instruction manual for spot welding machines gyspot 32d.c gyspot
Contents
1. BLUE PHASES PHASE 1 C C arr SUPPL CABLE NEUTRAL CONNECT ION 3 PHASES 40004 sSpHz NEUTRAL Protection of the line Circuit breaker 32A with D curve or delayed fuses 32A Case of dysfunction If the product releases the circuit breaker of the protection of installation please check that you have the right breaker size 32 A or more and D curve absolutely Compressed air Connect a compressed air pipe to the purifier behind the product The service pressure can t be over 8 bar The product can t be used on an air network with a pressure less 3 bar DESCRIPTION THE MACHINE Front side Indicator of air Button of welding Indicator of pressure current adjustment welding current EN ti er 43 Max 105004 7500 EA TEE E ETE 1 0 FE j Adjustmen Yellow indicator Mode t of thermal Welding with the clamp in automatic mode of air protection pressure Back side Circuit breaker on off 400 V 2 32A D Ld www gys fr Ref 049291 IIIS 080 Ref 049727 20 Ref 049451 ez 19 Ref 050648 Cm w x50 RX3 Ref 051058 GS P SS Paix P 1 220 mm 3x6mm2 HO7RNF Type Q 13m Ref 049970 Ref 049994 AN Hao N CONSUMABLE BOX Ref 050068 The user shall enter the reference steel plate thickness2. gt us Ref 049468 Ref 050631 Ole Indicator of time or steel Button of time or sheet thickness adjustment Button of tool and mode selection Clasp automatic mode manual mode Single side gun mode Carbon pen shrinking Mode D Smoothing of bumps Procedure to swag a graphite pen Mode C Welding of studs ets nails and bolts Withdrawal of impact of hail Dent puller Welding with the clamp in manual mode The user shall select the welding intensity and the welding time Air purifier with incoming joint of compressed air Ref 050440 eo Ref 049444 Q COOLING AND THERMAL PROTECTION The cables are cooled with compressed air The cooling process can be permanent if the red switch is on Manual position or permanent except during the welding cycle if the red switch is on Automatic position A thermal protection forbid the use of the product in case of overheating yellow indicator on the front side Recommendation When you use it intensively you should cool the cables continuously with compressed air WELDING WITH THE SINGLE SIDED WELDING GUN Connect the ground pad to the spade terminal of the generator Fix firmly the ground pad near the place to be welded as possible In the case of a single sided spot welding process leave always the ground pad on the metal sheet that is not in contact with the welding electrode in order to make t
3. of the car manufacturers recommendations concerning the protection of electrical and electronic procedures car computer car radio alarm air bag etc 5 Before an operation of servicing the power supply with compressed air must be cut off and off loaded 6 The electrodes arms and the other secondary conductors can reach a very high temperature and remain hot very long after having stopped the machine Be careful high risk of burns 7 It is necessary to make a regular preventive maintenance ELECTRICITY Check that the unity must be connected to the earth coupler and that the connection to the earth is in good condition 2 Check that the work bench is connected to the earth coupler 3 Make sure that the operator has no contact with the metal parts to be welded without any protection or with wet clothes Avoid to be in contact with the welding part Don t make spot welding operations in very wet areas or on a wet floor Don t weld with worn out cables Check that there is no default with the isolation with stripped cables or with loose connections 7 Switch off the unit before replacing the electrodes Before controlling or repairing please disconnect the unit directly to the level of the plug QN CA PROTECTION OF EYES AND BODY 1 During the welding process the process must be protected from the eventual flashes of the electrical arc with protection clothes like leather gloves welding aprons saf
4. 106x34 mm LxP 160x80 mm LxP 220x450 mm Tilt electrode 159 XIII X clamp arms Recommended clamping for welding galvanised steel with X clamp Sheet thickness in mm Suggested Force in daN Arm length inmm bars De 0 4 08 100 200 0 4808 100 200 De 0 4 0 8 100 200 2 Set of X arms useful height 120 mm Aluminium made arms and copper made electrodes RX1 Arm useful length RX2 useful length 220 mm RX3 useful length 220 mm 120 mm asymmetrical electrodes 30 85 mm tilt electrodes 209 1 2 v Replacement of the caps electrodes guarantee an efficient welding spot it is necessary to replace the caps every 200 spots using the dedicated caps key tis forbidden to grind the caps Assemble the caps with copper grease ref 050440 A type caps ref 049987 F type caps ref 049970 Bevelled caps ref 049994 Several combinations are possible Cleaning or replacement of the welding tools SON SS NUS Any welding tool is degraded after a certain period of use However all tools must stay clean in order to get the best performance of the unit When using the unit in pneumatic clamp mode check the good state of the CAPS electrodes flat rounded or bevelled If this is not the case clean them with sandpaper fine grain or replace them see reference on the unit All moving parts of machinery suffer constraints on their us
5. Clamp ajustment If AF clamp adjustment mode is selected the clamp remains closed until the user presses the trigger Blinking of the displays The thermal protection is activated because the station is too hot The selected mode is incompatible with the tool already used This happens if the user presses the trigger of the clamp when the mode single sided gun is selected on the control panel Cautions When using the clamp the ground cable of the single sided gun must be disconnected from the car body Y The electrodes must be regularly sharpened Blow off regularly the dehumidifying filter on the back side of the product Please adjust with a medium pressure of 6 bars IX RECOMMENDED ADJUSTMENTS FOR BODY CAR WORKSHOP only indicative and to modulate depending on the type and the thickness of the sheets Gun Gun Gun Gun Gun Gun Gun Welding single side gun 10to25 Tails welding 5 to 8 2 to 4 to 5 Nails and rivets welding Shrinking with carbon pen EE 2 Pneumatics Welding 2 pieces of steel sheet reference 10 camp steel thickness less than 2 5 Pneumatics Welding 2 pieces of steel sheet reference clamp steel thickness more than 2 5 XII C clamp arms a z e NU Y a a 11 WO O i i 5 a x A 4 _ M Ye 8 ic et RC2 RC1 RC3 LxP
6. GYS Last update 26 05 09 Version V1 1 INSTRUCTION MANUAL FOR SPOT WELDING MACHINES GYSPOT 32D C GYSPOT 32D X Congratulations for the selection of this product which has been designed with great care Before installing and using the product please read carefully the following recommendations of safety in order to avoid accidents to the users and damages of the welding process GYS can t be responsible for the damages occurred to persons or things which derive from the use of the machine in following circumstances Modification or neutralization of safety elements Non respect of the recommendations written in the manual instruction Modification of the characteristics on the product Use of the accessories which are different from the ones delivered by GYS I PRESENTATION This product has been designed to carry out the following operations in car body workshop Spot welding machine on sheet metals with pneumatic pliers except GYSPOT P230 P400 Welding of sheet metals with gun Welding of nails rivets discs and pins Suppression of bumps and impacts impact of hail with the option quick repair II SAFETY STANDARDS AND GENERAL PRECAUTIONS GENERALITIES 1 Before disassembling the product s body plug out the lead cable 2 The operators must have the appropriate qualification 3 The operations of servicing can only be controlled by qualified technicians 4 The operator is responsible for respect
7. IES Surouverture Ventilation EV 3 VOIES EV 2 VOIES Fermeture Ventilation pinceen C ou X Pistolet 32D C av nw P id boc var yen HTT EV 2 VOIES EV 3 VOIES EV 2 VOIES Ventilation Ventilation pince en C ou X pinceen C pu X Pistolet 12
8. es Although monitoring is no screw loose this could degrade the quality of welds If so re tighten For a use in gun mode it is necessary to check the state of the tools stars singe sideelectrode carbide electrode and if they look in bad conditions clean or replace them The anti dust filter at the back of the unit must regularly be cleaned to avoid the overheating of the generator 10 v Purging of the pneumatic filter Regularly drain the dehumidifier filter placed on the rear side of the unit v Generator maintenance The maintenance and the repair of the current generator must be done by an appointed and GYS trained technician Any maintenance operation done by another person will cancel the warranty conditions GYS cannot be held responsible for damages or accidents which happen subsequently to operations performed by people exterior to GYS XV CHARACTERISCTICS ELECTRICALCHARACTERISTICS Power at 50 duty factor S50 Circuit Breaker _____ ____ _ Di THERMAL CHARACTERISTICS _ Altitude be M 5 MECHANICALCHARACTERISTICS Welding clamp cable length ee eee PNEUMATICS CHARACTERISTICS Maximum force F with C clamp Fmax 300 daN Maximum force F with X clamp and 440 mm arms 150 daN Maximum force F with X clamp and 120 mm arms 500 daN 11 XVI Electrical schematics 32D X Tl 1 1 ames COM RCE CIN Ful THT Ahr EV 3 VOIES EV 2 VO
9. ety shoes welding helmets or glasses for filtering radiations and projections As well during operations of rubbing and hammering the operator must protect his eyes 2 The force of tightening of the clamp can reach 500 daN Keep away all body parts from the mobile elements to avoid risks of tightening 3 keep rings watches or jewellery which are current lead can create burns 4 All the protection board must be in good condition and maintained in place Protect the environment near the product against projections and reflections SMOKES AND GAZ Welding operations can cause the emission of toxic smokes and harmful metallic dusts The welding material must be degreased and cleaned in order to limit the toxic gas during the welding process FIRE Check that the sparks don t cause fire especially near inflammable material Check that fire extinguishers are not too far from the operator Leave the product in a place with air movers Don t weld neither on containers of combustibles and lubricants even empty nor on containers with inflammable material 5 Don t weld in an atmosphere full with inflammable gas or fuel steam gt ELECTRO MAGNETIC COMPATIBILITY Near the spot welding check there is neither no other power supply cable nor control lines nor phone cables nor radio or TV reception appliances nor watches nor mobile phones nor magnetic cards nor computers or any other electronic a
10. he current circulate in the two plates to be welded select the mode to be used and adjust with the values written on the charts chapter IX Blinking of the displays the displays can blink because of 2 reasons The thermal protection is activated because the station is too hot The selected mode is incompatible with the tool already used This happens if the user presses the trigger of the single sided gun when the mode clamp is selected on the control panel USE OF THE PNEUMATIC CLAMP Select the function mode 1 Mode Welding with the clamp in automatic mode The user shall enter the reference steel plate thickness value from 0 6 mm to 3 mm If thickness 3 mm is selected then the welding is performed with 4 pulsations Proposed parameters for welding 2 pieces of galvanised steel with the clamp Reference sheet thickness Intensity Time in p riods Pulsations Forc in daN Forc in daN X C clamp clamp arms length a mm 06mm JH 12 1 7 10 1160 25mm THE 50 1 1300 AO 3 0mm m 10714 1359 40 Table of reference sheet thickness 2 Mode Welding with the clamp in manual mode The user shall select the welding intensity and the welding time Intensity and time adjustment table Welding Time in periods Intensity 99 Welding Time in periods Intensity 9 Welding Time in periods Intensity Welding Time in periods Welding Time in periods Welding Time in periods
11. ppliance there is in the surroundings minimum 3 metres of each point of the product no persons using active medical appliances pacemakers acoustic prosthetics Make supplementary protections if other products are used in the same environment III CE certification This product has been designed with respect of the European regulation e Low voltage directive 2006 95 EC of 12 12 2006 directive Electromagnetic Compatibility 2004 108 EC of 15 12 2004 e Machinery directive 98 37 EC of 22 06 98 and therefore are in compliance with the European harmonized standards e EN 62135 1 e EN 62135 2 EN 60204 1 IV Pictograms Caution Read the user manual before use Separate collection required Do not throw ina domestic dustbin Do not use in the open air Do not use the product under water projections IP21 People wearing pace makers should not approach this product Risk of interference and disturbance of pace makers near of the product Caution Strong magnetic field People wearing active or passive implants must be informed Use eye protection or wear safety glasses Body protection must be worn Hand protection must be worn Risk of burns Trolley assembl V th 7 VI RACCORDEMENTS DES ALIMENTATIONS VII CONNECTIONS OF POWER SUPPLY CABLES Electricity Two phases 400V 50Hz Use of the PHASE 1 PHASE 2 and EARTH CONNECTION on a 3 phases plug
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