in contact with a ame, electric arc, torch, earth clamp or all other sources of heat.

Always keep gas cylinders away from electrical circuits and therefore never weld a pressurised cylinder.

Be careful when opening the valve of a cylinder, it is necessary to remove the valve head and to make sure that the correct gas mix

is used.

ELECTRICAL SAFETY

The electrical mains used must have an earth terminal. Follow the fuse rating recommended in the table.

An electrical shock can directly or indirectly cause serious and potentially deadly accidents.

Do not make physical contact with live parts inside or outside the machine when it is powered such as the torch, earth clamp,

electrodes and cables, as they are part of the welding circuit.

Before opening the device, it is imperative to disconnect it from the mains and to wait for 2 minutes in order for the capacitors to

release the energy.

Do not touch the torch or electrode holder and the earth clamp at the same time.

Make sure to replace the torches and cables if they are damaged. This should be done by a qualied and authorised technician.

The dimensioning of the accessories should be sucient.

Always wear dry clothes which are in good condition in order to be insulated from the electrical circuit. Wear insulating shoes,

regardless of the environment in which you work in.

CALIBRATION CASE CALIWELD EN

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.

Validation of welding equipment according to the standard is an action to verify the performance of the product in relation to its settings.

Validation is carried out on 5 measuring points within the adjustment range. It is nevertheless possible to validate a reduced adjustment range at

the customer’s request.

Select the validation/calibration range of the control or indicator assembled on the power supply as follows:

a) the complete range of the control or measuring device (see note);

b) a partial range of the control or measuring device;

c) the selected points within the range of the control or measuring device.

NOTE

The maximum values of the range for voltmeters and ammeters are given by the no-load voltage and the maximum welding current of the

current source.

Before performing the validation/calibration, it is necessary to agree with the manufacturer, customer or user on options b) or c).

Perform measurements at the minimum setting, maximum setting and at three other points which are at nominally equal distance between

minimum and maximum over full range

In the case of EN 50504, the measurement is carried out twice (rising «a» measurement and falling «b» measurement) after a stabilisation time of

10 seconds for the measured values.

For En 60974-14, the measurement is performed 3 times (measurement «a», «b» and «c») at short intervals after a stabilisation time of 10 seconds.

It is recommended to leave the product in operation for 5 minutes before carrying out the validation procedure.

The validation must be carried out at least every year and after each repair or modication that may aect the settings.

Only a qualied person can perform these measurements. This person ensures that the test conditions are optimal and the results accurate. We

highly advise to go through the text of the standard before performing a validation.

For specic processes such as Pulsed MIG and TIG AC, user errors and the use of indapated measuring tools may result in measurement errors.

The manufacturer of the welding machine must be consulted.

Welding machine precision

The precision of the settings and/or displays is determined by a category, itself determined according to the welding specications (PQR/WPS) and

the welding machine specications.

Validation type:

- For EN 50504, the type of validation can be «consistency» or «accuracy».

- For EN 60974-14, the validation type can be «validation», «calibration» or «consistency».

This category is split in 2 types: «Standard» or «Precision». It determines the tolerance for the welding settings, the measure-

ments taken and displayed on the machine as well as the measuring tools that should be used.

CALIBRATION CASE CALIWELD EN

TECHNICAL FEATURES

The CALIWELD case is a device which allows:

- to issue a validation report (certicate 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 (± 10%) 

Frequency

: 50 to 60 Hz (± 3Hz)

Power :

30 VA

Supply cable :

plug connection IEC 60320-C13

Interface :

Norme USB-2

Remote control : 120 V max

Measurement characteristics :

• Voltage: from -120 V to 120 V AC/DC - 0.5% of precision (instantaneous, average or TRMS)

• Current: from -500 A to 500 A AC/DC - 0.5% of precision (instantaneous, average or TRMS)

• Gas ow: from 1 l/min to 30 l/min - 5% of precision

• Wire speed: from 1 m/min to 30 m/min - 1% of precision

• External temperature: from 0° to 50 °C (± 2K)

Temperature:

• Operation: from 5°C to 40°C

• Calibration (temperature): from 20°C to 25°C

• Storage: from -20°C to 60°C Preheating: 30 min to take into account the temperature of the room

Relative humidity (without condensation):

• Operation: from 5°C to 40°C < 80%

• Storage: from 0°C to 60°C < 80%

Altitude:

• Operation: <2000 meters

• Storage: <12 000 meters

CALIBRATION CASE CALIWELD EN

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

connection to CALIWELD case.

(25°C)

316 A@60%

120 V Max

Ref: 060524 - Measuring cable 2 m CALIWELD ECM1 - Euro connection / CGU1.0

Allows the measurement of MIG/MAG machines (voltage, current, gas ow, wire speed, remote

control ...) for calibration.

Press the button to unlock the mechanism when feeding the wire.

(25°C)

316 A@60%

120 V Max

Ref: 060548 - Measuring cable 2 m CALIWELD VM2

Clamp for MIG welding voltage measurement (pinch on the machine euro connector).

(25°C)

120 V Max

Ref: 060586 - Control cable 2 m CALIWELD ARC1 - Amph / DIN (male) connection

Cable allowing the remote control of a TIG welding machine, with the software (plug into the

case) or the pear shape remote (connect to the remote).

Ref: 060579 - Control cable 2 m CALIWELD DRC1 - DIN / DIN connection (male)

Cable allowing the remote control of a TIG welding machine, with the software (plug into the

case) or the pear remote (connect to the remote).

Réf. : 060562 - Remote control 2 m CALIWELD RC1 - DIN connection (female)

Pear shape control allowing to remotely control the welding machine (connects to the control

cable).

Réf. : 060593 - Power cable 2 m CALIWELD PC1 - connection CM50.21 Cable Texas/

Dinse

Cable transfering power from the generator to the case.

(25°C)

316 A@60%

Réf. : 060555 - Measuring cable GAZ 2 m CALIWELD GM1

Cable transfering gas from the generator to the case.

Ref. : 060517 - Wire speed sensor CALIWELD SWM1

The speed sensor measures the wire speed between the wire reel and wire feeder.

Push the button to unlock the mechanism when the wire is fed.

Ref. : 060609 - USB cable 2.0 1,5 m CALIWELD USB1 - connection USB-A / USB-B

CALIBRATION CASE CALIWELD EN

TRIGGER CONNECTION DIAGRAM

1 - Common

3 - Welding button

SET UP

1. Minimal conguration

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. Connection of the machine to the case

There are two dierent cabling situations depending on the welding process tested:

1. In welding, for the verication of the parameters.

2. On resistive load to be able to generate a validation report (the verication of welding parameters can also be checked on a resistive load).

In TIG desactivate the HF (High Frequency) as on resistive load. However, the CALIWELD case is equipped with a «HF protec-

tion» which ensures that the product operates correctly in HF if the test conditions are optimal (cabling...). To use the HF, please

follow the installation and connection procedure. In the event of incorrect connection or use, the software may not work (stop

recording, software shutdown, Windows blue screen...).

MIG

TIG

MMA

CALIBRATION SETUP WELDING SETUP

XXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXX

VM1 Texas Voltage Measurement

120 V max

PC1 Texas-Texas cable

TIG connections

RC1 Remote control

DRC1

ARC1

ECM1 Euro connector Multi-Measurement

SWM1 Tachometer 30m/min max

VM2 Clamp Voltage Measurement

GM1 Gas Measurement

USB Caliweld PC Cable

AMPHENOL

RC / Caliweld

DIN

x 2 (+) (-)

CALIWELD

GCU 1.0

+ -

TIG - +

- +

+ -

MIG

+ -

MMA

USB

VM1

PC1

USB

VM2

VM1

PC1

USB

VM1

PC1

SWM1

+ -

- +

TIG

GM1

LOAD

USB

VM1

ARC1 / DRC1

PC1

+ -

- +

MIG LOAD

USB

VM1

+ -

- +

MMA LOAD

USB

VM1

PC1

EMECM1

XXX

XXXX

XXXXXXXXXXX

XXXX

PC1 : Current 500A max

ARC1 : Remote control

VM1 : Voltage 120V max

SWM1 : Tachometer 30m/min max

GM1 : Gas 30l/min argon max

GM1

SWM1

VM1

ARC1

PC1

RC / Caliweld

ARC1 / DRC1

OPTION

1.5m

Ref. 060609

Ref. 060555

Ref. 060593

Ref. 060586

Ref. 060579

Ref. 060562

Ref. 060517

Ref. 060531

Ref. 060548

Ref. 060524

IP 30

PC1

(

)

CONNECTION OF THE WELDING MACHINE TO THE CASE

CALIBRATION CASE CALIWELD EN

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,

verication date.

◊Language: (choice of language FR (default), GB, DE, ES, IT, HU)

◊Backup folder: choice of backup directory for «PDF» and «CSV» les.

◊Date/Time: choice of date format dd/mm/yyyy; mm/dd/yyyy; yyyy/mm/dd ; time in 24-

hour or 12-hour format.

◊Settings :

• Choice of metric or SAE (American unit of measurement).

• Assignment of the energy coecient for welding processes (default data) :

◦MMA coef 0.8 SMAW

◦TIG coef 0.6 GTAW

◦MIG/MAG coef 0.8 GMAW

◦UNDER FLOW coef 1 SAFP

◦GAS

• Choice of energy calculation standard.

• Manual assignment of the correction coecient for the gas using the Ax + b correc-

tion coecients and creation of the gas library.

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