020894_V7_GYSPOT Evolution PTI
Contents
1. Once the reports have 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 WW To archive a report select it and click on the icon LE Attention The imported reports cannot be cancelled until they are archived 3 2 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 erase a report select a report and click on the icon I 3 3 Purge the SD card A purge operation will erase all the reports saved on the SD card To purge and SD card insert the SD 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 purging 3 4 Entering the report information Each report can include 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 he2. The user s program is available in all modes by pushing the buttons bellow the memory icon Report log book Saving a report allows spot welding data to be stored on a memory card in order to retrieve it at a later date e g on a computer GYS supplies software called GYSPOT to read the SD card and the user manual By default the report mode is not activated when the machine is started Pressing the record button on off o and the mode button starts the recording process in the selected log file To stop saving the information 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 I LOW P CAPS PB 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 p allows the user to retrieve a previously saved report and view it on the screen 0 To view a report stop any current recording by pressing Use the mode button to exit the report displayed 14 a7 2 GYSPOT To erase the content of a report it has to be To erase the report shown press and the following message will be on the screen on screen by pressing view 13 85 08 13 14 REIMIMIBLIITILE A
3. GYSPOT INVERTER EVOLUTION PTI s7 400V USER MANUAL v7 Table of Contents 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS ener nnnm nnn nnns 2 EE TA MACHINE iere 3 4 S INSTALLATION OF THE MA EE 5 6 A PRO DUCE OPERATION E 7 LEE E EE 7 Recommendations on the use of welding modes NNN 8 USING prheumatie Campe om 9 12 see DUN mt M M 12 EFT OT wat Le nn E 13 Weldihg SI GG COUNTS a assuuee 00 14 Recording features report user identification mode user programs eese 14 17 ol BRU eh Cdi Ree nee ERES ND SIM EE IER CM MIN ED EI ED SINE NEIN E 17 GYSPOT SONWANE surat 00 e a i 18 21 5 USE AND MAINTENANCE EE Eege 22 e an e E 22 Preparation of the work piece ccscssccsscsurecnecurecuecersanecersanecersaneeusnaeeausnsceeusnseeuussueeueesuseusesurecuesurecueserscussersaneees 22 mae SIG eet Tel ie Le Pr ccc 22 Cooling guid level and nde le P LL LLLI 22 Cleaning Ene pneumatic TILED EET a IEE 22 GMS EO Ti ANAC face 000011000011 22 Cleaning replacement of welding tools and other items ENNER 22 Installation and use of the p 23 gredi eem 24 OFC 1 lt 1 121212 12 12 12 1 2 100 25 7 651 MPTOMS REASONS 7 000 28 7 DECLARATION OF CONFORMITY Dos eoeaadenncasesea ni
4. GENERAL PRECAUTIONS 1 Operators must have received appropriate training 2 Repair and maintenance operations must only be carried out by qualified personnel 3 The operator is responsible for respecting the car manufacturer s recommendations regarding the protection of the car s electrical and electronic equipment on board computer car radio alarm air bags etc 4 Ensure compressed air supply is disconnected and depressurised before any repair or maintenance operation is carried out 5 The electrodes arms and other secondary conductors can reach a very high temperature and remain hot for a long time after the machine has stopped 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 The unit must be connected to an earthed power supply ensure that the earth connection is in good condition 2 Ensure the workbench is connected to the earth 3 Dry protective clothing and accessories must be worn before working with the metal Make sure that the operator has no contact with the metal parts to be welded without any protection or with wet clothes 4 Avoid contact with the welding pool 5 Do not undertake welding or place the machine in wet areas or on wet flooring 6 Ensure all welding cables are in excellent condition before undertaking any work Ensure that any defects in isolation cables or connectors are addressed and that
5. can be also be disabled in this menu GLUE MODE In the SETTINGS menu shown above a specific mode can be selected in case there is glue in between the steel sheets to be welded In this case a GLUE mode can be switched ON or OFF in this menu If the GLUE mode is activated a pre spot is performed prior to the welding spot The duration of this pre spot is selected in milliseconds from 0 to 400ms by increments of 50ms When this mode is selected the text GLUE appears in the welding modes STANDARD MANUAL MULTI GYSTEEL CIT STANDARD IBMISEEUTLI EY 2 STEEL wf Bi esau oc MULTI TOFFEE aN Use of the single sided qun 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 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 In 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 an
6. name of the welding spot and then press the TAB key or click outside the list programmed welding spots in order to program the welding parameters GP 2 To program a welding spot it is possible to select The prespot tightening duration The preheating current and duration The parameters of the pulses up to 4 maximum with pulse ramp up time current and duration Inter pulse parameters can also be selected The current and duration of the forgeing stages hot and cold can also be selected RS In order to modify the parameters click on the buttons When the user changes a parameter the chronogram of the welding spot profile is updated To validate the programmed welding spot click on the button EA To cancel a programmed welding spot click the button gt 20 4 3 Edit a welding spot programmed in the USER file In order to edit the parameters of a programmed welding spot select a welding spot in the list and then edit the welding parameters To validated the modifications click on the button NI To cancel the modifications click on the button i 4 4 Delete a welding spot programmed in the USER file Select a welding spot programmed in the list then click on the button x on the right of the list 21 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 tra
7. the machine is ready to use When the machine starts up liquid will circulate in the cables Check that there are no leaks AVOLUTION f 4 PRODUCT OPERATION Key definition Ww ATE e key This key is used to select the tool required Clamp single sided gun or clamp adjustment Press for 2 seconds to return to normal mode from any other mode To re set the spot counter to 0 when displayed Press for 2 seconds In visualisation mode Press twice to erase the report that is displayed on the screen In Program Saving mode Press the button briefly to erase the selected program Q Save a report More details can be found on this function in the corresponding chapter The record key enables or disables the saving of a report The View key allows the user to read the sequence of spots performed Using advanced modes The MODE button navigates through 4 different modes STANDARD MODE MULTISHEET MODE MANUAL MODE and AUTO MODE A prolonged press on the MODE key enters the configuration mode where the language and date can be edited and the warning sound activated for current too low or low pressure messages The up and down keys go through the parameters to modify sheet thickness type of steel arm used The and keys INVERTER wcsorsocesson contaot 29 07 07 15 30 i Posen e allow modification of each parameter sich die Werte andern oder a
8. NECTIONS Cylinder command Cooling liquid out Air cooling loe pto o o Wl 3e 3E Cooling liquid back red pipe Cylinder pressure measurement 31 12 Technical specifications ELECTRICAL CHARACTERISTICS Nominal input voltage UIN pA 25 A Power at 50 duty cycle S50 Maximum welding input power Smax Secondary voltage U2d Maximum short circuit output current I2cc Maximum permanent output current I2P THERMAL CHARACTERISTICS Ambient temperature range Transport and storage temperature range Altitude Thermal protection by thermistor on the diodes bridge MECHANICAL CHARACTERISTICS 21 Protection ratinc IP21 Width Depth Height Weight Network cable length Clamp cable length reference 019614 Clamp cable length reference 020320 PNEUMATIC CHARACTERISTICS BEEN Maximum air pressure P1 Liquid flow rate Minimum regulated force F min Maximum regulated force with C clamp F max Volt Amps Three phase power suppl Nominal input voltage Permanent input power Maximum welding input power Alternating current defined unload Secondary current on short circuit Protected against rain and moisture No access to dangerous parts Caution Read the user manual before use Separate collection required Do not throw in a domestic waste bin Do not use in the open air Do not use the product in damp wet environments IP21 Risk of interference and di
9. POT icon is automatically created on the desktop of your PC 1 Language 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 2 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 3 Traceability As a default the GYSPOT software opens in Traceability mode In the Welding spot programming module click on Traceability in the Options menu 3 1 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 LJ 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
10. 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 button E will retrieve a previously saved report and display it on the screen 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 card E Access the user manual stored on the SD memory card 237047608 14 33 The memory space can store information on more than 65 000 spots 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 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 removed from the reader failure to do so may result in the loss of data from the card Insert SD card 17 GYSPOT Software The software allows the user to edit and save the weld reports made by a GYSPOT equipped with a SD drive The GYSPOT software can be installed from files present on the SD card In the GYSPOT V X XX directory double click on the INSTALL EXE file and follow the instructions to install the software on your PC A GYS
11. achine Every 30 welding spots a new calibration will be requested ENERGY Mode The ENERGY mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds ENERGY MODE ON OFF This mode allows controlling the energy transferred during the welding spot This mode is not designed for the repair but is rather meant to be used by car manufacturers and independent control labs In order to use this mode a calibration should be first performed by closing the clamp without any steel sheets between the electrodes Press the Close clamp weld button The message Close clamp without steel appears on the screen Press the button again to perform the calibration Once the calibration has been performed the machine displays the last parameters selected for welding current and energy The user can then change the welding current the energy and the impedance The machine will weld during the time necessary to reach the requested energy If the welding is too long the machine will display an error message Timeout ms TTE ENERGY serasese terse Pressure 7 0 Close damp without steel 11 p AVOLIITON SETTINGS MODE The SETTINGS mode can be accessed by pressing the MODE key during more than 2 seconds The language of the menus can be selected on line 1 The date and time can be entered on line 2 The GYSTEEL CAR MANUFACTURER AUTO and ENERGY modes
12. ader 18 3 5 Print a report To print a report select the one required and click T 3 6 Export the report as a PDF file To export the report as a PDF select a file and click on 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 5 4 5 GYS T l phone 0243012380 Adresse 134 BOULEVARD DES LOGES T l copie 243683571 Ges Email c ontactiegys fr Code postal 53941 Site Web Why qys saudure cam Ville SAINT BERTHEY IM Interven ant DUPOND JEAN PIERRE V hicule MEGANE CC 1 6L 18V Ordre de r paration 4558 Immatriculation 16005953 Date du joumal 13 05 2008 Mise en circulation 21 01 2005 Commentaires RAS Intervention REDRESSAGE AILE ARRIERE GAUCHE GY SPOT INVERTER BP LC 0000001000 ims kA dall kA dal USMS 11 11 23 1 Point OK 0505 2008 11 11 48 Manuel Pression faible 0505 2008 11 11 54 Pression faible GYSPOT INVERTER 0123455788 ins KA dall kA daH OB S 2008 11 18 35 Pince C 1 ae si2008 11 18 53 4 Welding spot programming module In order to enter the Welding spot programming mode click on Welding spot programming in the Options menu The Welding spot programming mode allows the user to select welding spots defined by Car Manufacturers This mode also allows the user to program his own welding spot profiles Insert th
13. an be adjusted in this mode are Sheet thickness it can vary from 0 60mm up to 3 0mm in steps of 0 05mm The type of steel for each sheet standard steel HSS steel UHSS steel BORON steel To activate the required sheet press the up and down keys button Pressure definition diagram 3 to highlight the required sheet then use the se and keys to select the thickness and type of steel cvs ZIVDLL TIDT T 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 E 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 auto mode is identical
14. bi EL UI N Tika EE EIU dan Observation Lal EN Or e D d Led ll Coll hel Gell hal Gel hel Lal al e Us CIUS 0 O o 0n e os ca o8 01 CB s Cd PO m T USC E CA ee DA TIGE ID PW ToT FT TE FO Fo O CF FP Fa FF 00 mom oc FF FS FF EP LP ES LHP E PS ER P9 PII As C tl ue sun une sun uni emm 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 If the identification mode setting is ON all the fields of the repair order must be completed or the machine 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 SUPERVISION NODE 25 When the Identification SD card is inserted and the identification mode is ON the following screen is displayed EUN This screen allows the selection of default fields registration number car brand car model chassis number vehicle make To exit the screen press a
15. d keys 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 entering the metal sheet thicness to weld with the keys and It is possible to midify the parameters current and time in manual mode MON POINT TU TF 5 Press ai for 2 seconds to revert back to standard mode When highlighted a parameter can be adjusted using the and keys The A and V keys allow movement from one parameter to the next Error Management ERREUR s 52 ieee 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 Major Faults These defects cause the display of an error message that locks the machine Surchauffe The thermal protection relies on a thermostat located on the diode bridge this feature will lock the machine and display the message overheating Low battery clock The message Low battery clock appears after switch ON of the machine and alerts the user that the voltage of the battery on the command board is too low This battery ensures the saving of the date and t
16. d the machine is ready to weld 10 a LETEA mone CAR MANUF ase wove CAR MANUF d Re CHE c g B2 EUROPE GME B2 Lr mE B3 RENAULT BMW VOLKSWAGEN MERCEDES a User programmed welding spots can be recalled by selecting USER in the list of car manufacturers The welding spots can be programmed using the welding spot programming module in the GYSPOT software AUTO Mode The AUTO mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds AUTO MODE ON OFF This mode can be used with the C1 C2 C3 C4 C5 C6 C7 and C9 arms It cannot be used with the C8 and C10 arms for which the error message ARM NOT COMPATIBLE will be displayed if they are selected This mode allows welding steel sheets without specifying any parameter on the screen of the machine The machine determines the adapted welding parameters Close damp without steel In order to use this mode a calibration should be first performed by closing the clamp without any steel between the electrodes Press the Close clamp weld button The message Close clamp without steel appears on the screen Press the button again to perform the calibration Once the calibration has been performed the machine displays all the parameters to zero and is ready to weld Close the clamp on the area to weld and weld automatically without entering any parameter inside the m
17. e Check the cross section of the cable going from the main electrical board to the socket where the machine will be plugged in to it should be 4x6 mmz If the cable is longer than 10m use a 10mm conductor If you are using an electrical extension cord use a 6mm conductor use 10mm if the total length of the electrical line extension cord is greater than 10m Connect a 3 phase plug with earth minimum 324A to the power cable GYSPOT Evolution FTI POWER SUPPLY 3 PHASES 400 50 Hr Caution in order to avoid voltage drops which can generate bad welding spots do not overload the electricity supply do not use cables with insufficient diameter cross seciton Do not use a mains socket that is located too far from the circuit breaker If the machine is not sufficiently powered it will not be possible to ensure a good quality weld Check that the compressed air network can deliver a minimum of 7 bars dry air then connect the compressed air network to the back of the machine The machine must not be used on a compressed air network with a pressure lower to 3 bars Assembling the clamp handle and the air connector Assemble the clamp handle on the left side of the clamp Air connector Screw the air connector on the back of the air filter Filling the cooling tank GYS recommends that you use CORAGARD 05330 or equivalent cooling liquid in this cooling tank for more information visit the websit
18. e 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 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 n case of contact with the eyes rinse thoroughly with plenty of wate
19. e SD card delivered with your GYSPOT spot welding machine in the SD card reader of your PC then select the corresponding reader identifier in the Unit Choice menu The GYSPOT spot welding machines can accept up to 16 files which can contain each up to 48 programmed welding spots The first file called User cannot be deleted It enables the user to add edit or delete a programmed welding spot The other files are restricted to Car Manufacturer defined welding spots It is possible to import downloaded Car manufacturer files from the GYS website http www gys fr It is not possible to add edit or delete a welding spot saved in a Car Manufacturer file 19 AVOLUTION em SPOT 4 1 Import a Car Manufacturer welding spot file Double click in the first column and highlight a car manufacturer name USER GM EUROPE PSA RENAULT TOYOTA Then double click in the second column to select a Car Manufacturer file previously downloaded from our website USER User 3M EUROFE ctril PSA TOYOTA The list of welding spots defined by the Car Manufacturer are displayed in the second table below Select a programmed welding spot in order to display the welding spot profile on the screen 4 2 Add a programmed welding spot in the USER file In order to add a welding spot in the USER file select the USER file in the list of files and then click on the button Ed on the right of the table below Enter the
20. e indications of the manufacturer as well as the necessary preparations implementations and tests of welding jobs lies within the responsibility of the user Several welding modes are available on GYSPOT S7 spot welding machines The STANDARD MULTI and GYSTEEL modes allow programming the machine by entering sheet thickness and type of steel The MANUAL mode allows programming individually each welding parameter according to the car manufacturer s specification welding current welding time clamp force The AUTO ENERGY and CAR MANUFACTURER modes are available on GYSPOT S7 models only The AUTO mode allows welding without entering any parameter inside the machine This mode may be used on all welding spots identified as non critical by the car manufacturers For the welding spots identified as critical by car manufacturers refer to their repair specification and use either the MANUAL mode or the CAR MANUFACTURER s mode In the MANUAL mode the exact welding parameters from the repair specification may be entered In the CAR Manufacturer s mode welding parameters approved and sometimes requested by car manufacturers are saved and can be recalled In order to safeguard the quality of each welding spot we recommend carrying out 2 sample welds and a pull out test with the same steels and applying the same distance from one another required by the job The welding spot is acceptable if the pull off leads to the extraction of the nugget and the
21. e machine will display the following message Low Pressure Insultinent pressure 13 aa N FIVOLLITION f RERE GYSPOT 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 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 display 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 caps are not changed before resetting the counter to zero the caps may become badly damaged and cause poor quality welding 21 04 08 17 03 4 C Elektrodenkappen berpr fen PET TR lus 66u F 147 ze T 320 ms T 3220 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
22. ement of SD cards gt 2 Gb e 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 e 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 16 ZVOLLITICTP LeriuIEEROA ATLS 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 the 4 buttons up and down arrow keys When entering an existing user the machine will erase the previous parameters The recall button E7 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
23. equipment is checked for any gas or coolant liquid leaks before commencing work 7 Before performing any control or maintenance operation switch off and disconnect the unit directly from the electricity supply EYE AND BODY PROTECTION 1 During the welding process the operator must protect themselves from possible metal projections leather gloves welding aprons safety shoes welding helmets or glasses for filtering radiation 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 all body parts away from the mobile elements of the clamp to avoid any risk of injury particularly to fingers and other small extremities 3 Do not wear rings watches or jewellery as metal current conductors can cause serious burns 4 All protection boards must be in good condition and kept in place 5 Never look at a welding arc without eye protection 6 Protect the environment surrounding the work area from projections and reflections FIRE 1 Do not undertake welding near flammable material as sparks may cause fire 2 Ensure that there is a fire extinguisher in close proximity to the operator 3 Ensure the machine is used in an area with adequate ventilation 4 Do not weld on or near combustible or lubricant containers or those used to contain flammable material even if empty 5 Do not weld in an atmosphere charged with flammable
24. f steel arm used The and keys allow the modification of each parameter Button B on the clamp allows the user change the thickness of the sheets to be welded remotely Button A 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 button A on the clamp MULTI sheet Mode This mode allows the user specify the thickness and type of each sheet in an assembly of 2 or 3 sheets Using The up and down button key definition diagram 5 allows 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 key definition diagram 3 The individual sheet parameters that c
25. gas or fuel fumes ELECTRO MAGNETIC COMPATIBILITY When using the welding equipment ensure that There are no other power supply cables control lines or any sensitive electronic devices mobile phones radios computers medical equipment etc in the vicinity of the machine People using electronic medical devices such as pacemakers or hearing aids should consult their doctor before using this device Take extra protections if other products are to be used in the vicinity of the machine The battery is disconnected from the vehicle We recommend you to take the machine away at the maximum from all the devices of the vehicle calculators relay embedded computer FIVOLLITIONS zac Lt 2 DESCRIPTION DE LA MACHINE Front panel SD card reader Display panel Rear panel 32A D Curve Switch Pneumatic filter 30 mA differential Pneumatic network air connector C clamp Button A Button B Open Close S remote control of the welding parameters clamp Lock Unlock Lever Removable electrode a X4 b X4 PTI Stand assembly Col 4 6c0 alibi a i 80mm 0 70mm D 5 3 INSTALLATION OF THE MACHINE Before use Several checks 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 32A delayed circuit breaker curve D or aM type fus
26. 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 the 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 factory GYS with the following certificate of warranty validate by the seller and an explicative note of the breakdown After the warranty our After sales service provides the repairs by acceptance of the quotation CERTIFICATE OF WARRANTY Seller stamp Reference of the unit Site e EE Valid for one year as from the purchase date 29 9 CIRCUIT DIAGRAM rafo sap mu per LS Tle St GPS pE EU Ute A aN Fat Mid SALLY SR PY p sarpu LOE i LL Fuld sO ey FURIA Uum FESO AUDF ZS Tid LOdSAD Lies M A 117 ENS X 32d LATO LS ld HALI A LOS ONC Tel v CH LASER AN TAI pre OS 30 BW voLuTion GER YSPOT 10 COOLING LIQUID CIRCUIT 11 CLAMP CABLE BEAM CON
27. he clamp arm tightening C arm The get Kei Replace the caps iniove nest Gui Check the connection of the au The arm C badly cooled C Arm to the cooling swelling of the power cable section of the clamp The gun sheath should Gun sheath outside the come inside the gun for the Overheating of the gun gun air cooling to cool inside the The spot weld made doesn t 5 hold Check the tightening of the 0 Bad ge de Or ing mandrel the star holder and the state of the sheath o Bad contact of the earth nex ue Is ER The weld is not good ESCH securely connected to the H metal sheet Bad contact of the earth Check the ground clamp Lack of power with the gun connection 28 7 DECLARATION OF CONFORMITY 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 50445 of 2008 Le 27 11 2012 Nicolas BOUYGUES Soci t GYS Pr sident Directeur G n ral CEO 134 BD des Loges 53941 Saint Berthevin isa ets s 8 WARRANTY 1 The warranty is valid for one year only when the certificate of warranty
28. ime when switching OFF the machine Low battery cock Tool out of order The message Tool out of order appears after switch ON of the machine and alerts the user that a button or trigger is constantly pressed or a permanent short circuit is detected Control the trigger of the gun as well as the buttons on the clamps in order to make this message disappear Current too low EU UU If the welding current measured during the spot is 6 less than the setting the machine A 7 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 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 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 current too low 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 th
29. ining 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 gun 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 the 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
30. ipes to the 2 connectors Connect the command cable to the Jack plug 5 Check if the screw connected from the earth plate to the earth clamp terminal 1s tightened correctly 23 ZIVDLL TIDTFP n c A 78 f Replacement of 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 Unscrew screw 1 which holds the arm to the clamp Leave it on the arm to not lose it Disconnect the cooling liquid pipes Unscrew screw 2 and loosen the lever 3 on the side of the clamp Remove the clamp arm f p 3 Lubricate both a new arm and the support with contact i i 7 Er E a m 3 NI d grease ref 050440 ERE di B CX Lei T CI ones Ju j E 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 geg H j A UR Long Stretches Long Injector hort Inj Short Stretches Short Injector S
31. ms steps of 10 ms F 195 UNE Electrode force 100 to 550 daN steps of 5 daN us Arm used on the clamp number and length 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 Dreccute CPP Press E for 2 seconds to revert back to standard mode CAR MANUFACTURER Mode The CAR MANUFACTURER mode is optional and is configurable in the setup menu that is activated by pressing the mode key for 2 seconds CAR MANUFACTURER ON OFF This mode allows calling in a nominative manner a pre recorded welding spot according to a car manufacturer repair specification Select the CAR MANUFACTURER in the left column then by pressing the key the spots list is displayed on the right column Select the requested welding spot highlighte
32. nd hold the mode button for 2 seconds Then re insert the Program SD card into the BP drive Vehide model Chassis number 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 Job number Screen User identification hb 0045 5 User ID X 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 15 E 5 5 ZIVOLLITICP f ae ET OY SPOT The Mode button changes the field to modify playback Screen Registration number optional HODE 23 Registration lt a CI X Screen Vehicle model optional Screen Chassis number optional HODE 25 25 HODE EJ vehicle model DI Chassis number ga C Be Catalogue The View button p 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 2284288 17 10 Use the mode button to exit the report view e The SD card driver allows the manag
33. ne ates ctas tuere d 29 Reach Ree ee ee ee ee ee ee ee ee eee 29 EE 30 coo EE TT 31 DL CLAMP CABLE BEAM CONNECTORS eege 31 RR le PECIFIC A KE ER E E ER Autres langues disponibles sur la carte SD Other languages are available on the SD card Weitere auf SD Karte verf gbare Sprachen 21 01 2015 V7 p 3 AVOLUTION f c ATIS Thank you for choosing this GYS product Please read the instructions carefully before installing using the product or before maintenance in order to avoid accidents and keep the manual in a safe place for future reference GYS cannot be held responsible for damage to persons or items as a result of using the machine in the following circumstances Modification or neutralisation of safety elements has been undertaken Safety recommendations written in this manual have not been adhered to Modification of the product s specifications Use of accessories not specified by the manufacturer Failure to observe regulations specific to the country or state in which the machine is used 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 washers and studs Repair of bumps and dents small dents i e from hail or small stones with the quick repair option
34. o19294 5 Bhar 550 dan 8 bar 550 daN c mm m w 5 2 A TETEE C6 atM 8 bar 550 daN B bar 300 daN CB Act mr 8 8 bar 550 daN C3 Art Mr 018157 B bar 550 daH v i 00 0 pm CA at Me cee US Bbar 550 daN B bar 550 daN ELERTRODENARME C2 C3 4CA Art Nr 019126 a i GA L x LAH IHS C10 5 Art Nr 051638 i 4 bar 150 daN Spot control Consumables gt l D I Elektrodenkappen Schl ssel Typ Art Nr D50B16 A 013mm Art Nr 0490967 Bleche HLE HTS LO mrm xi50 Art Nr 050181 i 5 0 13mm THLE VATS 25 mim 150 Art Nr 050167 ee ee Art Nr gad D gt 2 AC 042970 e m D j Spotter Verschleifsteile Kit Art Nr 050068 27 6 SYMPTOMS REASONS SOLUTIONS SYMPTOMS REASONS SOLUTIONS The caps used are worn the cane out faulty 0 ES Insufficient grinding Sand and clean the metal preparation of the workpiece sheet again The arm selected doesn t Check the arm with the match the one installed software The caps used are worn out faulty Replace the caps Check the compressed air Not enough pressure network The Spot weld doesn t hold is not good The spotter makes holes in o the steel min 7 bar E Insufficient preparation of Sand and clean the metal O the work piece sheet again PPY voltage delivered Bad tightening of the C Check procedure for Lack of power on t
35. r 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 Make 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 the clamp to activate the pump Use the container to collect the liquid as it drains from the clamp In 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 for approximately 10 seconds At the end of this cycle
36. sturbance 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 Always wear suitable protective clothing to shield eyes hands and skin when welding 32
37. tearing of the steel with a minimum nugget diameter in accordance with the car manufacturer specifications cvs _AVOLUTION 5 2YSPOT Using the C pneumatic 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 calculated by the machine considering the force setting or the thickness of the sheets selected CLAMP SETTING MODE The zi 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 electrodes without any current flowing This mode is used to adjust the arms The clamp will remain closed as long as the button 5 remains pressed this allows the user to check the alignment of the electrodes m dJii 28 2 and positioning of the caps d 1 FN meee Press the key for more than 2 seconds allows returning to the Pressure j STANDARD mode This is the default mode when the machine starts Quick and easy spot welding by selection of The C arm used The Sheet thickness it can vary from 0 60mm up to 3 0mm in steps of 0 05mm When welding 2 metal sheets enter the thickness of thinnest one When welding 3 metal sheets enter the total of the 3 divided by 2 The type of steel standard steel HSS steel UHSS steel BORON steel The up and down keys go through the parameters to modify sheet Pressure E ee thickness type o
38. to normal mode except that the user enters the yield strength of steel The Ys may be found using a durometer such as the 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 Sheet thickness it can vary from 0 60mm up to 3 0mm in steps 05 wove GYSTEEL 603013 16149 The C arm used on the clamp The up and down button key definition diagram 3 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 ISTE TETTE Press E for 2 seconds to revert back to standard mode MANUAL Mode This mode allows the user to manually select the welding parameters for example when following instructions from a Manufacturer E The default settings in manual mode correspond to the settings move MANUAL sees 16 48 automatically selected in standard mode thickness and type of sheet electrode force arm The parameters can be adjusted using the and keys Key Definition diagram 3 The up and down keys allow navigation from one parameter to the next T 310 ms Welding current 2000 to 13000 A steps of 100 A displayed in kA Welding time 100 to 850
39. 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 Use grease ref 050440 when replacing caps Caps type A ref 049987 Caps type F ref 049970 Caps beveled ref 049994 Caution The caps must be perfectly aligned To check the electrode line see change of arms on pages 18 and 19 22 E S FIVOLLITION SREP ET OY SPOT Installation and use of the gun The gun and the earth clamp are optional Ref 051010 1 2 Select the clamp adjustment mode in the menus in order to stop the pump and the flow of cooling liquid Fix the earth cable on the removable electrode put the clamp and tighten the lever Remove the arm from the top and put the gun cable instead of that one 3 4 Connect the cooling liquid p
40. tretches types Short C1 C3 C4 C5 C6 C7 C9 C10 Long C2 C8 24 a AVOLUTION em SPOT Adjustment of C arms Position screw 4 to fix the arm on the clamp Tighten it in manually do not overtighten Tighten ring 5 manually then the tighten 6 using the Allen key Tighten the lever manually and check it is not end up against the joint stop see diagram below If it is the case go back to step D Warning Clamp and arm may be damaged if the lever is not tightened properly Check the cooling liquid level Check screws and lever incorrectly tightening can damage the material Switch on the machine 25 ZIVDLL TIDT T C clamp overhaul The tightening of the following screws need to be inspected every month Screw between the arm and the clamp LI C These 4 screws fix the arm to the clamp They need to be tightened to have a good transmission of the current A bad tightening leads to a loss of current and worst can damage your arm or clamp irreversibly Screws between the copper cable terminals to the jack at This screw fixes the copper cable terminals to the clamp The tightening needs to be overhauled or you can have a loss of current or worst you can damage irreversibly your machine 26 ZIVOLLITIOI ZIN VERTER GYSPOT Arm types for the C clamp HT CT ana 30 C5 Art Nr
41. usw hlen die und Tasten erh hen bzw verringern den ausgew hlten Wert 2 Saving of user welding parameters The save button DI allows the user to save selected welding parameters mode sheet thickness welding current welding time or electrode force The open button F will restore 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 Select sheet thickness The sheet thickness can be adjusted using the and keys The thickness can be selected from the following preset values 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm Select type of steel This allows the selection of the type of metal to weld from 4 different options coated steel HTS steel UHTS steel BORON steel This setting can be adjusted using the and keys C Adjustment of the arm used When a clamp is used either C or X the user should specify the length of the arms fitted to the clamp so that the machine will automatically adjust the air pressure to reach the required electrode force Recommendations on the use of welding modes Only qualified and specially trained personnel are permitted to use of the spot welder Please observe repair manuals of respective car manufacturers before carrying out any welds The correct application of instructions specified in the user manual and commitment to th
Download Pdf Manuals
Related Search