user manual v5
Contents
1. Edit the parameters is in the SD memory card Access the user manual stored on the SD memory card ERROR 257 04 08 14 22 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 15 INVERTER ax we GYSPOT Software The software allows the user to edit and save the weld reports made by a GYSPOT equipped with a SD drive 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 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 T2. USER MANUAL vs Table of Contents 1 PRESENTATION SAFETY RECOMMENDATIONS AND GENERAL PRECAUTIONS 2 5 Oe LA MACHINE nenne een nee Eee 3 4 3 INSTALLATION OF THE MACHINE nee 5 6 4 PRODUCT OPERATION nn ea ee een 7 150 H een 7 571 Elina Hampe r s s m m a 8 9 in nn nn b b ba 10 ETL TT WEN een 10 11 Welding 0 Ezan asa een 11 Recording features ANHANG 12 15 LU LO MOE amala eriden A Aaa EErEE EEEE ANENE 15 LE bo ub T AA AT A 15 16 61777 Or NE E E AE AE EE E AE AEE 15 16 5 USE AND MAINTENANCE PRECAUTIONS 0eeesesesenenenennenenennennenenenenn 17 Re SE Te c ie sei hee che E ern Ge Ace ge ne nO ere So ee 17 Preparation of the Work DIECE aan anna ana 17 SINGIS sided GUM WEI NG anni 17 Cooling liquid level and aaa daaa nnnn ann nun mann nnnnnnn nun 17 Cleaning the pheumatic Ura er a aa 17 General or Malin so ir iq ana a renee 17 Cleaning replacement of welding tools and other items 17 Installation and use OF the au u 17 T 17 specific Installation for CZ and CO 18 Bd lblunu cm a lala lala ala EA A 19 21 0 0 REASONS 7 SOLUTIONS ernn einen nannten nennen 24 y DELURAHODLOPCOHPORMUUT in 25 ENAR RANI
3. Nous vous rappelons que nous n acceptons pas le retour d appareil en port d SOCIETE 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 unit Purchase date Valid for one year as from the purchase date 25 W m Wy gt 2 9 CIRCUIT DIAGRAM s l Z SUUMRNOIPDII3 Cc SESLLY LAIZA 0676 gt 3214 23 18V BELLS sequl juawassipiojay LYAWYOASNVYL 61096 LOSLEND 9031 dv Liesing eesiong N gt z A r T um IN Kae AV 1dS IQ Z lis 1614 z cA ep LLLES fer wis ddpu iz za S m adden g lqe 21x JONId S T8026 6824 1 2 L oszzng 01613 O Ly So6ls LAY 14514 S60ES addeu o 820 6 o z as au 3 N 820 67824 2 a adden 2824 31985 8 o R m EINEN 2 3 x m or 2 TLLlZ 34431 u aouessind MY IN ILY Id 2 4 LOSL8dr HOLDVYLNOD NJE UNeJd 2041014 1041014 m 34 04 mal iz 12 1 2 3 augue 2 januasayip d l 5 vSOS6 al P E 9 5 L lqe LYODVLNOD JUSWUSSSIPIOIJol LA 26 INVERTER cy AT 28 8 aa 10 Tec
4. 32A delayed circuit breaker curve D or aM type fuse Check the cross section of the cable going from the main electrical board to the socket vvhere the machine vvill 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 32A to the power cable Gyspot Evolution 3 PHASEN 400V SOHz NEUTRAL 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 I v zu traum Assemble the clamp handle on the left side of the clamp Air connector Attach the air connector to the air filter INVERTER cy AT 28 8 pp Filling the cooling tank GYS recommends that you use CORAGARD CS330 or equivale
5. 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 18 AVOLUTION I INVERTER OAA m Installation and use of the gun The gun and the earth clamp are optional Ref 051010 1 Check if the cooling system pump is on the clamp in order to deactivate it 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 4 Connect the command cable to the Jack plug 5 Check if the screw connected from the earth plate to the earth clamp terminal is tightened correctly 19 AVOLUTION I INVERTER OAA Replacement of C arms Please read the follovving 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 assembiy are not covered under the vvarranty 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 7 Lubricate both a new arm and the support with contact m N grease ref 050440 Y a Y
6. 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 AVOLUTION m INVERTER OAA m 2 DESCRIPTION DE LA MACHINE Front panel SD card reader Display board Rear panel 32A D Kurve Einschalter Pneumatische Filtereinheit R ckstromschalter Verbindung zum pneumatischen System C clamp Button A Remote control Of the Metal thickness Button B Open Close The clamp C Arm Locking Unlocking Clever Removable electrode AVOLUTION I INVERTER n Stand PTI assembly 47 Adjust the tension of the spring with the allen key equipped a AVOLUTION I INVERTER OAA 2 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
7. 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 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 22 PIVOLLITIONT Arm types for the C clamp 1 Art Nr 019140 8 bar 550 daN dr a 210 55mm 45 1 8 550 daN 310 C10 Art Nr 051638 4 bar 150 daN Spot control Art Nr 050433 Bleche HLE HTS LO mm x150 Art Nr 050181 THLE VHTS 2 5 mm x150 Art Nr 050167 C2 Art Nr 019133 8 bar 550 daN C3 art Nr 019157 85 8 bar 550 daN YA Art Nr 051 614 INVERTER OAA ET 7 C5 art nr 019294 8 bar 550 daN z g 141 Art Nr 019775 8 bar 300 daN Art Nr 020078 ELEKTRO 8 bar 550 daN 205 C8 Art Nr 020016 ao 8 bar 550 daN ELEKTRODENARME C2 C3 C4 Art Nr 019126 Art Nr 020009 8 bar 550 daN Art Nr 050044 D Consumables Spotter Verschlei teile Kit Elektrodenkappen Schl ssel Typ A 013mm Art Nr 050068 Art Nr 050846 Art Nr 049987 x1 f r RC2 Art Nr x6 Schmierfett Tube 813mm Art Nr 050440 Art Nr 049994 x1 Els f r 06 Art Nr Typ Fe 813mm 050617 Art Nr 049970 23 INVERTER m 6 SYMPTOMS RE
8. steel To activate the required sheet press the up and down keys button definition diagram 3 to highlight the required sheet then use the Pression 6 9bar 4 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 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 The auto 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 1
9. 9 35 corresponds to UHSS steels 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 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 Press 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 The default settings in manual mode correspond to the settings move MANUEL 1181 automatically selected in standard mode thickness and type of sheet electrode force arm 9 0 The parameters can be adjusted using the and keys Key Definition O kA diagram 3 The up and dovvn keys allovv navigation from one parameter to the next VVelding current 2000 to 13000 A steps of 100 A displayed in kA VVelding time 100 to 850 ms steps of 10 ms Electrode force 100 to 550 daN steps of 5 daN Arm used on the clamp number and length Pression 6 Sbar 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 mess
10. ASONS SOLUTIONS SYMPTOMS REASONS SOLUTIONS The caps used are worn Renace ean out faulty ps 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 the steel min 7 bar E Insufficient preparation of Sand and clean the metal O the work piece sheet again voltage delivered Bad tightening of the C Check procedure for Lack of power on the clamp arm tightening C arm The caps used are worn out faulty Replace the caps hikaveriisats aulddy Check the connection of the q arm 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 gun hold l Check the tightening of the 5 g Baq 5757 Orme mandrel the star holder l and the state of the sheath Check the earth clamp is o Bad contact of the earth o The vveld is not good alana securely connected to the metal sheet Bad contact of the earth Check the ground clamp Lack of power with the gun l connection 24 INVERTER ax we 7 DECLARATION
11. 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 50455 of 2008 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 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 ATTENTION
12. VOLUTION I INVERTER OAA User programs The ave option allows a user program to be entered to save information for future use 20 memory slots are available each one contains the follovving parameters tool arm vvelding intensity vvelding 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 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 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 FF 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
13. age 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 AVOLUTION I INVERTER GYSPOT performed by pressing the B button on the clamp Press for 2 seconds to revert back to standard mode Use a 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 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 MODE NORMAL 237804788 17 16 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
14. ators 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 equipment is checked for any
15. 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 voor MANUEL BEAL IAL eke 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 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 Press Taste wechselt zur ck in den STANDARD Modus Pression 7 2Zbar STANDARD Modus This is the default mode when the machine starts Quick and SEATS EE easy spot welding by selection of Type of tool used 6 Sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 When you weld 2 metal sheets put the thickness of thinnest one When you weld 3 metal sheets put the total of the 3 divided by 2 The type of steel coated steel HTS steel UHTS steel BORON steel and the arm to be used The up and down button go 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 sheets to be welded remotely Button B on the clamp allows the user to spot weld
16. carbon shrinking star welding studs rivets washers stitches The tool selection is made with and 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 Pression 7 3bar Press for 2 seconds to revert back to standard mode When highlighted a parameter can be adjusted using the and keys The A and W keys allow movement from one parameter to the next AVOLUTION I INVERTER OAA Error Management ERREUR sis dues 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 Burchaull The thermal protection relies on a thermostat located on the diode bridge this feature will lock the machine and display the message overheating Current too ovv If the welding current measured during the spot is 6 less than the setting the machine will display th
17. 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 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 DO NOT grind the caps Use grease ref 050440 when replacing caps Caps type A ref 049987 Caps type
18. cycle of the parameters for approximately 10 seconds At the end of this cycle the machine is ready to use When the machine starts up liquid will circulate in the cables Check that there are no leaks AVOLUTION I INVERTER 4 PRODUCT OPERATION Key definition la gt INVERTER MICROPROCESSOR CONTROL mope NORMAL 25 07 07 15 30 Pression 6 1 bar WADE IN FRANCE 2 _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 2 Save a report More details can be found on this function in the corresponding chapter The record key 9 enables or disables the saving of a report The View key gt 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 vvhere the language and date can be edited and the vvarning sound activated for current too low or low pressure messages The up and down keys go through the pa
19. d the SD card and the user Z89ABF34 manual By default the report mode is not activated when the machine is started Pressing the record button on off 9 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 FF 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 Use the mode button to exit the report displayed To erase the content of a report it has to be To erase the report shown press and the following on screen by pressing view FF message will be on the screen 13765708 12 14 4 gt in ee ee ee d Fi re m Sid iS Beso oe e en Ed 14 14 en a N dd 14 11 1 m m O EC re PA Pa Fo ra r r Pe Per Pa Pe Pe Bu FE PO 00 0000 00 00 00 02 02 00 00 00 00 Hall ell Gel Gell Cal Caf Cal Gal Cal Cal Ga 0 fe imb oe ee kai ki 4 5 9 a 1 4 iziririririviri
20. d 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 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 d D Always wear suitable protective clothing to shield eyes hands and skin when welding 28
21. e error message Current too low the welding spot should be checked A message will be displayed at the end of every vvelding spot showing the measured vvelding current This message is displayed on the screen until a key on the control panel is pressed or until a nevv vvelding spot is performed by pressing the B button on the clamp 13705708 13 24 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 Schwei punkt unzureichend g p g Sp 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 13705708 13 24 Druck unzureichend 6 5 kA F 438 daN T 320 ms Anpressdruck zu niedrig 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 b
22. 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 gas or fuel fumes ELECTRO
23. his 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 L 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 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 To search for a report fill the field and click on the icon Fi To edit a report select it and click on the icon To archive a report select it and click on the icon i 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 ico
24. hnical specifications ELECTRICAL CHARACTERISTICS 5 m Nominal input voltage U1N 400V 3ph Erde 50 60Hhz Permanent input current 11N 25A Power at 50 duty cycle S50 20 kVA Permanent input power Sp 14 kVA Maximum welding input power Smax 80 kVA Secondary voltage U2d 7 VDC Maximum short circuit output current I2cc 14500 A Maximum permanent output current I2P 1 800 A Maximum regulated welding current 13 000 A Circuit breaker 25 AKurve D Earth Leakage Circuit Breaker 30 mA Duty cycle 2 THERMAL CHARACTERISTICS Ambient temperature range 5 C 45 C Transport and storage temperature range 20 C 70 C Hygrometry 80 Altitude 2000m Thermal protection by thermistor on the diodes bridge 70 C MECHANICAL CHARACTERISTICS Protection rating IP21 Width 610 mm Depth 720 mm Height 2260 mm Weight 100 kg Network cable lenght 8 000 mm Clamp cable lenght reference 019614 4 000 mm Clamp cable lenght reference 020320 6 000 mm PNEUMATIC CHARACTERISTCS Maximum air pressure P1 8 bar Liquid flow rate 2L min Minimum regulated force F min 100 daN Maximum regulated force with C clamp F max 550 daN 27 INVERTER YAA aa 11 Icons Volt Amps Three phase power supply 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 Rea
25. n Z To edit a report select it and click on the icon To erase a report select a report and click on the icon 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 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 16 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 To export the report as a PDF select a file and click on l A preview of the print is displayed Click gl Belovv shovvs an example of the parameters saved and printed by using the GYSPOT softvvare PDF Raison sociale 5 4 5 GYS T l phone 0243012360 Adresse 134 BOULEVARD DES LOGES Telecopie 0743683521 en Email contact str Code postal 53941 Site Web Why S carm Ville SAINT BERTHEY IM Interven ant DUPOND JEAN PIERRE Vehicule MEGANE CC 1 6L 16 Ordre de r paration 4558 Imma
26. nt 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 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 liq
27. 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 AVOLUTION I INVERTER GYSPOT Screen Car model optional Screen Chassis number optional Catalogue The View button F 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 A q gt I x C 1 ka CP Observation 1 2 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 14 A
28. rameters to modify sheet thickness type of steel arm used The and keys allow modification of each parameter sich die Werte ndern oder ausw hlen die und Tasten erh hen bzw verringern den ausgew hlten Wert 4 Saving of user welding parameters The save button allows the user to save selected vvelding parameters mode sheet thickness vvelding current vvelding time or electrode force The open button V will restore previous y saved vvelding settings The machine automatically goes to manual mode recalling the saved parameters current vvelding time force and the tool used clamp or gun 5 Select sheet thickness The sheet thickness can be adjusted using the and keys The thickness can be selected from the follovving 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 allovvs the selection of the type of metal to vveld from 4 different options coated steel HTS steel UHTS steel BORON steel This setting can be adjusted using the and keys Adjustment of the arm used VVhen 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 AVOLUTION I INVERTER OYSPOT 2 Using pneumatic clamps C Tighten the C clamp using the locking lever and check that the screw
29. ririririmimimi mnm When the warning image is displayed press again and the report content will be erased The warning image will disappear after 3 seconds 12 AVOLUTION I INVERTER User identification mode EINSTELLUNG MODUS 25 SPRACHE DATUM ZEIT TONSIGNAL ANPRE DRUCK BERPR FUNG IDENTIFIKATION AUTO MODUS STEUERUNG MODUS 2S REGISTRIERUNG FAHRZEUG MARKE FAHRZEUG MODELL FAHRGESTELLNUMMER Entry of repair order screen quide 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 When the Identification SD card is inserted and the identification mode is ON the following screen is displayed 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 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
30. s 2x A DK 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 A Short Injector Short Stretches Stretches types Short C1 C3 C4 C5 C6 C7 C9 C10 Long C2 C8 20 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 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 21 AVOLUTION i INVERTER GYSPOL J a C clamp overhaul The tightening of the following screws need to be inspected every month Screw between the arm and the clamp These 4 screws fix the arm to the clamp They need to be tightened to have a good transmission of the current A
31. t 25 26 CIRCUL DIAGRAM Taala ee ae 26 O TECRHN C AE SPECIEI ATI ONS een see 27 ILS E A ee ee ee een 28 73502 190911 V5 Autres langues disponibles sur la carte SD Other languages are available on the SD card Weitere auf SD Karte verf gbare Sprachen AVOLUTION INVERTER cy AT x9 I pp 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 GENERAL PRECAUTIONS 1 Oper
32. triculation 1600553 Date du ioumal 1 3 05 2008 Mise en circulation 21 01 12005 Commentaires RAS Intervention REDRESSAGE AILE ARRIERE GAUCHE GYSPOT INVERTER BP LO 0000001000 ims kA dal kA dall 05 05 2009 11 11 29 GYSPOT INVERTER 01 23456799 ims kA kA dall T Pince Point OK 06 05 2005 11 15 53 Point OR 17 INvertren 201 a 5 USE AND 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 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
33. uid 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 In 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
34. utton 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 nozzles are not changed before resetting the counter to zero the nozzles may become badly damage and cause poor quality welding 12 05 0808 12 20 PUNKTE 200 21 04 08 17 03 4 Elektrodenkappen berpr fen Lins 6 6 7777 Ian 6 6 F147 an T 320 ms T 320 AVOLUTION I INVERTER OAA 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 bellovv the reporting icon The user s program is available in all modes by pushing the buttons bellow the memory icon Report log book ha te Sa Saving a report allows spot welding data to be stored on a memory card on in order to retrieve it at a later date eg on a computer GYS supplies software called GYSPOT to rea
35. 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 AVOLUTION I INVERTER OAA Mehrfach Modus 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 dovvn button key definition diagram 5 allovvs selection of the parameters for each sheet VVhen the parameters for a 0 6 sheet are highlighted the sheet thickness and type of steel can be mm adjusted using the and keys key definition diagram 3 The individual sheet parameters that can be adjusted in this mode are Sheet thickness 0 6 0 8 1 0 1 2 1 5 1 8 2 0 2 5 3 0 mm The type of steel for each sheet coated steel HTS steel UHTS steel BORON
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