Air Liquide DV YARD User manual

DV YARD
EN Instructions for Safety, Use and Mainteance
Cat. nr. : 8695-8033
Rev : 00
Date : 07/2014
www.airliquidewelding.com
Arc welding and plasma cutting may be dangerous for the operator and
persons close to the work area.
Please ensure you read the operating manual carefully before use.

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CONTENTS
1 - GENERAL INFORMATION .....................................................................................................4
1.1 - PRESENTATION OF INSTALLATION....................................................................................... 4
1.2 - WELDING SET CONSTITUENT .............................................................................................. 4
1.3 - TECHNICAL SPECIFICATIONS............................................................................................... 4
1.4 - DIMENSIONS AND WEIGHT................................................................................................... 4
2 - SETTING UP...........................................................................................................................5
2.1 - PRECAUTIONS........................................................................................................................ 5
2.2 - UNPACKING THE SET............................................................................................................. 5
2.3 - WIRE FEEDER SLINGING....................................................................................................... 5
2.4 - WIRE FEED UNIT CONNECTION ........................................................................................... 5
3 - INSTRUCTIONS FOR USE ....................................................................................................6
3.1 - FEED ROOLS .......................................................................................................................... 6
3.2 - INTERCONNECTIONS ............................................................................................................ 6
3.3 - GAS.......................................................................................................................................... 6
3.4 - TORCH..................................................................................................................................... 6
3.5 - REVERSE POLARITY ............................................................................................................. 6
4 - HUB ASSEMBLY MOUNTING................................................................................................6
4.1 - PROCEDURE .......................................................................................................................... 6
5 - ALARMS .................................................................................................................................7
6 - MAINTENANCE......................................................................................................................7
6.1 - WIRE ROLLERS AND GUIDES ............................................................................................... 8
6.2 - WIRE-FEED PLATE WEAR PART ............................................................................................ 9
6.3 - SPARE PARTS ....................................................................................................................... 10

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1 - GENERAL INFORMATION
1.1 - PRESENTATION OF INSTALLATION
The DV YARD can be adapted to most direct current ARC ( MMA )
power-sources , you must use it with 300 mm wire spool.
Its power supply is ensured directly by the arc voltage. It is
therefore very simple to implement and does not require any
auxiliary transformer.
Using the DV YARD, you can transform your ARC ( MMA ) power-
source into an authentic MIG-MAG welding source.
Air Liquide Welding recommend to use with CV power source for
best welding performances
When properly installed, the DV YARD will enable you to obtain
high-quality welds with a good visual appearance.
Optimum use of the system requires full knowledge of this manual;
it is important to follow all the instructions described in this
document.
1.2 - WELDING SET CONSTITUENT
The welding-set is comprise of:
■a wire feeder unit, with 5 m long earth cable and its clamp & 5 m
long gas hose,
■user and maintenance manual,
■safety instruction.
1.3 - TECHNICAL SPECIFICATIONS
- W000382134 : DV YARD : wire feeder without owmeter
- W000382135 : DV YARD FM : wire feeder with owmeter
DV YARD
W000382134
DV YARD FM
W000382135
Rollers plate 4 rollers
Input voltage range 14-48 VDC 15-110 OCV
Welding current range 50 – 425 A
Duty cycle 60% at 40 °C 425 A
Duty cycle 100% at 40 °C 330 A
Wire dia. usable 0.8 to 2.4 mm
Max. spool size spool capacity 300 mm 15/20 kg
Wire feed speed 1.2 -20 m / min
Designed to t through a manhole Yes
Protection index IP 23 S*
Standard EN 60974 - 5 / EN 60974 - 10
Torch connection "European type"
*Protection index
Code letter IP Equipment protection
First number 2 Against the penetration of solid
foreign bodies
with Ø ≥ 12,5 mm
Second number 1 Against the penetration of vertical
drops of water with harmful eects.
3 Against the penetration of rain
(inclined up to 60° in relation to the
vertical) with harmful eects.
S Indicates that the protection test
against detrimental eects due to
water penetration has been done with
all parts of the equipment at rest.
1.4 - DIMENSIONS AND WEIGHT
Dimensions
(LxWxH)
Net weight
Wire feeder unit DV YARD 600 x 220 x 420 mm 13.9 kg
GENERAL INFORMATION

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2 - SETTING UP
2.1 - PRECAUTIONS
■Ensure to not pinch the cables and gas hoses
■Ensure correct installation of power connections.
■Do not leave liquid or hot material to be in contact with the cables.
■The stability of the system is supported up to angles of 10°.
■The connection of the wire feeder unit is to made while the power
source is o.
2.2 - UNPACKING THE SET
Remove the various items from their packaging.
2.3 - WIRE FEEDER SLINGING
For slinging the wire feeder, you must use the handle.
2.4 - WIRE FEED UNIT CONNECTION
1. Place the ¼ female turn on power cable, then connect cable to the
DV YARD terminal on the front.
2. Connect the other end of cable to + terminal of power source.
3. Connect power source - plug to the workpiece.
4. Connect the DV YARD earth clamp to the workpiece.
5. Connect the MIG torch on DV YARD
6. Place the gas hose on the regulator of gas installation (use specied
gas for MIG-MAG welding).
7. Adjust the gas ow and bleed the circuit ..
The DV YARD has a microprocessor based system that allows it to
automatically recognize whether the power source works in Constant-
Current (CC) or Constant-Voltage (CV) and to adapt accordingly without
any selector.
Adjust the power (voltage) on power source and the wire speed on DV
YARD according to the advice placed on DV YARD door. Close the wire
feed unit door and press the torch trigger. Let the wire appears at the torch
end, on the contact tip output.
Your installation is ready to weld.
SETTING UP
POWER SOURCE

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3 - INSTRUCTIONS FOR USE
3.1 - FEED ROOLS
Before connecting the electrical and gas supplies, ensure that the
equipment is set for the correct type and size of wire to be used, Check
that the diameter stamped on the feed roll is the same than the diameter
of the wire used.
3.2 - INTERCONNECTIONS
While the machine is switched o, connect the wire feeder to the power
source with the t connection cable, It is advisable to layout the lead as
straight as possible.
3.3 - GAS
Connect the gas hose placed on the rear of the wire feeder with the gas
manometer of the gas cylinder.
PRESSURE REDUCER
GAS TUBE
3.4 - TORCH
Check that the contact tip mounted on the torch head is t for the wire
used, Remove the contact tip and using the torch button to feed the wire
till it comes out of the torch itself, Ret the contact tip and ensure it is well
tightened.
3.5 - REVERSE POLARITY
For some ux cored wire without gas or specics and recharging -
Connect the power cable from the negative terminal of the MMA power
source and the input of DV YARD.- Connect the cable with clamp on the
positive terminal of the MMA power source and the pieces to be welded.
4 - HUB ASSEMBLY MOUNTING
4.1 - PROCEDURE
■Remove the hand nut from the hub assembly wire guide.
■Place the wire reel on the hub so that the wire will be drawn o from
the top.
■Release the end of the wire, but do not allow the wire to loose, cut o
the kinked portion of the wire removing any deformation.
This must be done each time that the wire is referred through the
equipment.
■Adjust the hub assembly by using the screw inside the hub assembly
wire guide, so as the prevent the wire reel over-run once the motor of
the wire feeder stop. Do not tighten the hub assembly too much.Too
much pressure will cause excessive drag.
■By the tting lever release the pressure roll
3
revolving on ball
bearing and lift it. Thread the wire through the tting inlet guide
4
and feed it out of the central adaptor.
■Lower the pressure roll
3
, ret it into the initial position by the
lever
2
, adjusting the pressure with the knob. Minimum pressure
is sucient so as not to allow the feeding rolls to slip. Excessive
pressure will cause wire deformations and entanglements inside
the liner (in case of aluminium wires) and generally early wear-and-
tear of the wire feeding motor bushing. A scanty pressure will cause
welding uneven or irregular.
■Connect the torch to the tting adaptor and ensure that the wire is
positively fed inside the torch lead liner. Remove the nozzle from
the torch extremity and unscrew the contact tip. Feed the wire till it
comes out of the torch.
■Ret the contact tip keeping in mind that it must have the same
diameter of the wire diameter used.
4.2 - SLOPE UP start welding.
The operator can choose 4 positions for SLOPE UP start welding:
Keep pressed recall A/V button and in the same time press Test gas
button , on the front panel you can read this number 111 , 222, 333, 444
these numbers suggest a dierent time for a small delay for start welding.
1 step 111 short time 0,4 s
2 step 222 medium time 0,75 s
3 step 333 long time 1,2 s
4 step 444 long time 1,6 s
INSTRUCTIONS FOR USE - HUB ASSEMBLY MOUNTING
3
4
2

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5 - ALARMS
1. Alarm for big current, I out up to 550 A for 1 second, feeder stop to
work for 5 seconds on the display you can read 666.
2. Alarm for minimum voltage, when the minimum welding voltage is
less than 12 V the feeder stop to work for 5 seconds; on the display
you can read 777.
When you want to work at lower voltage this condition help you to
nd right parameters because to start welding is necessary increase
the current or reduce the speed wire until you nd a good welding.
3. Alarm for high temperature, when the temperature inside the feeder
for any reasons become too high the feeder stop to work until the
temperature return to the nominal value; on the display you can read
888.
4. Alarm for high voltage, maximum work voltage is 100 V so when the
voltage go up to this value the feeder stop to work. On the display
you can read 999.
6 - MAINTENANCE
Routine maintenance
Disconnect power before maintaining.
Maintain more often during severe condition.
3 Months
Replace Damaged or Unreadable Labels.
Replace Damaged Gas Hose.
Repair or Replace Cracked Cables and Cords.
6 Months
Clean Drive Rolls.
Blow Out Or Vacuum Inside.
ALARMS - MAINTENANCE

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6.1 - WIRE ROLLERS AND GUIDES
CONTROLS
1. Digital voltmeter and ammeter
2. Wire feed speed adjustment
ܟProvides continuously variable wire feed speed control. The
wire speed is directly proportional to welding current so that
increasing the wire speed increases the current and vice- versa.
3. 2T/4T switch
4. Recall A/V
Push on the key “Recall” allows to see the last parameters
used (I/U) after welding.
5. Central European connector
ܟAllows an easy connection to the welding torch simultaneously
carrying power, torch button connection, gas and liner
connections.
6. Connecting Gas Hose
7. Connecting Weld Cable
MAINTENANCE

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6.2 - WIRE-FEED PLATE WEAR PART
REP DESCRIPTION PART NO.
1 PCB FR 109 W000382445
2 KOHM POTENTIOMETER W000382446
2A LARG KNOB W000382447
2B SMALL KNOB W000382455
3 POLE SWITCH W000382450
4 CENTRAL ADAPTER W000382451
5 CONTACTOR W000382452
6 PCB FR 459 W000382453
724 V AC GAS VALVE W000382454
8 WELDING CONNECTOR W000382456
9 REEL HUB ASSY W000382457
10 24V 70W LEFT MOTOR W000382458
11 POLE SWITCH W000382459
12 FLOWMETER W000382470
13 FUSE HOLDER W000382472
13A FUSE 4A DELAY W000382460
MAINTENANCE

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6.3 - SPARE PARTS
MAINTENANCE