instruction manual for spot welding machines gyspot
Contents
1. Useful length 220 mm 20 tilt electrodes RX1 Useful length 120 mm RX2 longueur utile 220 mm 30 85 mm RX4 Useful length 440 mm assymetrical electrodes XIII MAINTENANCE Replacement of the X clamp arms Adjust and tighten the arms of the clamp after having put the electrodes perfectly in line torque 15 Nm Select the clamp adjustment function to check that the electrodes are in line This function is accessed in the manual clamp mode B mode AF has to be selected Replacement of the caps electrodes To guarantee an efficient welding spot it is necessary to replace the caps every 200 spots using the dedicated caps key It is forbidden to grind the caps Assemble the caps with copper grease ref 050440 A type caps ref 049987 F type caps ref 049970 Bevelled caps ref 049994 Several combinations are possible v Cleaning or replacement of the welding tools Any welding tool is degraded after a certain period of use However all tools must stay clean in order to get the best performance of the unit When using the unit in pneumatic clamp mode check the good state of the CAPS electrodes flat rounded or bevelled If this is not the case clean them with sandpaper fine grain or replace them see reference on the unit All moving parts of machinery suffer constraints on their uses Although monitoring is no screw loose this could degrade the quality of welds If so re tighten For a u2. VOIES EV 2 VOIES Ventilanon Fermeture Ventilation pince en C ou X pinceen C pu X sz Ec ERI Y a zu ar 14 XVII Symbols Caution Read the user manual before use Separate collection required Do not throw ina domestic dustbin Do not use in the open air Do not use the product under water projections IP21 People wearing pace makers should not approach this product Risk of interference and disturbance of pace makers near of the product Caution Strong magnetic field People wearing active or passive implants must be informed Use eye protection or wear safety glasses Body protection must be worn Hand protection must be worn Risk of burns 15
3. om if Ref 049291 2 I 120 220 1 220 Le oie os nana culi 0 _ Ref 049727 8 Rete ee Vou 049451 h RES ED Ref 049468 pec 440 mm De gt Ref 050648 e CE We 049987 1049970 049894 Ci we Ref 050631 CONSUMABLE BOX Ref 050068 Ne Qw New Awa Ref 049444 Q VI COOLING AND THERMAL PROTECTION The cables are cooled with compressed air The cooling process can be permanent if the red switch is on Manual position or permanent except during the welding cycle if the red switch is on Automatic position A thermal protection forbid the use of the product in case of overheating yellow indicator on the front side Recommendation When you use it intensively you should cool the cables continuously with compressed air VII WELDING WITH THE SINGLE SIDED WELDING GUN Connect the ground pad to the spade terminal of the generator Fix firmly the ground pad near the place to be welded as possible In the case of a single sided spot welding process leave always the ground pad on the metal sheet that is not in contact with the welding electrode in order to make the current circulate in the two plates to be welded select the mode to be used and adjust with the values written on the charts chapter IX Blinking of the displays the displays can blink because of 2 reasons The thermal protection is activated because
4. GYS Last update 03 04 12 Version V3 1 E i A N 231 LJ 1 B J EN me q 1 gt 5 5 EN a ot gt eh 0 A m A V INSTRUCTION MANUAL FOR SPOT WELDING MACHINES GYSPOT 32D C GYSPOT 32D X Congratulations for the selection of this product which has been designed with great care Before installing and using the product please read carefully the following recommendations of safety in order to avoid accidents to the users and damages of the welding process GYS can t be responsible for the damages occurred to persons or things which derive from the use of the machine in following circumstances Modification or neutralization of safety elements Non respect of the recommendations written in the manual instruction Modification of the characteristics on the product Use of the accessories which are different from the ones delivered by GYS I PRESENTATION This product has been designed to carry out the following operations in car body workshop Spot welding machine on sheet metals with pneumatic pliers except GYSPOT P230 P400 Welding of sheet metals with gun Welding of nails rivets discs and pins Suppression of bumps and impacts impact of hail with the option quick repair II SAFETY STANDARDS AND GENERAL PRECAUTIONS GENERALIT
5. IES 1 Before disassembling the product s body plug out the lead cable 2 The operators must have the appropriate qualification 3 The operations of servicing can only be controlled by qualified technicians 4 The operator is responsible for respect of the car manufacturers recommendations concerning the protection of electrical and electronic procedures car computer car radio alarm air bag etc 5 Before an operation of servicing the power supply with compressed air must be cut off and off loaded 6 The electrodes arms and the other secondary conductors can reach a very high temperature and remain hot very long after having stopped the machine Be careful high risk of burns 7 It is necessary to make a regular preventive maintenance ELECTRICITY Check that the unity must be connected to the earth coupler and that the connection to the earth is in good condition 2 Check that the work bench is connected to the earth coupler 3 Make sure that the operator has no contact with the metal parts to be welded without any protection or with wet clothes 4 Avoid to be in contact with the welding part Don t make spot welding operations in very wet areas or on a wet floor 6 Don t weld with worn out cables Check that there is no default with the isolation with stripped cables or with loose connections Switch off the unit before replacing the electrodes Before controlling or repairing please disconnect the unit dir
6. ar the spot welding check there is neither no other power supply cable nor control lines nor phone cables nor radio or TV reception appliances nor watches nor mobile phones nor magnetic cards nor computers or any other electronic appliance there is in the surroundings minimum 3 metres of each point of the product no persons using active medical appliances pacemakers acoustic prosthetics Make supplementary protections if other products are used in the same environment III CE certification This product has been designed with respect of the European regulation e Low voltage directive 2006 95 EC of 12 12 2006 e directive Electromagnetic Compatibility 2004 108 EC of 15 12 2004 e Machinery directive 98 37 EC of 22 06 98 and therefore are in compliance with the European harmonized standards e EN 62135 1 e EN 62135 2 e EN 60204 1 IV CONNECTIONS OF POWER SUPPLY CABLES Electricity Two phases 400V 50Hz Use of the PHASE 1 PHASE 2 and EARTH CONNECTION on a 3 phases plug PHASEZ2 BLUE PHASES PHASE 1 C SUPPL CABLE NEUTRAL CONNECT ION 3 PHASES 40004 S5SBHz NEUTRAL Protection of the line Circuit breaker 32A with D curve or delayed fuses 32A Case of dysfunction If the product releases the circuit breaker of the protection of installation please check that you have the right breaker size 32 A or more and D curve absolutely Compressed ai
7. ars IX RECOMMENDED ADJUSTMENTS FOR BODY CAR WORKSHOP only indicative and to modulate depending on the type and the thickness of the sheets OPERATION POWER TIMER Single side welding 10 to 30 Tails welding Ring welding 60 204 Wavy wire dent pulling 7 Smoothingofbumps 2000 Gun JShrnkngwih carbonpen D 20to40 2 Pneumatics Welding 2 pieces of steel sheet reference 1 HI 10 to 50 clamp steel thickness less than 2 5 pulsation Pneumatics Welding 2 pieces of steel sheet reference 4 HI 52 to 96 clamp steel thickness more than 2 5 pulsations X C clamp arms 60 204 Star welding sliding hammer 60 _ Setting recommendations for welding mild steel sheets Sheets thickness in mm Arm type Minimum air Suggested force pressure bars daN From 0 4 to 1 C1 C2 C3 C4 100 to 200 1 2 3 150 to 300 1 2 3 250 to 350 R lt RC3 HEN 1 Ref 051083 RCI 06mm 6 gt 57 051065 Ref 051072 SO 8 300 daN 8 300 daN 8 bar 300 daN 5 5 bar 120 Tilt electrode 159 XII X clamp arms Recommended clamping for welding galvanised steel with X clamp Sheet thickness in mm Suggested Force in daN Arm length inmm bars From 0 410 08 100 to 200 From 0 415 08 100 to 200 From 0 415 08 100 to 200 Set of X arms with a useful height of 120mm Arms made of aluminium and electrodes made of copper RX3
8. ectly to the level of the plug N PROTECTION OF EYES AND BODY 1 During the welding process the process must be protected from the eventual flashes of the electrical arc with protection clothes like leather gloves welding aprons safety shoes welding helmets or glasses for filtering radiations and projections As well during operations of rubbing and hammering the operator must protect his eyes 2 The force of tightening of the clamp can reach 500 daN Keep away all body parts from the mobile elements to avoid risks of tightening 3 Don t keep rings watches or jewellery which are current lead and can create burns 4 All the protection board must be in good condition and maintained in place Protect the environment near the product against projections and reflections SMOKES AND GAZ Welding operations can cause the emission of toxic smokes and harmful metallic dusts The welding material must be degreased and cleaned in order to limit the toxic gas during the welding process FIRE Check that the sparks don t cause fire especially near inflammable material Check that fire extinguishers are not too far from the operator Leave the product in a place with air movers Dont weld neither on containers of combustibles and lubricants even empty nor on containers with inflammable material 5 Don t weld in an atmosphere full with inflammable gas or fuel steam E UN ELECTRO MAGNETIC COMPATIBILITY Ne
9. r Connect a compressed air pipe to the purifier behind the product The service pressure can t be over 8 bar The product can t be used on an air network with a pressure less 3 bar V DESCRIPTION OF THE MACHINE Front side Indicator of air Button of welding Indicator of Indicator of time or steel Button of time or sheet pressure current welding current plate thickness 1 7 adjustment ce Mare 10500 TEES 2 1 0 Adjustment Yellow indicator of air of thermal Welding with the clamp in automatic mode pressure protection Back side Circuit breaker on off GYSPOT I X e Uu GYSPOT 32 D X EN 50 063 400V 2 32A D 10 500A Inms 7 500 A Duty Cycle 1 y www gys fr RX1 Ref 051034 RX2Ref 051041 RX3 Ref 051058 fa po The user shall enter the reference steel plate thickness Button of tool and mode selection Clamp automatic mode Clamp manual mode Single side gun mode Carbon pen shrinking Mode D Smoothing of bumps Procedure to swag with a graphite pen Mode C Welding of studs rivets nails and bolts Withdrawal of impact of hail Dent puller Welding with the clamp in manual mode The user shall select the welding intensity and the welding time Air purifier with incoming joint of compressed air gt gt Ref 050440 3x6mm2 HO7RNF
10. se in gun mode it is necessary to check the state of the tools stars single side electrode carbide electrode and if they look in bad condition clean or replace them The anti dust filter at the back of the unit must regularly be cleaned to avoid the overheating of the generator Purging of the pneumatic filter Regularly drain the dehumidifier filter placed on the rear side of the unit Generator maintenance The maintenance and the repair of the current generator must be done by an appointed and GYS trained technician Any maintenance operation done by another person will cancel the warranty conditions GYS cannot be held responsible for damages or accidents which happen subsequently to operations performed by people exterior to GYS XIV CHARACTERISCTICS ELECTRICAL CHARACTERISTICS THERMAL CHARACTERISTICS 70 C MECHANICAL CHARACTERISTICS Protection degree PNEUMATICS CHARACTERISTICS Maximum force F with C clamp Fmax Maximum force F with C clamp with RC4 arm Maximum force F with X clamp and 440 mm arms Maximum force F with X clamp and 120 mm arms XV TROLLEY ASSEMBL Y M8 x 12 M8 x 85 X30 X1 8 M6 26 XVI Electrical schematics 32D X NU FTE PRC EV 3 VOTES EV 2 VOIES Fermeture Ventilation pinceen C ou X Pistolet EV 3 VOIES EV 2 VOIES 5 Ventilat Pinteen pinceen C ou 32D C ii 15 THTT EV 2 VOIES EV 3
11. the station is too hot The selected mode is incompatible with the tool already used This happens if the user presses the trigger of the single sided gun when the mode clamp is selected on the control panel VIII USE OF THE PNEUMATIC CLAMP Select the function mode 1 Mode A Welding with the clamp in automatic mode thickness to be selected Proposed parameters for welding 2 pieces of galvanised steel with the clamp Forc in daN Forc in daN X Reference sheet thickness Intensity Time in p riods Pulsations clamp arms length C clamp 120 mm 2 Mode B Welding with the clamp in manual mode intensity and duration of welding shall be selected Intensity and time adjustment table Intensity 99 Welding Time in periods Intensity 98 Welding Time in periods Intensity Welding Time in periods Welding Time in periods Welding Time in periods Clampajustment AF If AF clamp adjustment mode is selected the clamp remains closed until the user presses the trigger Blinking of the displays As for the welding gun mode the display blinks when the machine is in thermal protection or if the selected mode is unappropriate Cautions When using the clamp the ground cable of the single sided gun must be disconnected from the car body v The electrodes must be regularly sharpened Blow off regularly the dehumidifying filter on the back side of the product Please adjust with a medium pressure of 6 b
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