GYSPOT PTI Evolution_V2.10.00_ENG
Contents
1. mode key auto mode on off The auto mode is identical to normal mode except that the user enters the yield strength of steel The Ys may be experienced in using a durometer such as Gysteel Vision Re 1 10 corresponds to mild steels Re 11 18 corresponds to HSS steel VHSS Re 19 35 corresponds to steels UHSS Re 36 99 corresponds to boron steels The thickness of the sheets to be welded to choose from 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 The arm used Pressing the up and down key in the circle allows to navigate from one parameter to the next thickness yield strength of steel arm used Each parameter can be adjusted by pressing the and keys in the circle Button A on the clamp allows to remotely change the thickness of the sheets to be welded Button B on the clamp allows to make a welding spot using the selected parameters MANUAL Mode This mode allows the user to manually select the welding parameters following instructions from a manufacturer for example The settings proposed by default in the manual mode correspond to the settings automatically selected by 7 25 the standard mode thickness and type of sheet electrode force arm When entering this mode the parameter selected by default is the welding current The parameters can be adjusted using the and keys in the circle The up and down keys allow to navigate from one parameter to the next Welding curre2. Insufficient Pressure ATE LEA DEBET Insufficient pressure 9 25 Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the actual measured clamping force is too low then the machine will display the following message Low Pressure 2970405 13 531 SE UU I 320 v Welding spot counter A welding spot counter allows to count the number of spots performed with the same caps If the welding spot is performed without any problem the following message appears lt 8 04 08 OK Ime EIU T 320 w 3206 POINTS The counter is displayed on the top left corner of the screen Pressing the key E resets this counter to zero after the caps have been replaced If more than 200 welding spots are done with the same caps then the machine will display a warning message In this case the warning message Change tips is also recorded in the traceability report POINTS 288 21 04 88 17 63 Do control caps F 147 aon Tel Tams 6 6 kA T 320 ms Y Recording features The mode identification is optional it is configurable in the settings menu that is activated by pressing for 2 seconds on the mode key identification mode on off The log report allows to save the characteristics of the welding spots performed with the clamp It is available from all modes by simply pressing the keys located below
3. is completed the welding spots performed are sorted by an identifier of the repair order This identifier corresponds to the name of the report in the spot welding machine This identifier is displayed in the Active tab When all the reports have been imported it is possible to perform a search edit or archive each report To visualize the characteristics of welding spots in a report select the report the characteristics of each spot appear in a table 14 25 To perform a search fill the search field and click on icon l To edit a report select the report and click on icon To archive a report select the report and click on icon E Beware the imported reports cannot be deleted if they have not been previously archived Visualize log reports of welding spots To visualise log reports click on the Archive tab The reports are sorted by year and month To visualise the characteristics of the welding spot performed select a report the data corresponding to each welding spot appears in a table For the archived reports it is possible to perform a search edit or delete a report Beware a report which is archived and then deleted will be imported again in the next import operation in case the SD card has not been blanked To perform a search fill the search field and click on icon l To edit a report select the report and click on icon ez To delete a report select the report and click on icon X Purge of the S
4. must not be used on an air compressed network with a pressure inferior to 3 bars v Assembling the clamp handle Handle Assemble the handle on the left hand side of the clamp Air connector Assemble the air connector on the air filter T Eu 31 dH Y Filling of the cooling liquid tank To fill the cooling liquid in the tank please proceed as follows put the pneumatic clamp on its stand pour cooling liquid in the tank to reach the maximum level indicated on the tank 30 litres v Starting the machine Position the switch on the ON position The electronic card starts a test and initialisation cycle of the parameters during a period of about 10 seconds At the end of this cycle the machine is ready to be used When the machine starts to work liquid circulates in the cables Check that there are no leaks 4 25 4 PRODUCT OPERATION v Key definition moose NORMAL Pression 6 9b Pressing this key allows to select the tool that will be used either clamp or single sided gun For the BP LCX machine pressing this key changes the mode from C clamp to C clamp adjustment X clamp X clamp adjustment and finally single sided gun The clamp adjustment mode allows to close the clamp and apply the programmed force on the electrodes with any current flowing This mode is used to adjust the arms Pressing this key 2 seconds allows to come back to normal mode from the other modes Pressing this k
5. the icon REPORTING The user welding parameters mode is also available from all modes by pressing the keys below the icon MEMORY LOG Report lt 7 Name of report RN A gt Recording a report allows to save the characteristics of a series of welding spots and save them on the SD memory card such that they can be transferred to any standard PC GYS provides a software to read the SD card and edit reports This GYSPOT software is stored in the SD card together with a copy of the user manual By default this function is disabled at the start of the machine Pressing the key and the mode key allows to start recording in the selected log file Pressing again the record key will stop the record The log file thus created contains an identifier entered by the user as well as for each welding spot performed the tool used the arms used and the settings of the machine welding current and electrode force It also contains the possible error messages that have been displayed during the record I low P low Use the and keys as well as the up and down keys to enter the identifier If a previously existing identifier is entered the machine will save the new welding spot characteristics at the end of the file without erasing any information from the file The key gt allows to recover a report previously saved and to read it on the screen Before visualizing a report the record must be
6. washers and studs Repair of bumps and impacts impacts of hail with the option quick repair GENERALITIES 1 The operators must have followed up an appropriate training 2 The repair and maintenance operations can only be performed by qualified personnel 3 The operator is responsible for the respect of the car manufacturer s recommendations regarding the protection of the car electrical and electronic equipments car computer car radio alarm air bag etc 4 Before any repair or maintenance operation the compressed air supply must be disconnected and depressurized 5 The electrodes arms as well as the other secondary conductors can reach a very high temperature and remain hot very long after having stopped the machine Pay particular attention to the risks of serious burns 6 It is necessary to make a regular preventive maintenance on the machine MAINS SUPPLY 1 Check whether the unit is correctly connected to the earth and that the connection to the earth is in good condition 2 Check whether the workbench 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 being in contact with the welding part 5 Do not make any spot welding operations in very wet areas or on a wet floor 6 Do not weld with worn out cables Make sure that there is no isolation defect nor stripped cables nor loose connections and
7. 0 the job number and the user id of the file are displayed No The page is shown in the top left All jobs are stored in the file catalog GYS It contains the total number of job name of each job and user id max 100 jobs User welding parameter record The saving of user welding parameters allows to save the preferred welding parameters for different users of the machine 20 user profiles can be saved Each of them contains the following settings tool arm welding current welding time electrode force A user can save his preferred parameters for the clamp or single sided gun Two keys allow to navigate in this mode The save key fe allows to record the settings currently used in manual mode welding current welding time electrode force The 20 user profiles are then displayed with either an identifier for those that are already used or for those that are still available Use the and keys as well as the up and down keys to enter the identifier When entering a previously used identifier the machine will erase the previous settings saved The Open key Y allows to access the user profiles previously saved Selecting an empty user profile has no effect Pressing briefly the key erases the selected program in the list of saved programs The mode key allows to exit the program selection mode and makes the machine enter the manual mode where the parameters and the tool saved i
8. 8 11 11 21 Hom al 85 PentoK OK Noma EEE a Point OK 05 05 2008 11 11 28 Hornnal Point OK rr Nome kam 90 es s s Pont OK v Use of the pneumatic clamp A Tighten the C clamp using the locking lever and check that the screw between the arm and the clamp is correctly tightened The clamping force is calculated by the machine considering the force setting or the thickness of the sheets selected for the good operation of the cooling liquid system it is essential that the pipes are properly connected on their respective connectors to ensure the flow of the cooling liquid Maximum electrode force Recommended parameters to weld mild steel Epaisseur des t les en mm Type de bras Effort de serrage en daN De 0 4 0 8 C1 C2 C3 C4 C5 C6 C C7 C8 C9 100 200 CLCI GO GS CS TES 1503 300 CEA CH OO 300 550 16 25 Y Installation and use of the single sided gun The single sided gun and the earth cable are sold separately as an option The reference is 051010 2 check whether the cooling liquid pump has stopped fix the earth cable on the mobile electrode of the clamp 1 remove the arm from the top of the clamp and assemble instead the cable of of the single sided gun 2 connect the cooling liquid pipes to the connectors connect the jack connector to the plug on the side on the top of the clamp of the handle check whether the screw that connects the earth pl
9. D card A purge operation on the SD card will erase all the reports previously saved on the SD card To purge the SD card insert the SD card in the reader of your PC and in the menus click on Options and Purge SD Card Beware during a purge operation the reports that have not yet been imported in the software will be automatically imported Filling the information of a report The following information can be automatically added on each report Operator Vehicle Repair Order Registration Report Date First registration Remarks Operation To fill this data select a report and enter this information in the header of the report Print a report To print a report select the report and click on icon A print preview appears Click on icon I 15 25 Export in PDF format To export a report in PDF format select a report and click on icon A print preview appears Click on icon Example of a report Company name 5 4 5 GYS Phone number 0243012360 Adress 134 BOULEVARD DES LOGES Fax number 0243017360 a Email contact epgys fr Zp code 53941 Website www qys soudure com City SAINT BERTHEVIN Oper ator DUPOND Jean Pierre Vehicle MEGANE CC 1 6L 15V Repair order 4558 Registration 1600553 Report date 13 05 2008 First Registration 21 01 2005 Remarks Operation REAR FENDER GYSPOT INVERTER BP LC 000001000 Mode hi Time ime ensis Fere intensity Forte dall E F ER 5405 200
10. 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
11. These messages appear on the screen and remain until a key is pressed the defects that correspond to a bad installation air pressure electrical power supply the messages that inform of major failures such as IGBT failure bad charging of the power capacitors etc These defects cause the display of an error message that blocks the machine the thermal protection makes use of a thermistor on the diode bridge which block the use of the machine and displays the message overheating Current too low If the welding current obtained during the welding spot is 6 less than the current setting the machine displays once the welding spot is performed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the actual measured welding current This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the button on the clamp If the machine cannot deliver the requested current then the following message appears The welding spot is not performed and the message must be acknowledged to perform a welding spot 23704 00 TET current too low Insufficient air pressure If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message
12. USER MANUAL v2 10 00 VOLLITICNT 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS 2 2 DESCRIPTION OF THEMAGBINE tinitet sekttnt in chivan tu I ite Em Seti citu Pu Sun Eco Tei Cb ai cuu EO Du eo EPI HI du oan 3 MEE COO LOU PEROAU Dane RET TT RS 3 SGYSPOT PETI Red Paheli orrira dese ete Pcia va oov ar ata ce tein te pesa v ond Ru ae Lc Sn bv pU DLE 3 2e Guo e oT A A A 3 B INSTALLATION OF THE MACHINE su teste tui ttn ra tut Hv san a ram aput DU vr Sun parua mt Doa 4 0 0t teer 4 Assembling the clamp handle irr rie yo xn Y ERES Nea via ve pal ess Fa ue Vous oa Vb ve ERR s div PR R 4 s silhgofrti1iecoolng GUI tank deese mtu x a ODER in toc ae git ar tac S FR e E a foo a 4 Startna the Machine ssec v et C Se v cess E Res UD LIPPE MS D PU M DELLI MID PULS 4 4 gt PRODUCT OPERATION vicsssettasssasachcaoncacdcavaciuduiuadacdugedcasiaaaadauasheadaidugeniasdsduaraudshuadeidudeataunsdnlaudsdealdiaabataaneiss 5 z eise A 5 C clamp modes standard manual multisheet Auto clamp adjustment 6 7 Jseofthe single sided GUN issiimti anan Y ERU VE ES XR E Ne EXER Mak Y EYUx Aaa 8 s EBROrTh dhdgelrierib susci kou Pana rex kind daba eus hd ulema oed iwl Vatkpd uera E Mea a brie Ex VER aa 9 Welding SPOCONE rnea cu au ERE A o Fe n EDDA PE uet a LU LK DE RII ALS 9 Recording features log report User ID mode user programs cececeeseeeeeeeeenseere
13. ar joint Inside the guide of the mobile electrode there is a circular joint which should be changed in case of leaks or every 6 months This circular joint is necessary to avoid any risk of leak of cooling liquid Circular joint d215 thickness 2 When changing this joint use some copper grease ref 050440 Y Use of the under fender arm Considering the strong locking pressure of the clamp the air compressed pressure should be lowered to 4 bars WARNING a pressure higher than 5 bars can cause the destruction of the arms set and therefore metal projections that might cause body damage to the operator Y Replacement of C clamp arms To change a C arm on the clamp put the clamp on its stand and proceed as follows The machine should be switched off Unscrew the screw that maintains the arm in position on the clamp 1 Disconnect the 2 cooling liquid pipes 2 Unscrew the lever on the side of the clamp 3 Remove the arm from the clamp Beware put the screw back on the arm in order to avoid loosing it 4 Take another arm put some grease ref 050440 all around the extremity of the arm and insert on the axis on the top part of the clamp Beware do not forget to unscrew the screw on the arm tighten the black screw on the arm to block the arm on the clamp rotate the lever to block the arm Check the level of the cooling liquid Switch the machine ON 18 25 S NS NNN NN ng Adjustment and tighteni
14. ate to the earth cable is properly screwed 17 25 Use of the gun firmly fix the earth plate as close as possible to the working area in case of monopoint welding with the gun always place the earth plate on the sheet that is not in contact with the welding electrode so that the current will flow through both sheets to be welded Select the GUN tool using the Esc key Single face welding choose the type of steel using keys and Other processes choose the desired accessory using the and key 1 Dent pulling 2 Contact shrinking 3 Graphite pen 4 Stud welding 5 Rivet welding 6 Bolt welding 7 Stitch welding or seam welding adjust on the generator the thickness of the steel sheets to be welded using the and keys It is possible to change the current and welding time parameters in manual mode 5 PRECAUTIONS AND SERVICING v User training Operators must have an appropriate qualification for the use of the machine in order to get the best of the unit and to make Satisfying work e g car body repair training v Preparation of the parts to assemble It is essential to grind clean and to accost the part to be welded In case of a protection application first verify that it is conducting by testing a sample Y Single sided gun welding Before repairing a vehicle check that the car manufacturer authorizes the welding process you have chosen v Electrode circul
15. axis WARNING bevelled side outside then put it inside manually 1 Place the short spindle and screw it on the clamp axis couple 15Nm 2 Type of spindles Short spindle C1 C3 C4 C5 Long spindle C2 22 25 v 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 Y Level and efficiency of the cooling liquid The level of cooling liquid is important for the good operation of the unit It must always be between the minimum and the maximum level indicated on the tank You have to check with an appropriate tool the efficiency of the cooling liquid If this one is no more efficient change it Change the cooling liquid every 2 years Never add water Always add cooling liquid Y 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 For a use in gun mode it i
16. dentify ON THEN supervision following Screen user ID screen appears This screen allows you to make the fields registration vehicle make vehicle model vehicle identification number required when entering the repair order To exit the screen you must press the mode key for 2 seconds Then you must put the SD card that contains the program into your BP card reader Screen registration gt optional List of screens that allow you to enter a repair order When a job number has already been created it can not be changed or deleted on the BP To remove it you must use the software GYSPOT PC You can create up to 100 job numbers 11 25 Screen vehicle make optional Screen vehicle model optional Screen chassie number optional 12 25 When consulting jobs with the View key The screen CATALOG appears CATALOG J woes EN The page number is displayed 13 max Keys left and right are used to change the page The up and down keys are used to select the next or previous Job number The mode key allows displaying the selected repair 22704708 17 18 order Dmm S q gt fC Oh Ahr z The mode key is used to leave from viewing the report The library management of the SD card can handle SD cards gt 2 GB Each job has an associated log file xxx dat where xxx id from 001 to 100 In every report the maximum recorded spot welds is 50
17. e allow to select the parameter to modify sheet thickness type of steel arm used The and keys allow to modify the parameter Save a report More details can be found on this function in the corresponding chapter The record key allows to enable or disable the saving of a report The visualise key allows to read the sequence of spots performed Saving of user welding parameters The save key allows to save user welding parameters mode sheet thickness welding current welding time or electrode force The open key yz allows to call back previously saved welding settings The machine automatically goes to manual mode recalling the saved parameters current welding time force and the tool used clamp or gun v C clamp modes STANDARD Mode moo STANDARD eSvaroOs8 T3155 Te ies This mode is the default mode when the machine starts It allows to easily perform a welding spot by selecting The tool to be used The thickness of the sheets to be welded to choose from 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 The type of steel to be welded Coated steel HTS steel UHTS steel BORON steel The arm used Pressing the up and down key in the circle allows to navigate from one parameter to the next thickness type of steel arm used Each parameter can be adjusted by pressing the and keys in the circle Button A on the clamp allows to remot
18. ely change the thickness of the sheets to be welded Button B on the clamp allows to make a welding spot using the selected parameters If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure too low Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 6 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp 6 25 MULTISHEET Mode HODE MULT Pressu s This mode allows to precisely specify the thickness and type of each sheet of an assembly of 2 or 3 sheets Using the up and down keys in the circle allows to select the parameters for each sheet When the parameters for each sheet are highlighted the sheet thickness and type of steel parameters can be adjusted using the and keys in the circle The parameters to be adjusted in this mode are The thickness o
19. ess Locking unlocking C lever Carm Mobile electrode 3 25 3 INSTALLATION OF THE MACHINE Y Before use Several verifications are necessary before using the unit to ensure good performance of the machine Here are the verifications to do Check the electrical line voltage it should be 400V AC 3 phases with a 25 A or more delayed circuit breaker curve D or fuse of aM type and with an Earth Leakage Circuit Breaker of 30 mA Check the cross section of the cable going from the main electrical board to the socket where the machine will be plugged it should be 4x6 mm2 If this cable is longer than 10m use a conductor size of 10mm If you use an electrical extension cord use a 6mm conductor size 10mm if electrical line extension cord total length is superior to 10m Connect a 3 phases earth plug minimum 324 on the supply cable PHASE 2 GYSPOT INVERTER POWER SUPPLY PTI 3 PHASES 400V 50 Hz Be careful in order to avoid voltage drops which can generate bad welding spots you must never have overloaded electrical lines nor supply cable diameters which cross section are not large enough Also the mains plugs must not be too far from the circuit breaker If the machine is not sufficiently supplied it is not possible to ensure a good welding quality Check that the air compressed network can deliver a minimum of 7 bars dry air then connect the compressed air network on the back of the machine The machine
20. ey 2 seconds brings the spot counter to zero when it is displayed Pressing briefly twice this key erases the report that is displayed on the screen when in the visualisation mode Pressing briefly this key when in program saving mode erases the selected program Steel sheet thickness This setting allows to select the thickness of the steel sheets to weld The sheet thickness can be adjusted using the and keys in the circle position 5 The thickness can be selected amongst the following preset values 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm Type of steel sheet This setting allows to select the type of steel sheet to weld amongst 4 families coated steel HTS steel UHTS steel BORON steel This setting can be adjusted using the and keys in the circle position 5 Arm used When a clamp is used either C or X the user should specify here the length of the arms fitted on the clamp so that the machine will adjust automatically the air pressure to get the requested electrode force 5 25 ei 29764768 13 45 ACIER y Use of the advanced modes The MODE key allows to navigate through 3 different modes STANDARD MODE MULTISHEET MODE MANUAL MODE A long press on the MODE key allows to enter the configuration mode where the language and date can be edited and the sound alarm activated for current too low or low pressure messages The up and down keys in the circl
21. f each sheet to be welded to choose between the values 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm The type of steel for each sheet coated steel HTS steel UHTS steel BORON steel In order to activate sheet 3 press the up and down keys in the circle to highlight sheet 3 then use the and keys in the circle to select the sheet thickness and type of steel If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure too low Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 6 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp Pressing during 2 seconds the key allows to come back to the normal mode Auto Mode 04 01 2008 13 36 wm AUTO The auto mode is optional it is configurable in the setup menu that is activated by pressing for 2 seconds the
22. hed on v GYSPOT software for PC GYSPOT Software The purpose of this software is to allow the user to edit or save reports of the welding spots performed on a car body repair with a GYSPOT machine equipped with an SD card reader In order to use this software the PC Personal Computer must be equipped with an SD memory card reader Language selection The software proposes several languages By default the following languages are available French English German Spanish Dutch To select a language click on Options and then on Languages in the menus Beware once the language is selected the user should exit and enter again the GYSPOT software for the new language to be considered User identity In order to customize the information that appears on the reports the user should fill some data in the software To enter this data click in the menus on Options and then on Identity A new window then appears with the following information Company Name Address Postal code Town Telephone Fax E mail Web site Logo This information will then automatically be displayed on the reports Import log reports saved on the SD card In order to import on the PC log reports of welding spots performed with the GYSPOT machine insert the SD memory card in the card reader of your PC and then start the GYSPOT software Then select the reader where your memory card is inserted and click on the import icon When the import
23. i oU daga si rca Fave ainsi 23 Generator malfitenarice resice dete usa er er Re A a TEPE aet cel rpE ADEE Fue dta Gel tdnw 23 OOUGHARACTUERISTEOS 1 soiree to abbas oe ne LE aUe LC 24 Te SN GRINS steers taeda tea arte Van iosuada o Et stc id ide totu cds tetas chai tint 25 Autres langues disponibles sur la carte SD S102 Other languages available on the SD card FoU pcgte 200 2010 Weitere auf SD Karte verf gbare Sprachen Thank you for your choice Before installing and using the product or before maintenance please read carefully the following safety recommendations in order to avoid accidents to the users and damage of the welding process GYS cannot be held responsible for the damages occurring to persons or belongings following the use of the machine in the following circumstances Modification or disabling of safety elements Non respect of the recommendations written in the user manual Modification of the characteristics of the product Use of accessories other than the GYS accessories or accessories not adapted to the machine Non respect of the regulations and particular dispositions in the country where the machine is installed 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS This product has been designed to carry out the following operations in car body workshops Spot welding on metal sheets with a pneumatic clamp Welding of metal sheets with a single sided gun Welding of nails rivets
24. n the program are recalled To disable a progam simply change the value of a parameter in the manual mode standard mode or mutisheet mode or simply change tool by pressing key v SD Memory card SD Card reference 050914 This card allows the user to transfer files from the machine to a PC to collect log reports in order to keep traceability of his work and possibly show it to an insurance company Update welding parameters add new menu languages A copy of the GYSPOT software to collect and edit the traceability reports is stored on the SD card A copy of the user manual is also stored on the SD card The memory space will allow saving the characteristics of more than 65 000 welding spots The machine can operate without any SD card in manual mode only 13 25 If the memory card is not inserted in the card reader then the following message is displayed If the SD card is locked the following message appears The SD card should be unlocked before inserting in the card reader ERREUR 20706708 16 35 V rifier la protection de la carte SD Message Check SD card write protection Ara ma M MEM Insert SD card Important Switch off the machine insert the SD card and switch the machine ON again SD card shall be inserted or removed only if the machine is switch off There is a risk to detroy the datas on the SD card if the user remove the SD card when the machine is switc
25. neeners 10 13 e CSDuenoby Cara visioni vti oder nudam Ecos tix educ Mn danke s E EM I D LED D E EIN 13 NGYSPOTSOMWaAC sresnesonasesruseert areal snes Dru QU Fio Te Dvbda a TOROS Dvd a o PR Urxe esed MoPueES Orr nr FER ved 14 16 Use of the pneumatic C clamp iiaiai a enne enne nemen nnne rune nnne nnne nnns 16 Installation and use of the single sided gun eeeeeeenennnmnmmmm mnn 17 5 PRECAUTIONS OF USE AND SERVICING eere 18 Eque 18 Preparation of the parts to assemble 1 1eeieeeeieeeeene nennen nennen nnnm nennen 18 Single sided gun welding o iioii nhe n exi irm nn n n n n x E Nn rc n rc en o nc 18 Replacement or adjustment of C clamp arms ccc eceeeceecceecceecceecteccsecceeccsecceecseeess 18 Adjustment and tightening of C Clamp arms in their holder sssssssses 19 e sypeotarmsfor the C sclatmp Ssmus texere a ra Des De Vx decre rock dang v Des d xd ER 21 s Ujewrtiec2adnd 68 afi osos riti nasa tu io EY Ex uter iai rins tex EFE VER uta Mi TIRE EM Mei TUE 22 Replacement of the caps and electrodes esseeeseeeeseeeenennen nennen nenne nnne nnn 23 Level and efficiency of the cooling liquid esee 23 Cleaning or replacement of the welding tools esee mmm 23 s Db trdibid OF Te PNEUMALIC TILER ooi cete et ee tata ir cU td aqu talc tv E tela i
26. ng of C Clamp arms in their holder The C arm is adjusted at Gys factory before shipment like in picture 2 If for any reason the lever arm can move like in picture 1 then the user shall adjust the arm clamping system and perform the following operations 19 25 Step 1 Loosen the M5 screw Step 5 Tighten the M5 SCREW Step 2 Add contact grease ref 050440 on the surfaces in contact Insert the C arm in its holder Step 3 Turn the lever at a position like on the picture angle of Step 6 60 with the holder Tighten the lever STEP 4 Tighten the ring manually ZZ TEN NS V 20 25 Type of arms for the C clamp 21 25 TEN C1 Ref 019140 EVOLUTION BP LC amp BP LCX 118 Ref 019164 ORIGINAL EQUIPMENT TY C2 neto19133 C6 net 019775 C4 v Use of C2 and C8 Arms This arm requires the change of the short spindle To do this follow the process entitled Changing of the arms of C clamp but using a flat key to unscrew the short spindle off and substitute it by the long one Replace the short spindle by the long one Take a recipient with a capacity of 100mL to collect the cooling liquid Unscrew the short spindle off and take it off without forgetting the injector Collect the cooling liquid which is in the clamp axis Move the long injector to center it in the clamp
27. nt 2000 to 13000 A by steps of 100 A Display is in kA thousand amps Welding time from 100 to 850 ms by steps of 10ms Display in milliseconds Electrode force from 100 to 550 daN by steps of 5 daN Display in decaNewtons arm used on the clamp arm number and length If the input air pressure is too low to reach the requested electrode force the machine will beep and display before the welding spot the following error message Pressure too low Pressing again on the button allows to force the execution of the welding spot which will be performed with the air pressure available If the welding current measured during the spot is 6 less than the setting the machine will display when the spot is completed an error message Current too low warning that the welding spot should be checked In any case a message is displayed at the end of the welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key is pressed on the control panel or until a new welding spot is performed by pressing the B button on the clamp Pressing during 2 seconds the key allows to come back to the normal mode Clamp adjustment oon MANUEL 21784708 17 01 The key allows to switch from one tool to the next and also allows to enter the clamp adjustment mode The clamp adjustment mode allows to close the clamp and apply the selected electrode force wi
28. r there are no other power supply cable no control lines no telephone cables no radio or TV reception appliances no watches no mobile phones no magnetic cards no computers nor any other electronic appliance there are in the surroundings no persons using active medical appliances pacemakers acoustic prosthetics Plan extra protections if other products are to be used in the vicinity of the machine This product is designed to be used in an industrial or professional environment as defined in the CISPR11 publication In a different environment it might be difficult to ensure electromagnetic compatibility CE MARK GYS testifies that this product has been designed and manufactured in conformity with the following European standards Low Voltage Directive 2006 95 EC in application of the norm EN 50063 and EN 50178 Electromagnetic Compatibility Directive EMC 2004 108 EC in application of the norm EN 62135 2 Machines directive 2006 42 EC in application of the European standad EN 60204 1 Exposure of workers to electromagnetic fields directive 2004 40 EC dated April 29 2004 2 DESCRIPTION OF THE MACHINE v BP Front panel SD Card Reader Display board for communication with the user v Rear panel 25 A D curve switch 30 mA Pneumatic filter connection Earth leakage circuit breaker to the pneumatic network system v C Clamp Button B to open close the Button remote control of the clamp sheet s thickn
29. s necessary to check the state of the tools stars monopoint electrode carbide electrode and if they look in bad conditions 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 v Purging of the pneumatic filter Regularly drain the dehumidifier filter placed on the rear side of the unit Yv 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 23 25 6 CHARACTERISCTICS ELECTRICAL CHARACTERISTICS LU Nominal input voltage UIN 400V 3 phase earth 50 60Hhz Circuit Breaker a ee THERMAL CHARACTERISTICS Pe Ambient 5 C 45 C temperature Range Transport and storage 20 C up to 70 C Temperature range Hygrometry 2000m Thermal protection by thermistor on the diode bridge MECHANICAL CHARACTERISTICS 0 Coo O PNEUMATICS CHARACTERISTICS 24 25 7 Pictograms 25 25 Caution Read the user manual before use Separate collection required Do not throw in a 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
30. stopped by pressing the key The mode key allows to exit the report visualisation mode 10 25 XE Fidani Observation OA pi rp T E r 65 g i m Ex he ao yy oe CAA L4 C4 C4 P3 Ce L4 PO C4 I D T E m m er use c n for ca woo Papa A Po Pa PES PO T To erase the contents of a report display it on the screen using the visualize key hen press key The following message appears on the screen When the triangle sign is displayed pressing key a second time definitively erases the contents of the report displayed on the screen The triangle sign disappears from the screen after 3 seconds USER IDENTIFICATION MODE USER ID Screen Job number If the identification mode is set to ON then you should enter all required fields of the repair order to the welding points if the machine will issue the defect identification To enable and disable the identification mode insert an SD card reader in the identification of BP instead of the SD card that contains the programs The screen below setup is activated by pressing for 2 seconds on the mode button Keys left and right moves the cursor in the field The up and down buttons allow you to change the letters or numbers The short press the Esc key clears the field The mode button allows scrolling fields for the modification or reading When the SD card identification is inserted and you select i
31. that there is no cooling liquid leaks 7 Before performing any control or maintenance operation switch off and disconnect the unit directly from the plug EYE AND BODY PROTECTION 1 During the welding process the operator must protect himself from possible projections of steel in fusion with clothes like leather gloves welding aprons safety shoes welding helmets or glasses for filtering radiations and projections Similarly during grinding or hammering operations the operator must wear eye protection 2 The tightening force of the clamp can reach 550 daN Keep away all body parts from the mobile elements of the clamp to avoid any risk of squeezing of fingers in particular 3 Do not wear rings watches or jewellery which are current conductors and can cause serious burns 4 All the protection boards must be in good condition and maintained in place Never look at a welding arc without any eye protection Protect the environment near the product against projections and reflections FIRE 1 Make sure that the sparks will not cause fire especially near flammable material 2 Check that fire extinguishers are near the operator 3 Use the product in a room with extractor fans 4 Do not weld on combustible or lubricant containers even empty nor on containers containing flammable material 5 Do not weld in an atmosphere charged with flammable gas or fuel fumes ELECTRO MAGNETIC COMPATIBILITY Near the spot welding machine check whethe
32. thout delivery of any current The clamp remains closed as long as the button on the clamp is pressed This mode allows to check the alignment of the electrodes and the good positioning of the caps Pressing during 2 seconds the key allows to come back to the normal mode v Use of single sided gun Pistan The single sided gun can be used in standard or manual mode In normal mode the single sided gun will be limited to steel sheets of thickness 1 5mm maximum With the single sided gun the operator can choose between a variety of tools monopoint welding star welding stud welding rivet welding washer welding carbon shrinking stitch welding The selection of the tool is performed using the and keys In manual mode the maximum permitted welding current is 9 kA during a period that will not exceed 600 ms This is why it is not possible to select higher values for these parameters b es Pressing during 2 seconds the key allows to come back to the normal mode The highlighting allows to select the parameter to adjust Each parameter can be adjusted using the and keys The up and down keys allow to move from one parameter to the next Piessuie 8 25 Error Management Different events might cause the appearance of error messages They can be classified in three categories the messages that warn the user of overheating or a lack of electrode force or welding current etc
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