31.12.2014-V1.6
Contents
1. GYSPOT RP INVERTER 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 PRESENTATI ON SAFETY RECOMMENDATI ONS AND GENERAL PRECAUTI ONS 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 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 el2. Position screw to fix the arm on the clamp Tighten it in manually do not over tighten Tighten ring manually then the tighten using the Allen key D Tighten the lever manually and check it is not end up If it is the case go back to step max Warning Clamp and arm may be damaged if the lever is not tightened property Check the cooling liquid level Check screws and lever incorrectly tightening can damage the material Switch on the machine ATTENTI ON The clamps and gun are connected to the same power supply therefore when one is in use current will be delivered to all tools For safety ensure sure that the clamps and gun are always placed on the trolley when not in use clamp stand on either side of the trolley and the gun stand on the arm Failure to follow this precaution may result in serious damage to the user the generator and its tools and there is a high risk of sparks and metal spatter The warranty does not cover damages and defects due to a bad tightening or assembly of the C arms C clamp overhaul The tightening of the following screws need to be inspected every month Screw between the arm and the clamp Era These 4 screws fix the arm to the clamp They need to be tightened to ensure good transmission of the current A loose bad connection leads to loss of current and even worse can cause irreversible dama
3. Unscrew the tightening screws of the circular arm joints e Remove the arms and drain any excess liquid from the arms Put contact grease around the end of the replacement arms that will be connected to the clamp ref 050440 Check the condition of the toric joint toric joint D 25 thickness 4 Put the arms on the joint stop set the alignment so that the electrodes are face to face then tighten the 2 screws of the circular joint couple 15 Nm Check the cooling liquid level Switch on the unit ATTENTI ON If the circular joints are not securely tightened as the liquid circulates the arms could be ejected and cause severe damage or injury X 25mm Caps 0 13mm X 25mm Caps 0 20mm cm 4 LQ 1 120mm _ Y 25 120mm X8 Gu 8 bar 100 daN Ref 050877 iu ae X 1netososo1 8 bar 550 daN X2 ref 050518 8 bar 400 daN 1 350 8bar 550daN mefoso006 Ref 049253 f ai XO ref ososes 1 260 mm 8 bar 350 daN 12220 mm Ua m eoe X7 X10 Ref 050587 8 bar 400 daN 8 bar 100 daN 1 400 X5 netososao 8 bar 200 daN 8 bar 100 daN 1 350 mm 123 i 1 200 Panneaux de bras 440 X1 Ref 051607 ll bar 150 daN N T n xasga NLK combinations X2 3 5 N 1 Ref 018785 LIQUID X4A X4A XAC c Ref050532 8 bar 120 daN Qa Ref 020702 X 8bar
4. Replace the consumables 22 GYSPOT RP INVERTER 7 DECLARATI ON OF CONFORMI TY GYS confirm that the product described within this manual conforms to the following directives Low Voltage Directive 2006 95 CE in respect of the harmonized norm EN 62135 1 Electromagnetic Compatibility Directive EMC 2004 108 CE in respect of the harmonized norm EN62135 2 Machine Directive 2006 42 EC in respect of the harmonized norm EN 60204 1 Electromagnetic Field exposure of workers Directive 2004 40 CE of the 29thof April 2004 in respect of the harmonized norm EN 50455 of 2008 01 08 2013 Nicolas BOUYGUES Soci t GYS Pr sident Directeur G n ral 134 BD des Loges 53941 Saint Berthevin huoeanaowshugs 8 WARRANTY 1 The warranty is valid for one year only when the certificate of warranty has been filled correctly by the seller 2 The warranty covers every default or manufacture vice for one year as from the purchase date spare parts and labourforce 3 THE WARRANTY DOESN T COVER THE VOLTAGE ERRORS if you don t use CORAGARD CS 330 or an equivalent liquid damage due to a bad use dropped product dismantling or any more issue due to the carriage 4 The warranty doesn t cover any issue due to a maintenance of the clamp or the generator 5 The warranty doesn t cover the normal wear and tear of the spare parts e g cables clamps etc In case of breakdown please return the unit to the GYS f
5. key allows to enable or disable the saving of a report The visualise key allows to read the sequence of spots performed 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 circle allow to select the parameter to modify sheet thickness type of steel arm used The and keys allow to modify the parameter 25 07 07 15 30 Save user welding parameters The save key m allows to save user welding parameters mode sheet thickness welding current welding time or electrode force The recall key 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 Steel sheet thickness settin 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 the steel sheet setting This setting allows to select the type of steel sheet to weld am
6. 150daN 350mm c A es cS FP tess 3 p B 12350 mm 7 g X4B Refo20719 8 bar 150 daN E E E D 1 X4B X4B Ce c XCIX Xic m x2 2 netoz0726 8 150 Ref 020733 LIQUID ATTENTION The clamps and gun are connected to the same power supply therefore when one is in use current will be delivered to all tools For safety ensure sure that the clamps and gun are always placed on the trolley when not in use clamp stand on either side of the trolley and the gun stand on the arm Failure to follow this precaution may result in serious damage to the user the generator and its tools and there is a high risk of sparks and metal spatter The warranty does not cover defects or damage caused by incorrect assembly or incorrect tightening of the X Clamp 21 AT 78 lf INVERTER 6 SYMPTOMS REASONS SOLUTI ONS BP Clamp Welding Gun SYMPTOMS The Spot weld doesn t hold is not good REASONS SOLUTI ONS The caps used are worn enlace th out faulty peer cake Insufficient preparation of the Sand and clean the metal work piece sheet again The arm selected doesn t Check the arm with the match the one installed software The spotter cuts the metal The caps used are worn out faulty Replace the caps Check the compressed air Not enough pressure network min 7 bar Insuffi
7. Bs sas e v3 18v5 gl AW1dS10 5 tents le ns es RERUM NINE 1066 gt E SESS TLLIL 2NV18 ao 5 LILES E xor 2 a MGE PE 8 3 2 4 35nou ZA LU 3 182 1 ST SON INOHO3 19 LHOddNS IN z SO 115 Eee 3onou 00666 1 exui js rears oe ms E ZLS muy Dvi 3ONId 1 924 0 G 4 XI J ELE t 9 0 a ZYOIDVINOD wii EA Oi als d E L q d d thy a ia 1924 61096 E 2NV18 Lrezs dd 5 X rsos6 2NV18 LYaWYO 4SNVYL SION tc 096 Sie Jaya T LL8t6 J1DV1LNOD a YZEXE INAU 3 L 5110015 o ZTYJWYO JSNVHL 1 24 ATs lf INVERTER 10 TECHNI CAL SPECI FI CATI ONS BP ELECTRI CAL CHARACTERI STI CS Nominal input voltage U1N 3 400V 50 60Hz Permanent input current 11N 32 Power at 50 96 duty cycle 550 13 kVA Permanent input power S 9 kVA Maximum welding input power Smax 120 kVA Secondary voltage U2d 16 VDC Maximum short circuit output current 12cc 13 000A Maximum permanent output current 12 1300A Maximum regulated welding current 12 000A Circuit breaker 32 A D curve Duty cycle 196 THERMAL CHARACTERISTICS Ambient temperature range 5 45 C Transport and sto
8. Ecran Num ro chassis optionnel Catalogue The View button gt allows you to view all repair orders on the screen CATALOGUE The number of pages is displayed max 13 at the top The left and right arrow keys scroll through the pages The up and down arrow keys scroll through the list of Repair Orders Press the Mode button to display the repair order selected CATALOGUE Use the mode button to exit the report view The SD card driver allows the management of SD cards gt 2 Gb Each repair order is linked an archive file xxx dat with xxx identifier from 001 to 100 In each archive you can save up to maximum 500 welding points The repair order names and users are displayed The page number is indicated top left All the repair orders are saved in the file catalog GYS This file contains the total number of repair orders the name of each repair order and the name of each user There are a maximum of 100 repair orders User programs The save option allows a user program to be entered to save information for future use 20 memory slots are available each one contains the following parameters tool arm welding intensity welding time and pressure A program can be linked to a clamp and gun The button will save the settings in the manual mode intensity time and pressure The 20 memory slots are indicated by their identifier when in use or by the symbol To enter an identifier use
9. be perfectly aligned To check the electrode line see change of arms on i pages 18 and 19 17 AS 78 f INVERTER Replacement of the C arms Please read the following instructions carefully Incorrectly tightening or setting the C clamp arms can lead to the arm and clamp overheating and causing damage Damage caused by incorrect assembly are not covered under the warranty Switch off the machine or put the machine into clamp setting mode e Unscrew screw O which holds the arm to the clamp Leave it on the arm to not lose it Disconnect the cooling liquid pipes Unscrew screw and loosen the lever the side of the clamp B ILE Y Remove the clamp arm h A Lubricate both a new arm and the support with contact SUY grease ref 050440 Specific Installation for C2 and C8 arms For these arms the Stretches will also need to be changed Unscrew the short stretches with a flat spanner and remove the injector Centre the injector along the axle of the clamp Caution beveled side outside and insert it manually 1 Position the long stretches in front and screw it on to the clamp axle maximum torque 15Nm 2 Long stretches Long injector are Short injector Short stretches Stretches types Short C1 C3 C4 C5 C6 C7 C9 C10 Long C2 C8 18 GYS GYSPOT INVERTER Adjustment of the C arms
10. highlighted a parameter can be adjusted using the and keys The AandW keys allow movement from one parameter to the next ATTENTI ON The clamps and gun are connected to the same power supply therefore when one is in use current will be delivered to all tools For safety ensure sure that the clamps and gun are always placed on the trolley when not in use clamp stand on either side of the trolley and the gun stand on the arm Failure to follow this precaution may result in serious damage to the user the generator and its tools and there is a high risk of sparks and metal spatter Error management ERREUR e192 1 08127 Different events might cause the appearance of error messages They can be classified in three categories General Warnings i e overheating lack of electrode force or welding current etc These messages appear on the screen and remain until a key is pressed Installation Errors air pressure electrical power supply e Major Faults These defects cause the display of an error message that locks the machine The thermal protection relies on a thermostat located on the diode bridge this feature will lock the machine display the message overheating Current too low If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be
11. of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp 8 GYSPOT FB IS INVERTER Press for 2 seconds to revert back to standard mode X clamp Line up the electrodes so they face each other then set and tighten the clamp arms couple 15 Nm Enter clamp adjustment mode to check the alignment of the electrodes The force is calculated by the machine according to the setting of the force or of the sheet thickness Clamp adjustment PEt The key is used change from one tool to the next as well as to enter the clamp adjustment mode The clamp adjustment mode allows the user to close the clamp and apply the programmed force on the electrodes without any current flowing This mode is used to adjust the arms The clamp will remain closed as long as the button remains pressed this allows the user to check the alignment of the electrodes and positioning of the caps Standard mode This is the default mode when the machine starts Quick
12. of CS330 10 litres of distilled water anti freeze protection down to 13 C 10 litres of CS330 20 litres of distilled water anti freeze protection down to 5 C Any damage to the machine due to the freezing of cooling liquid will not be accepted under warranty To fill the tank with cooling liquid proceed as follows Put the pneumatic clamp on its stand Fill the tank with 30 litres of cooling liquid this should reach the middle of the min max indicator on the side of the machine Safety recommendations regarding CS330 cooling liquid In case of contact with the eyes rinse thoroughly with plenty of water immediately after contact remove contact lenses first if worn Seek medical help if necessary In case of contact with the skin wash thoroughly with soap and plenty of water Remove any contaminated clothing and if skin irritation occurs redness etc consult doctor n case of ingestion rinse the mouth out thoroughly and drink plenty of water consult your doctor immediately Maintenance It is recommended that the cooling liquid is changed every 2 years To empty the coolant tank proceed as follows NB Ensure there is a container available near by to collect the cooling liquid as it drains sure an arm is fitted on the C clamp Select the C clamp adjustment mode in the machine menu Unscrew the mobile electrode from the clamp Select the normal mode in the menus Press the welding button on
13. the clamp to activate the pump Use the container to collect the liquid as it drains from the clamp n the absence of welding the pump will stop automatically after 2 minutes It will therefore be necessary to press this button several times to completely empty the tank When the tank is empty go back to the C clamp adjustment mode in the menus and re connect the mobile electrode to the clamp Fill the tank with the new cooling liquid Starting the machine Switch ON the circuit breaker 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 GYSPOT RP INVERTER 4 PRODUCT OPERATI ON Key definition move NORMAL Pression 6 1 bar E Key Pressing the key allow to select the clamp mode gun mode or clamp adjustment Pressing this key 2 seconds allows to come back to normal mode from the other modes Pressing this key 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 Save a report More details can be found on this function in the corresponding chapter The record
14. the following information User Car model Repair order Registration number Put into circulation Intervention Comments To enter this data select a report and enter the information in the report header Print a report To print a report select the one required and click e A print preview is displayed Click To export the report as a PDF c PDF To export the report as a PDF select a file and click A preview of the print is displayed Click Below shows an example of the parameters saved and printed by using the GYSPOT software Raison sociale GYSS AS T l phone 33 0 243012360 Adresse 21 134 boulevard des Loges T l copie 33 0 243013133 Email contact oys fr Code postal F 53841 Site Web http www gys fr Votre logo E Ville Saint Berthevin Intervenant DUPOND JEAN PIERRE Marque Renault Ordre de r paration 455B Mod le MEGANE CC 1 61 16V Date du journal 06 10 2009 N chassis VF7RD4HTH54042832 Intervention REDRESSAGE AILE ARRIERE GAUCHE Immatriculation 16008 W53 Commentaires RAS Mise en circulation 08 11 2008 GYSPOT INVERTER 0000000000 Consignes Mesures Date Heure Etat KA daN 06 10 2008 11 1 Norma ce en X n 5 205 Point 6 10 2009 11 1 Norma Pince en X n 5 7 7 205 Point Ok 6 10 2009 11 1 Norma Pinc X n 5 27 7 205 Point 4 0610 2009 11 1 Norma Pince en Xn s 270 7 6
15. 210 7 5 205 Point Ok 6 10 2009 11 1 Norma Pince en X n 1 i 7 3 Point Ok Norma Pince en X n 1 34 i i 3 Paint Ok Manue Pression faible Multi tdles Point Ok 06 10 2009 11 1 Multi t les ce en X n 1 39 5 Point Ok 16 B E INVERTER 5 USE AND MAINTENANCE PRECAUTIONS User training Any operator of this machine should receive training adapted to its use in order to gain maximum performance from the unit e g car body repair training Adjust the balancer s spring tension Adjust the balancer s spring tension with the Allen key equipped Do not leave the clamp hanging for a long time on the balancer as it would induce early wear out of this part Do not let the clamp fall down repeatedly without holding it as it could damage the balancer Preparation of the work piece Grind and clean the work piece thoroughly before welding If protection is being used ensure that the parts are conducting by testing a sample Single sided qun welding Before repairing a car check that the car manufacturer authorizes that welding process Cooling liquid level and efficiency The cooling liquid level is important to ensure the unit functions correctly The liquid level should always be between the minimum and maximum levels indicated on the tank Check the level and efficiency of the cooling liquid regularly replace if needed It is recommended replacing the cooling liquid every 2 years Cleaning t
16. 6 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 phase earth plug minimum 32 on the supply cable GYSPOT INVERTER CORDON SECTEUR BP LX VERT JAUNE BP LC BP LCX 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 fthe 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 must not be used on an air compressed network with a pressure inferior to 3 bars The unit can t be used on a air network with a pressure inferior to 3 bars Assembling the clamp handle clamp stand and earth cable accessories ba Xem X clamps BP LX and BP LCX Assemble the clamp stand the right or left side of the machine Assemble the clamp handle on the left or right side of the clamp depending on the preferred choice Depending on the arms used position the clamp either using the hook or using the clamp h
17. achine will display identification defect To activate or deactivate the identification mode an Identification SD card must be inserted in the BP drive instead of the Program SD card The setting screen below is activated by pressing the mode button for 2 seconds When the Identification SD card is inserted and the identification mode is ON the following screen is displayed gt This screen allows the selection of default fields registration number car brand car model chassis number To exit the screen press and hold the mode button for 2 seconds Then re insert the Program SD card into the BP drive IMMATRICULATION MARQUE DU VEHICULE MODELE DU VEHICULE NUMERO DU CHASSIS Entry of repair order screen guide To modify or erase a repair order that has already been created you will need to use the GYSPOT software on a PC you are unable to do this on the machine You can create maximum 100 repair orders Screen Repair order Screen User identification The left and right arrow keys move the cursor within the field The up and down arrow keys scroll through letters or figures Press Esc to erase the field The Mode button changes the field to modify playback Screen Registration number optional Screen Car brand optional Screen Car model optional Screen Chassis number optional 13 A 78 lf INVERTER BP
18. actory GYS with the following certificate of warranty validate by the seller and explicative note of the breakdown After the warranty our After sales service provides the repairs by acceptance of the quotation ATTENTI ON We remind you that we do not accept any product return with carriage cost not included SOCI ETE GYS S A V 134 Bd des Loges BP 4159 53941 SAINT BERTHEVIN cedex FAX S A V 02 43 01 23 75 CERTIFICATE OF WARRANTY Seller stamp Reference of the Purchase date Seller Name Company Valid for one year as from the purchase 23 a X21 x21 X1 i O A c1 1 1 I 3NV18 T T 3NV1S 3NV18 1 saong z auumonojo p umen puuroa ma N 1 uae 1 aX aX 8ESIL 8ESIL y ESU ESIL LESIL b MA A J 3NV18 O 3NV18 T 6607s jnajyde 9 osis 2NV1S 1 2NV18 S06IS 2NV18 18656 LAW 14510 3 18v2 S60 s 2 addeu ol 18686 Zunady gt QuvosA3 Bl E jai 5 2 2904 13 101519 EJ 3 3l r E
19. and easy spot welding by selection of Type of tool used Sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 Type of steel coated steel HTS steel UHTS steel BORON steel and the arm to be used The up and down keys key definition diagram 3 scroll through the parameters to modify sheet thickness type of steel arm used The and keys allow modification of each parameter Button A on the clamp remotely adjusts the thickness of the sheets to be welded Button B on the clamp creates a welding spot using the selected parameters Pressing button close weld allows the user to make a welding spot using the selected parameters Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp m Multi sheet m
20. andle see left C clamp BP LC and BP LCX Q Assemble the c clamp stand on the right hand side of the machine using the three M5x12 provided screws Q Assemble the handle on the left hand side of the clamp Earth cable BP LX BP LC BP LCX Air connector Assemble the copper plate on the extremity of the earth cable Assemble the air connector on the air filter This earth cable has to be used with the gun GYSPOT R P INVERTER Filling the cooling tank GYS recommends that you use CORAGARD CS330 or equivalent cooling liquid in this cooling tank for more information visit the website http www aqua concept gmbh eu The use of other cooling liquids and in particular standard cooling liquids can lead to the accumulation of solid substances inside the cooling system due to electrolysis this will negatively impact the cooling efficiency and possibly cause total obstruction of the system Any degradation to the machine caused by the use of cooling liquids different from the CS330 or equivalent will not be considered under warranty The CORAGARD CS330 used undiluted provides anti freeze protection down to 20 C If it is necessary to dilute the coolant only use distilled water TAP WATER is NOT RECOMMENDED to dilute CS330 NB a minimum of 10 litres should be used in the tank to provide minimum protection for the cooling system 30 litres of pure CS330 anti freeze protection down to 20 C 20 litres
21. anually select the welding parameters for j example when following instructions from a manufacturer The settings proposed by default in the manual mode correspond to the settings automatically selected I 7 7 xa bythe standard mode thickness and type of sheet electrode force arm The parameters can be adjusted using the and keys The up and down keys T 260 E scroll from one parameter to the next e Welding current 2000 to 13000 A steps of 100 A displayed in kA ZEE hel Z E Welding time 100 to 850 ms steps of 10 ms Electrode force 100 to 550 daN steps of 5 daN C 1 97 79 eArm used on the clamp number and length Pression 6 Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp Press for 2 seco
22. ave been imported it is possible to search edit or archive them To view the spots made in a report select a report and the spots will be displayed in the table To search for a report fill the field and click on the icon To edit a report select it and click on the icon To archive a report select it and click on I icon Attention The imported reports cannot be canceled until they are archived Consult archived spot reports To consult the report archives click on the tab Archives The files are grouped by year and month To view the spot information select a report and they will appear in the table For archived reports it is possible to search edit or to erase a report Attention When a report is archived or erased the SD card must then be formatted to prevent the report from being imported again To search for a report fill the field and click on the icon To edit a report select it and click on the icon To erase a report select a report and click on the x icon 15 GYs GYSPOT R P INVERTER Format an SD card All the reports made and saved on the SD card will be erased when formatted To format an SD card insert the card into your PC card drive or a card reader and in the menu click on Options and Purge the SD card Attention Any reports stored on the SD card that have not already been imported will be imported automatically before formatting To enter the report information Each report can include
23. be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp A 78 if INVERTER Press for 2 seconds to revert back to standard mode Gysteel mode The Gysteel mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds Gysteel mode on off The Gysteel mode is identical to normal mode except that the user enters the yield strength of steel The Ys may be found using a durometer such as Gysteel Vision Re 1 10 corresponds to mild steels Re 11 18 corresponds to HSS THSS steels Re 19 35 corresponds to UHSS steels Re 36 99 corresponds to boron steel 9j Sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 Type of arm used The up and down button A or W scrolls through the parameters to modify sheet thickness Yield strength arm used The and keys allow modification of each parameter Button A on the clamp allows the user change the thickness of the sheets to be welded remotely Button B on the clamp allows the user to spot weld with the selected parameters Press for 2 seconds to revert back to standard mode Manual mode MANUAL 567939 This mode allows the user to m
24. calculated by the machine considering the force setting or the thickness of the sheets selected C clamp MODE MANUEL 21 94 08 17 61 The key is used to enter the clamp adjustment mode The clamp adjustment mode allows the user to close the clamp and apply the programmed force on the 9 0 kA electrodes without any current flowing This mode is used to adjust the arms The clamp will remain closed as long as the button remains pressed this allows 200 the user to check the alignment of the electrodes and positioning of the caps Press for 2 seconds to revert back to standard mode 250 an Pression 7 2bar C 1 97 mm woos STANDARD z970 6 This is the default mode when the machine starts Quick and easy spot welding by selection of the type of the tool used the metal sheet thickness to select between 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 When you weld 2 metal sheets together enter the thickness of the thinner one When you weld 3 metal sheets together enter the sum of the 3 and divide by 2 the type of metal sheet coated steel HTS steel UHTS steel BORON steel and the arm used For the type of metal select the harder one The up and down button key definition diagram 3 scrolls through the parameters to modify sheet thickness type of steel arm used The and keys allow modification of each parameter Button A on the clamp allows the user change the thickness of the sheet
25. cient preparation of the Sand and clean the metal work piece sheet again Lack of power at the clamps C and X Power supply issue Check the stability of voltage delivered Caps worn out or damaged Change the caps Lack of power only at the C clamp Bad tightening of the arm Please follow the instruction in the C arm adjustment chapter BP LCX too much pressure during the replacement of the arm X Unit overheats quickly swelling of the power cable There is no C Arm on the clamp Insufficient coolant in the clamps Assemble the C Arm Check connection of C Arm to cooling section of the clamp BP LC Unit overheats quickly swelling of the power cable Abnormal overheating of the gun The arm C badly cooled Bad tightening of the chuck Gun liner out Check the connection of the C Arm to the cooling section of the clamp Check the tightening of the chuck the star support chuck and the liner condition Put back the liner to have the air cool going to the gun The spot weld made doesn t hold Bad positioning of the earth clamp Check the earth clamp is securely connected to the metal sheet Lack of power in the gun Bad contact of the earth clamp Check the earth clamp is securely connected to the metal sheet Loose chuck or accessories Check the tightening of the chuck and accessories and the condition of the liner Worn out Damaged consumables
26. cinity of the machine the battery has to be disconnected 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 5 INVERTER 2 DESCRI PTI ON OF THE MACHI NE BP Front panel Display board for SD card reader communication with if BODYPROTECT ECHNOLOGY the user BB ORECTIVE 2004 40 ct COMPLIANT g Fan with dust proof filter 32 A D curve circuit breaker Pneumatic filter connection to the pneumatic network X clamp for BP LX or BP LCX Over opening of the clamp Close the clamp and weld Sa Close Weld B button Remote control for the thickness of the sheet A button Remote control to choose the metal steel Arms nuts Pince en C ur les BP LC ou BP LCX C arm Locking Unlocking C Lever GYSPOT R P INVERTER 3 I NSTALLATI ON OF THE MACHI NE Before use Several verifications are necessary before using the unit to ensure good performance of the machine Check the electrical line voltage it should be 400V 3 phases with a 32 A delayed circuit breaker curve D or fuse of aM type 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 4x
27. displayed at the end of every welding spot showing the measured welding current This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp current too low 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 Insufficient air pressure Before the welding spot If the input air pressure is too low to reach the required electrode force the machine will beep and display the following error message Insufficient Pressure Pressing the button allows the user 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 Pression faible 6 50 F 435 aon Pression insuffisante Welding spot counter The spot counter will count the number of spot welds performed with the same caps If the welding spot is performed without any problem the message below left appears 11 A 78 if E pP INVERTER The counter is displayed on the top left corner of the screen After the caps have been replaced press the button to reset the counter to zero If more than 200 welding spots are done with the same caps then the machine will displa
28. ectrical 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 MAI NS 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 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 PROTECTI ON 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 filterin
29. el UHTS steel BORON steel and the arm used To activate the required sheet press the up and down keys to highlight the required sheet then use the and keys to select the thickness and type of steel Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp Press for 2 seconds to revert back to standard mode Gysteel mode The Gysteel mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds Gysteel mode on off oor GYSTEEL freee The Gysteel mode is identical to normal mode except that the user enters the 1 yield strength of steel The Ys may be found using a durometer such as Gysteel Vision Re 1 10 corresponds to mild steels Re 11 18 corresponds to HSS THSS ste
30. els pA Re 19 35 corresponds to UHSS steels m Re 36 99 corresponds to boron steel Sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 Type of arm used The up and down button or Y scrolls through the parameters to modify sheet thickness Yield strength arm used The and keys allow modification of each parameter Button A on the clamp allows the thickness of the sheets to be welded to be changed remotely Button B on the clamp allows the user to spot weld with the selected parameters Manual mode This mode allows the user to manually select the welding parameters for example when following instructions from a manufacturer The default settings in manual mode correspond to the settings automatically MILL EEE Selected in standard mode thickness and type of sheet electrode force arm The parameters can be adjusted using the and keys Key Definition diagram 7 7 A 3 The up and down keys allow navigation from one parameter to the next e Welding current 2000 to 13000 A steps of 100 A displayed in kA Welding time 100 to 850 ms steps of 10 ms Electrode force 100 to 550 daN steps of 5 daN 150 daN eArm used on the clamp number and length ec Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution
31. emoved from the reader failure to do so may result in the loss of data from the card Ins rer la carte SD GYSPOT Software The software allows the user to edit and save the weld reports made by a GYSPOT equipped with a SD drive Lanquage selection The software contains several languages French English German Spanish Dutch Danish Finnish Italian Swedish Russian and Turkish To choose a language in the menu select Options and then click Languages Attention once a language is selected shut down and re start the GYSPOT software in order to apply the change User identification In order to personalise the reports with your company information the required fields will need to be completed In the menu click on Options and select Identity A new screen is displayed with the following information Company name Address Post code City Phone Fax Email Website Logo This information will be displayed on your print outs Import the spot reports made from an SD card To import the spot reports made with your GYSPOT to your PC insert the SD card into the PC card drive or use a card reader and start up the GYSPOT software Select the drive and click on the Import icon When the import is complete the spot reports will be grouped by the identifier of the repair order The identifier matches up with the report name established on the welding machine and is displayed in the tab In progress Once the reports h
32. g 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 MAGNETI C COMPATIBILITY Near the spot welding machine check whether 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 vi
33. ge to the arm or clamp The screw shown opposite ensures secure attachment of the copper cable which carries current to the clamp It is recommended that screw tightness is checked every month to prevent irreversible damage inside the clamp 19 A 78 if INVERTER Arms types for the C clamp gm gm 1 neto19140 50 C5 ref019294 8 bar 550 daN 8 bar 550 daN 210 gt pm cr 141 5 C2 neto19133 C6 refo19775 8 bar 550 daN 8 bar 300 daN 8 bar 550 daN J Refo19157 8 8 550 Arms panel C2 C3 C4 Ref 019126 Nf h Ref 020009 8 bar 550 peto19164 18 8bar 550daN C10 Ref 051638 4 bar 150 daN M nef 051614 Ref 050433 e D x6 Spotter consumable box Spanner for cap Type A 13 mm Ref 050846 Ref 049987 Ref 050068 x1 Metal for RC2 HLE HTS 1 0 mm x150 050181 13 mm Ref 051157 THLE VHTS 2 5 mm x150 Ref 050167 Contact Grease Ref 049994 F Ref050440 D x6 x1 Type F 13 mm for C6 Ref 049970 Ref 050617 AT 78 lf BP INVERTER Changement des bras de la pince en X Follow the directions carefully Turn the machine off or place machine in clamp setting mode Place the clamp somewhere above the level of the cooling liquid tank to drain water from the arms Wait at least one minute to lower the pressure in the arms
34. he pneumatic filter Ensure the dehumidifier filter located at the back of the machine is cleaned regularly Generator maintenance The maintenance and repair of the generator should only be carried out by a GYS technician Any repair maintenance made to the generator by unauthorized personnel will invalidate the machine s warranty GYS will not take responsibility for any incident or accident under these circumstances Cleaning replacement of welding tools and other items All welding tools are consumable and will deteriorate during use To extend the lifespan and efficiency of the tools ensure that they are inspected and cleaned regularly When using with the Pneumatic Clamp check that the condition of the electrodes CAPS flats rounded or beveled is good If the condition is poor clean with fine grain sandpaper or replace see reference on the machine When using with the gun check the condition of the tools star single point electrode carbon electrode Clean or replace if necessary Ensure the pneumatic filter is clean to prevent the machine overheating Replacement of the caps electrodes To ensure an efficient welding point you need to replace the caps every 200 spots remove the caps using the spanner Ref 050846 DO NOT grind the caps Use grease ref 050440 when replacing caps i Caps type A ref 049987 Caps type F ref 049970 1 Caps beveled ref 049994 i Caution The caps must
35. ivated when the machine is started ue Pressing the record button on off and the mode button starts the recording process in the selected log file To stop saving the information E press the save button again The new report has an identifier entered by the user all the spots made the arm and the clamp used the settings voltage and pressure It puts also stores any messages received whilst recording LOW LOW P CAPS You can enter the identifier using the 4 buttons up or down If you enter an identifier that has already been used the unit will save the new spot information without erasing the old ones The View button allows the user to retrieve a previously saved report and view it on the screen To view a report stop any current recording by pressing o Use the mode button to exit the report displayed To erase the content of a report it has to be displayed To erase the report shown press on screen by pressing view and the following message will be on the screen 22704708 17 10 30704708 14 25 When the warning image is displayed press again and the report content will be erased The warning image will disappear after 3 seconds User identification mode REGLAGES LANGUES DATE HEURE SONS CONTR LE PRESSION IDENTIFICATION GYSPOT RP INVERTER If the identification mode setting is ON all the fields of the repair order must be completed or the m
36. nds to revert back to standard mode Using a single sided gun Connect the copper plate onto the generator s earth cable Firmly fix the earth plate as near as possible to the welding area In case of spot welding with the single sided gun always fix the earth plate to the sheet that will not come into contact with the welding electrode so that the welding current will flow through the 2 sheets to be welded Select the GUN tool using the e key or by pressing the gun trigger The standard mode with star welding is launched by default The gun can be used in both standard and manual modes Never leave the inertia hammer on the gun when it is hung from the balancer as this may damage the welding cables ooe NORMAL 25 04 08 17 16 n standard mode the gun can weld a maximum of 1 5mm thick sheets When using the gun the operator can choose between several tools single spot carbon shrinking star welding studs rivets washers stitches The tool selection is made with and keys 05 GYSPOT RP INVERTER In manual mode the maximum permitted welding current is 9 kA during a period that will not exceed 600 ms it is therefore impossible to select higher values for these parameters Set the generator by selecting the thickness of the sheet metal with the key and It is possible to modify the parameters time and current in manual mode Press for 2 seconds to revert back to standard mode When
37. ode This mode allows the user specify the thickness and type of each sheet in an assembly of 2 or 3 sheets The first piece Thickness of the metal sheet 1 is selected The up and down button allows the selection of the parameters for each sheet When the parameters for a sheet are highlighted the sheet thickness and type of steel can be adjusted using the and keys The parameters to set in that mode are Thickness of the metal sheet 1 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 Type of the metal 1 coated steel HTS steel UHTS steel BORON steel Thickness of the metal sheet 2 the same as the metal sheet 1 Type of the metal 2 the same as the metal sheet 1 Thickness of the metal sheet 3 deactivate the mode by default or the same as the metal sheet 1 Type of the metal 3 deactivate the mode by default or the same as the metal sheet 1 To activate the metal sheet 3 press the up and down keys to highlight the metal sheet 3 Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should
38. ongst 4 families coated steel HTS steel UHTS steel BORON steel This setting can be adjusted using the and keys Arm used setting 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 GYSPOT RP INVERTER Using pneumatic clam When using the pneumatic clamp always disconnect the copper plate used in single sided gun welding For the GYSPOT BP LCX select the type of clamp to be used with the key on the front panel are equipped with their respective arms and that the pipes are properly attached to their BP LCX to ensure the efficiency of the cooling system it is essential that both clamps and X respective connectors ATTENTION The clamps and gun are connected to the same power supply therefore when one is in use current will be delivered to all tools For safety ensure sure that the clamps and gun are always placed on the trolley when not in use clamp stand on either side of the trolley and the gun stand on the arm Failure to follow this precaution may result in serious damage to the user the generator and its tools and there is a high risk of sparks and metal spatter C clamp 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
39. rage temperature range 20 C 70 C Thermal protection by thermistor on the pont de diodes 70 C MECHANI CAL CHARACTERI STI CS Protection rating P21 Width 65 cm Depth 80 cm Height 205 cm Weight BP LC 160 kg Weight BP LX 160 kg Weight BP LCX 180 kg OTHER CHARACTERISTICS Maximum air pressure P1 8 bars Liquid flow rate 21 min Minimum regulated force F min 100 daN Maximum regulated force with C clamp F max 550 daN Maximum regulated force with X clamp and 440 mm arms 130 daN Maximum regulated force with X clamp and 120 mm arms 550 daN 11 ICONS Volts A Amps 3 Three phase power supply U 1n Nominal input voltage Sp Permanent input power S max Maximum welding input power U 20 Alternating current defined unload 12 Secondary current on short circuit 21 Protected against rain and moisture No access to dangerous parts AN Caution Read the user manual before use X Separate collection required Do not throw in a domestic waste bin A Do not use in the open air Do not use the product in damp wet environments IP21 Risk of interference and disturbance of electronic medical devices i e pace makers when near of the product Caution Strong magnetic field People wearing active or passive implants must be informed ON Always wear suitable protective clothing to shield eyes hands and skin when welding
40. s to be welded remotely Button B on the clamp allows the user to spot weld with the selected parameters Before the weld If the input air pressure is too low to reach the required electrode force a warning will sound and the machine will display the error message Pressure too low Pressing the button for a second time will force the execution of the welding spot with the available air pressure After the weld If the welding current measured during the spot is 6 less than the setting the machine will display the error message Current too low the welding spot should be checked A message will be displayed at the end of every welding spot showing the measured welding current and electrode force This message is displayed on the screen until a key on the control panel is pressed or until a new welding spot is performed by pressing the B button on the clamp GYSPOT RP INVERTER Multi sheet mode This mode allows the user specify the thickness and type of each sheet in an assembly of 2 or 3 sheets move MULTITO The first setting thckness of the metal sheet 1 is selected Using the up and down button allows to select the parameter to modify Using the right and left button increase or decrease the value The highlight allows to select the parameter to modify The parameters to change in this mode are sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 the type of metal sheet coated steel HTS ste
41. the 4 buttons up and down arrow keys When entering an existing user the machine will erase the previous parameters The recall button P77 allows access to previously saved settings Pressing will erase the selected program from the saved program list The mode button exits the program selection mode the machine will then enter manual mode with the parameters and the tool saved in the program To deactivate a program simply change the parameter value in one of the 3 modes manual normal or multi metal sheet or change the tool clamp or gun by using the The view gt button will retrieve a previously saved report and display it on the screen 14 GYSPOT P INVERTER SD memory card ref 050914 This card is a link between the GYSPOT BP and a PC to enable the user to Retrieve and print reports for a record of work and documentation for insurance companies if required Upgrade welding parameters or add new languages Edit the parameters is in the SD memory Access the user manual stored on the SD memory card ERREUR CUM e space can store information on more than 65 000 The unit can only work without memory card in manual mode In other modes if the memory card is not inserted in the card drive the following lt message will appear The machine must be shut down and restarted after inserting an SD card Important The machine must be switched off before an SD card is inserted or r
42. y the below warning message In this case the warning message Change tips is also recorded in the traceability report Attention After the warning message is displayed if the nozzles are not changed before resetting the counter to zero the nozzles may become badly damage and cause poor quality welding POINTS 5 28704708 13 08 POINTS 200 21704708 17 03 V rifier les caps Tel 6 60 443 aon 320 ms Recording features The Identification mode is optional you can configure it in the settings menu which is activated by pushing the mode button for 2 seconds identification mode on off If the identification mode is off enter a file name and activate it to store the information of the welding spots made in the memory The log book stores the spots made with the clamp in the memory It is available in all modes by pressing both buttons located bellow the reporting icon The user s program is available in all modes by pushing the buttons bellow the memory icon 19 un 6 6 aan T 328 a Report log book Saving a report allows spot welding data to be stored on a memory card in order to use it again later or retrieve it at a later date eg on a computer lt r du journal GYS supplies software called GYSPOT to read the SD card and the user 1 1 3 AMZ 3 5 manual This GYSPOT software is stored in the SD card with the user manual Et By default the report mode is not act
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31.12.2014 V1.6